BW213DH-4 BVC Operation Instruction E 00804461.e07 PDF

Operating instructions
Maintenance instructions
Catalogue number
008 044 61 05/2007
BW 213 DH-4 / PDH-4
BVC with attachment plates
S/N 101 583 06 ....
Single drum roller
Foreword
BOMAG 3 BW 213 DH-4/PDH-4 BVC
Foreword
BOMAG machines are products from the wide
range of BOMAG compaction equipment.
BOMAGs vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your ma-
chine.
This manual comprises:
l Safety regulations
l Operating instructions
l Maintenance instructions
l Trouble shooting
Using these instructions will
l help you to become familiar with the machine.
l avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
l enhance the reliability of the machine on con-
struction sites,
l prolong the lifetime of the machine,
l reduce repair costs and downtimes.
BOMAG GmbH will not assume liability for the
function of the machine
l if it is handled in a way not complying with the
usual modes of use,
l if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-
age resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and mainte-
nance instructions are part of the machine.
You should only operate the machine after you
have been instructed and in compliance with these
instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil En-
gineering Liability Association Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors and all relevant accident prevention regula-
tions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Apart from that, the spare parts catalogue is avail-
able from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines in
soil and asphalt construction.
The above notes do not constitute an extension of
the warranty and liability conditions specified in the
general terms of business of BOMAG GmbH.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
Foreword
Please fill in
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Machine type (Fig. 1)
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Serial-number (Fig. 1 and 2)
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Engine type (Fig. 3)
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Engine number (Fig. 3)
i
Note
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 1
Fig. 2
Fig. 3
Table of Contents
Technical Data 9
Safety regulations 13
Indicators and Controls 21
3.1 General notes 24
3.2 Description of indicators and control elements 24
3.3 Display and control elements
Variocontrol 35
3.4 Description of indicating and control elements
Variocontrol 37
3.5 Line diagram Automatic (EVIB) 39
3.6 Description of line diagram Automatic (EVIB) 41
3.7 Line diagram Manual (EVIB) 43
3.8 Description of line diagram Manual (EVIB) 45
3.9 Bar diagram (EVIB) 46
Operation 47
4.2 Tests before taking into operation 48
4.3 Starting the engine 49
4.4 Starting with jump wires 51
4.5 Driving the machine 52
4.6 Switching the vibration on and off 54
4.7 Operating the parking brake, stopping the machine 56
4.8 Shutting the engine down 56
4.9 Changing the LCD-display 57
4.10 Emergency exit 67
4.11 Adjusting the seat 67
4.12 Operating the hood 68
4.13 Towing in case of an engine failure 69
4.14 Transport 71
4.15 Tests before starting to operate 73
4.16 Mounting the attachment plates 73
4.17 Taking the attachment plates into service 75
4.18 Detaching the attachment plates 77
4.19 Variocontrol, selecting the operating mode 79
4.20 Measuring pass with Variocontrol 81
4.21 Finishing compaction of a track 84
4.22 Printing measuring data after completing compaction 85
4.23 Teaching distance pulses 86
4.24 Amplitude limitation (BVC only) 88
4.25 Changing the paper roll in the measuring value printer 90
4.26 Changing the printer ribbon in the measuring value printer 91
Table of Contents
Maintenance 93
5.1 General notes on maintenance 94
5.2 Fuels and lubricants 95
5.3 Table of fuels and lubricants 99
5.4 Running-in instructions 100
5.5 Maintenance chart 101
5.6 Check the engine oil level 104
5.7 Check, clean the water separator 104
5.8 Check the fuel level 105
5.9 Check the hydraulic oil level 106
5.10 Check the coolant level 106
5.11 Checking the dust separator on the oil bath air filter 107
5.12 Checking the tire pressure 108
5.13 Clean the cooling fins on engine and hydraulic oil cooler 108
5.14 Check the oil level in the drive axle 109
5.15 Checking the oil level in left/right wheel hubs 110
5.16 Check the oil level in the axle reduction gear 110
5.17 Check the oil level in the drum reduction gear 111
5.18 Checking the Vario exciter oil level 112
5.19 Changing engine oil and oil filter cartridges 113
5.20 Change the fuel filter cartridge 114
5.21 Draining the sludge from the fuel tank 115
5.22 Service the battery 116
5.23 Change the fuel pre-filter cartridge 117
5.24 Checking, replacing the refrigerant compressor V-belt 118
5.25 Service the air conditioning 119
5.26 Adjusting the valve clearance 122
5.27 Adjusting the control piston play 124
5.28 Checking / replacing the ribbed V-belt 125
5.29 Check the engine mounts 126
5.30 Change the oil in the drive axle 126
5.31 Changing the oil in the wheel hubs 127
5.32 Changing the oil in the axle reduction gear 128
5.33 Change the oil in the drum reduction gear 129
5.34 Vario exciter oil change 130
5.35 Change the oil in the exciter shaft housing of the attachment plates 131
5.36 Tightening the fastening of the axle to the frame 132
5.37 Tightening the wheel nuts 132
5.38 Check the ROPS 133
5.39 Cleaning the oil bath air filter 133
5.40 Changing hydraulic oil and breather filter 134
5.41 Changing the hydraulic oil filter 135
Table of Contents
5.42 Changing the steering oil filter 136
5.43 Changing the attachment plate oil filter 137
5.44 Change the coolant 138
5.45 Replacing the crank case ventilation valve 140
5.46 Electronic injector test EMR 141
5.47 Service the combustion air filter 142
5.48 Adjust the scrapers 144
5.49 Adjust the parking brake 145
5.50 Change the tires 146
5.51 Change the fresh air filter in the cabin 147
5.52 Tightening torques 147
5.53 Engine conservation 148
Trouble shooting 149
6.2 Reading out faults BVC/BTM05 150
6.3 Engine 152
Cab assembly before initial start-up 155
7.1 Preparations 157
7.2 Cabin assembly 158
7.3 Final function tests and checks 164
Table of Contents
1 Technical Data
Technical Data
Fig. 4
Dimensions in
mm
A B D H H2 K L O1 O2 S W
BW 213 DH-4
BVC/P
2960 2250 1500 2268 2972 490 5808 60 60 35 2130
*
BW 213 DH-4 BVC/P
Weights
Operating weight (CECE)
with ROPS and cabin
kg 15785
Axle load, drum (CECE) kg 7598
Axle load, wheels (CECE) kg 8187
Static linear load kg/cm 35,7
Travel characteristics
Speed km/h 0 ... 13
Max. gradability (depend-
ing on soil)
% 50
Engine
Engine manufacturer Deutz
Type TCD 2013 L04 2V
Cooling Water
Number of cylinders 4
Rated power ISO 3046 kW 119
Rated speed rpm 2200
Electrical equipment V 12
Drive system hydrostatic
Driven axles 2
Technical Data
Brakes
Service brake hydrostatic
Parking brake hydr.-mech.
Steering
Type of steering articulated
Steering operation hydrostatic
Vibration, drum
Frequency Hz 28
Amplitude mm 0 ... 2,4
Vibration, attachment
plates
Frequency Hz 40 ... 55
Tires
Tire size 23.1/18-26/12PR
Air pressure bar 1,8
Filling capacities
Engine Litres 15
Fuel Litres 340
Hydraulic oil Litres 60
* The right for technical modifications remains reserved
*
BW 213 DH-4 BVC/P
Technical Data
The following noise and vibration data acc. to
- EC Machine Regulation edition (98/37/EC) and
- Noise Emission Regulation 2000/14/EC
were determined at nominal speed of the drive engine and with vibration running. The machine was
standing on an elastic base.
During operation these values may vary because of the existing operating conditions.
Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
sound pressure level at the work place of the operator (with cabin):
L
pA
= 76,8 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is
guaranteed sound capacity level of the machine:
L
WA
= 111 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (L
wA
) and ISO
11204 for sound pressure level (L
pA
) at the place of the operator.
Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:
Vibration of the entire boy (drivers seat)
The weighted effective acceleration value determined in accordance with ISO 7096 is 0.5 m/sec
2
.
Hand-arm vibration values
The weighted effective acceleration value determined in accordance with EN 500/ISO 5349 , is
2.5 m/sec
2
.
2 Safety regulations
Safety regulations
General
This BOMAG machine is built in accordance
with the latest technical standard and the valid
technical rules and regulations. There is, how-
ever, a risk of danger for persons and property
if:
l the machine is used for purposes other than
those it is intended for
l the machine is operated by untrained person-
nel
l the machine is modified or converted in an un-
professional way
l the applicable safety regulations are not ob-
served.
Each person involved in operation, mainte-
nance and repair of the machine must there-
fore read and apply these safety regulations.
This should be confirmed by obtaining the sig-
natures of the customer, if necessary.
Furthermore the following regulations and instruc-
tions are obviously also valid:
l applicable accident prevention instructions
l generally acknowledged safety and road traffic
regulations
l country specific safety regulations. It is the
duty of the operator to know and observe
these regulations. This applies also for local
regulations and the regulations for various
types of manual work. If the recommendations
in this manual differ from the regulations valid
in your country, you must strictly observe the
regulations in your country.
Intended use
This machine must only be used for:
l compaction of bituminous materials, e.g. road
surface layers. (AC and AD machines only)
l medium and heavy compaction tasks in earth
work (road sub-bases)
l This machine must only be operated with fully
functional safety equipment.
l The machine should be checked by an expert
once every year.
Unintended use
Dangers may, however, arise from the machine if
it is used by untrained personnel in an unprofes-
sional way or if it is used for purposes other than
those mentioned in these instructions.
Do not work with vibration on hard concrete, on a
cured concrete layer or heavily frozen ground.
Starting and operation of the machine in an explo-
sive environment is prohibited.
Who is allowed to work with the ma-
chine?
The machine must only be operated by trained
and authorized persons which are at least 18
years of age. The responsibilities for the operation
of the machine must be clearly specified and com-
plied with.
Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
the machine.
Maintenance and repair tasks require specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Conversions and alterations to the ma-
chine
Unauthorized conversions to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
pressly clear that we have not tested or authorized
any original parts or special equipment not sup-
plied by us. The installation and/or use of such
products can impair the active and/or passive driv-
ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
Safety notes in the operating and main-
tenance instructions:
! Danger
Sections marked like this point out possible
dangers for persons.
Safety regulations
! Caution
Sections marked like this point out possible
dangers for the machine or for parts of the ma-
chine.
i
Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
Observe all environment protection regula-
tions.
Information and safety stickers/decals
on the machine
Keep stickers/decals complete (see spare parts
catalogue) and fully legible and observe their
meaning.
Replace damaged or illegible stickers/decals im-
mediately.
Loading the machine
Use only strong and stable loading ramps. The
ramp inclination must be lower than the gradability
of the machine.
Secure the machine against turning over or slip-
ping off.
Secure the machine on the transport vehicle
against rolling off, slipping and turning over.
Persons are highly endangered if
l they step or stand under loads being lifted
l they remain in the drive range of the machine
during a demonstration or during loading.
The machine must not swing about when lifted off
the ground.
Use only safe lifting gear of sufficient load bearing
capacity.
Attach the lifting gear only to the specified lifting
points.
Towing the machine
Since the machine is not fitted with a towing hitch,
the machine cannot be towed with a tow bar.
If the machine has to be towed urgently out of the
danger zone because of other risks, this must only
be done on level ground or uphill using chains and
ropes. For this purpose towing ropes of sufficient
tensile strength must be fastened on the lifting
eyes.
After releasing the brake the machine can only be
braked by the towing vehicle.
Before releasing the brake block the machine with
chocks to prevent unintended rolling.
Checking the Roll Over Protection
Structure (ROPS)
i
Note
On machines with cabin the ROPS is an integral
part of the cabin.
The machine frame must not be distorted, bent or
cracked in the area of the ROPS fastening points.
The ROPS must not show any signs of corrosion,
damage, hairline cracks or open fractures.
The ROPS must not rattle about during driving.
This would mean that it is not properly fastened.
All bolted connections must be in accordance with
the prescribed specifications and correctly tight-
ened (observe the tightening torque values).
Screws and nuts must not be damaged, bent or
deformed.
With the cabin installed check also the condition of
the cabin mounts (rubber elements and screws).
Neither must any additional parts be welded or
bolted on, nor must any holes be drilled without the
permission of the manufacturer, since this may im-
pair the strength of the structure.
Starting the machine
Before starting
Operation of the machine is only permitted when
sitting in the operator's seat.
Use only machines which have been properly
serviced at regular intervals.
Safety regulations
Become acquainted with the equipment, the con-
trol elements, the working mode of the machine
and the area you will be working in.
Use your personal protective outfit (hard hat, safe-
ty boots etc.).
Check before mounting the machine if:
l there are persons or obstructions beside or
under the machine
l the machine is free of any oily and combustible
material
l all handrails, steps and platforms are free of
grease, oils, fuels, dirt, snow and ice
l the engine compartment hood is closed and
locked
To climb onto the machine use steps and hand-
rails.
Check before starting, whether:
l the machine shows any obvious defects
l all protective devices are properly secured in
their place
l steering, brakes, control elements, lighting
and warning horn are in order
l the seat is correctly adjusted
l the mirrors (if available) are clean and correct-
ly adjusted.
Do not start the machine if any gauges, control
lights or controls are defective.
Do not take any loose objects with you or fasten
them to the machine.
On machines with ROPS you should always wear
your seat belt!
Starting
Start and operate the machine only from the oper-
ator's seat
For starting set all control levers to "neutral posi-
tion".
Do not use any starting aids such as Start Pilot or
ether.
After starting check all gauges.
Starting with jump leads
Connect plus with plus and minus with minus
(ground cable) - always connect the ground cable
last and disconnect it first! Wrong connections
may cause severe damage in the electric system.
Never start the engine by bridging the electrical
connections on the starter, because the machine
would probably start to move immediately.
Starting in closed rooms
Exhaust gases are toxic! Always ensure an ade-
quate supply of fresh air when starting in closed
rooms!
Driving the machine
Persons in the endangered area
If the machine has turned over and the cabin door
is jammed, use the right hand cabin window as an
emergency exit.
Before starting or resuming work and especially
when driving backwards, check that there are no
persons or obstructions in the endangered area.
If necessary give warning signals. Stop work im-
mediately if persons remain in the danger area de-
spite the warning.
Do not step or stand into the articulation area of
the machine while the engine is running. Danger of
squashing!
Driving
In events of emergency actuate the emergency
stop switch immediately. Do not use the emergen-
cy stop push button as service brake.
Restart the machine only after the danger, that has
caused the actuation of the emergency stop, has
been eliminated.
If the machine has come in contact with high-volt-
age power lines:
l do not leave the operator's stand
l warn others from coming too close to the ma-
chine or touching it
l if possible drive the machine out of the danger
zone
l have the power shut off.
Operate the machine only from the operator's
seat.
Keep the cabin doors closed.
Do not adjust the seat while driving.
Do not climb onto or off the machine while driving.
Change the travel direction only while the machine
is standing.
Safety regulations
Do not use the machine to transport persons.
Stop the machine if you notice unusual noises or
the development of smoke. Investigate the cause
and have the fault corrected.
Keep a sufficient distance to excavations and em-
bankments and make sure that you work does not
impair the stability of the machine.
Do not work with vibration on hard concrete, on a
cured concrete layer or heavily frozen ground.
When passing under flyovers, bridges, tunnels,
electric power lines etc. keep a sufficient distance.
Driving on slopes and gradients
Do not drive up and down gradients, which exceed
the max. gradability of the machine.
On lopes always drive directly up or down. Change
to the lower speed range before approaching the
slope.
Wet and loose soils reduce the ground adhesion of
the machine and inclinations and slopes consider-
ably. Higher risk of accident!
Behaviour in traffic
Match the speed of the machine to the working
conditions.
Always allow loaded transport vehicles to pass.
Switch the lights on when the visibility is poor.
Keep clear of edges and embankments.
Check the effect of vibration
When compacting with vibration check the effect
of the vibration on nearby buildings and under-
ground supply lines (gas, water, sewage, electric
power supply), stop vibratory compaction if neces-
sary.
Do not work with vibration on hard (frozen, con-
crete) ground. Risk of bearing damage!
Parking the machine
Park the machine on level and firm ground.
Before leaving the machine:
l straighten the articulated joint to allow easy
access to and from the machine.
l return the travel lever to neutral position
l apply the parking brake
l shut the engine down and pull the ignition key
out.
l lock the cabin
l secure the machine against unauthorized use.
Do not jump off the machine, use access steps
and hand rails.
Always secure parked machines, which could be
in the way, with appropriate measures.
Parking on slopes and gradients
Secure the machine against rolling, place metal
chocks in front of and behind the drums.
Filling the fuel tank
Do not inhale fuel fumes.
Refuel only after shutting the engine and the aux-
iliary heater down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Wipe off spilled fuel. Keep fuel free of dirt and wa-
ter.
Leaking fuel tanks can cause explosions. Ensure
tight fit of the fuel tank filling cover, replace it if nec-
essary.
Fire protection measures
Make yourself acquainted with the location and the
operation of fire extinguishers. Observe fire warn-
ing and fire fighting installations.
Maintenance work
Comply with the maintenance work described in
the operating and maintenance instructions, in-
cluding the information concerning the replace-
ment of parts.
Support the engine hood for all maintenance and
repair work in the engine compartment.
Maintenance work must only be performed by
qualified and authorized persons.
For overhead maintenance and assembly work
use the access steps and working platforms pro-
vided or other secure means. Do not use machine
parts as access steps.
Keep unauthorized persons away from the ma-
chine.
Do not perform maintenance work while the ma-
chine is driving or the engine is running.
Safety regulations
Park the machine on horizontal, level, firm ground.
Pull the key out of the ignition switch.
Secure the articulated joint with the articulation
lock.
Work on hydraulic lines
Relieve hydraulic pressures before working on hy-
draulic lines. Hydraulic oil escaping under pres-
sure 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 performing 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!
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always catch and dispose of hydraulic oils sepa-
rately.
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 be visually inspected at reg-
ular intervals.
Hydraulic hoses must be immediately replaced if:
l the outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
l the outer layer is brittle (formation of cracks in
the hose material)
l the hose shows deformations in pressurized
and depressurized condition, which do not
comply with the genuine shape of the hydrau-
lic hose
l the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, forma-
tion of blisters
l parts of the hose are leaking.
l hoses are not correctly installed.
l the hydraulic hose has separated from the fit-
ting
l the fitting shows corrosion that impairs both
function and strength.
l hoses are mixed up by mistake.
l fittings are damaged or deformed, whereby
the function and strength of the hose/hose
connection is impaired.
Only genuine BOMAG replacement hydraulic hos-
es 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 engine
hood.
Do not work on the fuel system while the engine is
running - danger to life due to high pressures!
l Wait another minute after the engine has
stopped.
l Keep out of the danger zone during the initial
test rung.
l In case of leaks return to the workshop imme-
diately.
l Make sure that the engine cannot be started
unintentionally during service and repair work.
Drain the engine oil at operating temperature
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oil contaminated ma-
terials in a separate, specially marked container
and dispose of environmentally.
Do not leave any tools or other objects, that could
cause damage, in the engine compartment.
The settings for idle speed and highest speed
must not be changed, since this would affect the
exhaust gas values and cause damage to engine
and power train.
Turbo chargers work with high speeds and high
temperatures. Keep hands, tools and materials
away from the intake and outlet openings of the
nturbo charger and do not touch any hot surfaces.
Check and change coolant only when the engine
is cold.
Catch coolant and dispose of environmentally.
Safety regulations
Working on electric parts of the machine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire haz-
ard!
Disconnect the battery before starting welding
work on the machine.
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 dan-
ger of short circuit and burning!
When recharging serviceable batteries remove all
plugs, to avoid the accumulation of explosive gas-
es.
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 bat-
tery 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 dispose off environmentally.
Working on wheels and tires
Explosion-like bursting of tires or parts of tires and
rims can cause most severe or even deadly inju-
ries.
Assembly of tires must only be performed with ap-
propriate experience and tools. If necessary have
tires assembled in a qualified workshop.
Always ensure the correct tire pressure and do not
exceed the specified maximum pressure.
Check tires and wheels every day for specified
pressure, cuts, bulges, damaged rims, missing
wheel studs or nuts. Do not drive with damaged
tires or wheels.
Ant-sticking emulsions for tires must only consist
of water and anti-sticking agent, in a concentration
in accordance with the specifications of the manu-
facturer of the anti-sticking agent. Observe appli-
cable environmental regulations.
Cleaning work
Do not perform cleaning work while the engine is
running.
Do not use gasoline or other easily inflammable
substances for cleaning.
When cleaning with steam cleaning equipment do
not subject electrical parts and insulation material
to the direct jet of water, or cover it beforehand.
l Do not guide the water jet into the exhaust and
into the air filter.
After maintenance work
After all maintenance work is completed reinstall
all guards and safety installations.
Repair
Mark a defective machine by attaching a warning
tag to the steering wheel.
Repair work must only be performed by qualified
and authorized persons. Use our repair instruc-
tions for this work.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
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, be-
cause fuel squirting out may cause severe injury.
After shutting down the engine wait for another
minute, until the pressure has dropped to a per-
missible level. In case of leakages you should con-
tact the Service Department of the engine
manufacturer and refrain from starting the engine.
Test
The safety of compaction equipment must be
checked by a specialist as required in dependence
on the application and the operating conditions,
however at least once every year.
Safety regulations
3 Indicators and Controls
Indicators and Controls
Fig. 5
1 Ignition switch
2 LCD display unit
3 Vent for heating and ventilation, driver
4 Vent for heating and ventilation, footwell
5 Control panel, travel lever
6 Display and control unit Variocontrol BOP
7 Rotary switch for speed range selection
8 Emergency stop push button
9 Push button for warning horn
10 Rotary switch for extension plates floating po-
sition
11 Rotary switch for extension plates vibration
frequency
12 Rotary switch vibration extension plates on/off
13 Rotary switch drum vibration on/off
14 Travel lever
15 Rotary momentary contact switch for engine
speed
16 Rotary momentary contact switch for drum vi-
bration frequency
*
17 Rotary switch for direction indicators left/right*
18 Rotary switch for hazard light system*
19 Rotary switch for lighting (StVZO)*
20 Rotary switch for working head lights*
21 Steering wheel
* Optional equipment
3.1 General notes
Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise de-
scriptions of the individual operating steps.
3.2 Description of indicators
and control elements
Fig. 6
No. 1 = Ignition switch
Position "P"/"0" = ignition off, the key can be
pulled out, engine not running.
Position "I" = ignition on, all control and
warning lights on the fault
monitoring board light up for a
moment. The lighting can be
switched on.
i
Note
The engine can only be started when the travel le-
ver is in braking position.
The ignition switch is provided with a lock against
repetitive starting. To repeat the starting proce-
dure you must first turn the ignition switch back to
"0"-position.
Position "II" = turn further against spring
pressure, the engine starts, re-
turn the ignition key to position
"I" when the engine starts
! Caution
Run the engine warm for a short while before
starting to work. Do not let the engine run at
idling speed for longer than 10 minutes.
Do not shut the engine down all of a sudden
from full speed, but let it idle for a while for
temperature equalization.
Fig. 7
No. 2 = LCD display unit
i
Note
With the ignition switch in position I all gauges and
instruments are switched on for 3 seconds.
Toggling between the displays is described in the
chapter "Operation".
a green = flashes when the direction indicator
switch is actuated.
b = Indication of fuel level
c = Upper display field, shows either the
time or the coolant temperature
d = Indication of travel speed and pre-se-
lected speed limitation (green ring
segment)
e red = flashes if engine oil pressure too low,
engine is shut down after 10 sec-
onds. Check engine oil level, repair
the engine if necessary.
f red = flashes if the engine overheats (oil
temperature), the warning buzzer
sounds, the engine is shut down after
2 minutes.
Switch off vibration, run engine with
idle speed or shut down engine if
necessary, clean engine oil cooler
and radiator, if necessary repair en-
gine.
g yellow = lights if combustion air filter cartridge
is soiled, clean or replace if neces-
sary.
h red = flashes when the coolant (filling) level
is too low.
Engine is shut down after 10 sec-
onds.
i yellow = lights if the hydraulic oil filter is con-
taminated, the engine is shut down
after 2 minutes.
Check hydraulic system, replace hy-
draulic oil filter.
j yellow = lights when the hydraulic oil tempera-
ture is too high
k yellow = lights when temperatures are low
(pre-heating for starting)
l yellow = Charge control light, lights if the bat-
tery is not being charged.
Check V-belt, if necessary repair the
generator.
m red = Water separator in fuel pre-cleaner.
Lights when the water proportion in
the transparent section of the fuel fil-
ter reaches the contacts.
n = Function display, set brightness of
display
o = Middle display field, can be switched
to display of operating hours or mean
fuel consumption by actuating the
"Info-button 1"
p = Bottom display field, can be switched
to display inclination, vibration fre-
quency, voltage, hydraulic oil pres-
sure, hydraulic oil temperature or
ambient temperature by actuating
"Info-button 2"
q = Hydraulic oil temperature gauge
r yellow = lights in case of problems with the air
conditioning
s yellow = lights in case of an ASC (Anti Spin
Control) failure
t red = The seat occupation monitoring sys-
tem lights when the seat is not occu-
pied. If the machine is travelling the
warning buzzer will sound, engine is
shut down after 4 seconds.
u red = Parking brake, with travel lever dis-
engaged
v red = Central warning light, lights if a fault
code is displayed
w red = Hazard light, flashes when the haz-
ard light is activated
x = Engine speed display
No. 3 = Vents for air conditioning, heating
and ventilation, driver
No. 4 = Vents for air conditioning, heating
and ventilation, footwell
*
Fig. 8
No. 5 = Control panel, travel lever
(a) Vibration button
l Select the vibration on with the selector switch.
l Switch the vibration on or off by pressing the
push button.
(b) Push button "Plates up"
Press the push
button = Raise the plates
(c) Push button "Extend plates"
Press the push
button = The plates are extended to the
right
(d) Push button "Plates down"
Press the push
button = Lower the plates
! Caution
Do not drive backward with the plates lowered
to the ground!
(e) Push button "Retract plates"
Press the push
button = The plates are retracted
Fig. 9
Changeover of display
i
Note
The operation is described in the corresponding
chapter
Info 1 button = to toggle between operating
hours and mean consumption.
Changeover possible during
travel
Info 2 button = to toggle between display of
inclination [%], vibration fre-
quency [Hz], voltage [V], en-
gine oil pressure [bar],
hydraulic oil temperature
**
[C/
F], ambient temperature
***
[C/F]
Changeover possible during
travel
Navigation in input mode)
= Activation of input mode only
possible with the brake applied
(see chapter operation)
F2 button = Change selected field
F3 button = Select field to change
F4 button = Select field to change
F5 button = Change selected field
** Optional equipment
*** Optional equipment
Fig. 10
No. 6 = Control unit Variocontrol BOP
i
Note
see section 3.4 display and control elements Var-
iocontrol.
Fig. 11
No. 7 = Rotary switch for final speed
Turn in direction
"Turtle" = Reduces the speed
Turn in direction
"Rabbit" = Increases the speed
Fig. 12
The adjusted travel range appears in the LCD dis-
play unit in form of a green ring segment (Fig. 12).
Fig. 13
No. 8 = Emergency stop switch
The engine will be shut down and the brake will
close.
! Danger
Danger of accident!
Operate only in emergency situations during
operation, do not use as a service brake.
The machine should only be started again after
the danger, that caused the actuation of the
emergency stop switch, has been removed.
operate = push the button completely
down, it will automatically lock
in end position.
unlock = turn the button clockwise and
release it.
to drive = move the travel lever first to
braking position, then start the
engine and choose the travel
direction.
For safety reasons the travel system of the ma-
chine will only be enabled after the travel lever has
been shifted back to braking position.
Fig. 14
No. 9 = Push button for warning horn
Fig. 15
No. 10 = Rotary switch for attachment plates
floating position
Position left = Floating position off
Position right = Floating position on
! Danger
Danger of squashing!
Maintenance and service work must only be
performed with the attachment plates in float-
ing position. For safety reasons the extension
plates are then lowered to the ground and the
hydraulic lines depressurized.
Fig. 16
No. 11 = Rotary switch for frequency of attach-
ment plate
With this switch (potentiometer) the exciter fre-
quency can be infinitely adjusted (see technical
data).
Choose the setting in dependence on soil condi-
tion and degree of compaction.
Fig. 17
No. 12 = Rotary switch vibration attachment
plates on/off
Position left = Vibration off
Position right = Vibration on
Fig. 18
No. 13 = Rotary switch for vibration
Position "Left" = Vibration off
Position "Right" = Vibration on
i
Note
Press additional push button on travel lever to
switch on and off.
Fig. 19
No. 14 = Travel lever
Position "mid-
dle" = Braking position service brake
Position "middle,
right" = Parking brake, to start the en-
gine
Position "I" = Forward travel
Position "II" = Backwards travel
i
Note
If the engine speed drops under load when driving
on steep gradients, take the travel lever slightly
back towards neutral. This relieves the hydraulic
system and reduces the load on the diesel engine.
Fig. 20
No. 15 = Rotary momentary contact switch for
engine speed
Electric engine speed adjustment
Position left = Idle speed position
Position middle = "ECO"-operation.
The engine speed adapts au-
tomatically to the power re-
quirements. This enables
economical operation.
Position right = Full throttle position, operating
position for driving and vibra-
tion
! Caution
Always drive and vibrate with max. engine
speed or in ECO-mode! Control the travel
speed with the travel lever.
Fig. 21
No. 16 = Rotary momentary contact switch for
vibration frequency
*
Turn "Left" = Frequency reduction
Turn "Right" = Frequency increase
Fig. 22
No. 17 = Rotary switch for direction indicators
left / right
**
Position "mid-
dle" = Direction indicators disabled
Position "left or
right" = The front and rear direction in-
dicators for the corresponding
side of the machine light up,
control light 6 in the fault mon-
itoring board flashes
Fig. 23
No. 18 = Rotary switch for hazard light system
***
Position "left" = Hazard light switched off, con-
trol lights off.
Position "right" = Hazard light switched on, con-
trol light 7 in the fault monitor-
ing display lights up.
Fig. 24
No. 19 = Rotary switch for light system (StV-
ZO)
****
Position "left" = Light off
Position "mid-
dle" = Sidelights on, with ignition
switch in position "I" or "P"
Position "right" = Travel light on, with ignition
switch in position "I".
** Optional equipment
*** Optional equipment
**** Optional equipment
Fig. 25
No. 20 = Rotary switch for working lights
*
Position "left" = Light off
Position "right" = Working lights on, with ignition
switch in position "I".
No. 21 = Steering wheel, electrically operated
turn = The machine steers to the cor-
responding direction
i
Note
The machine is equipped with an armrest contact
switch (safety feature).
If the armrest is raised while driving, the warning
horn is activated and the machine is decelerated
to standstill after four seconds. If the armrest is
lowered again within four seconds the machine will
continue the travel.
Lower the armrest before resuming operation, en-
gage the travel lever in "0"-position (brake posi-
tion), then operate the travel lever again to the
desired travel direction.
Fig. 26
No. 22 = Lever, swivelling of drivers seat
! Danger
Danger of accident!
Always lock the drivers seat in one of the lock-
ing positions while driving.
Do not swivel the drivers seat while driving.
swivel = Stop the machine and apply
the parking brake. Pull the le-
ver up and swivel the drivers
seat to the desired position.
i
Note
Swivelling angle max. 20 to either side.
Fig. 27
No. 23 = 2-pole socket
Current only with the ignition switch in position "I"
or when the engine is running.
Fig. 28
No. 24 = Fuses in electric installation box
F05, 10A = Display
F07, 15A = Hazard light
*
F08, 15A = Indicator*
F09, 10A = Parking tail light, left*
F10, 10A = Parking tail light, right*
F11, 15A = Head lights, StVZO*
F13, 30A = Starting
F18, 10A = Working head lights, relay*
F19, 15A = Working head lights, front*
F22, 15A = Working head lights, rear*
F23, 15A = Warning horn
F24, 10A = Joystick, DASA
**
, display
F39, 15A = Socket, cabin*
F67, 15A = Last ESX
***
F84, 10A = Voltage supply MESX
****
, ESX
via emergency stop
F95, 10A = EMR
*****
-control, joystick
F145, 20A = Attachment plates*
F146, 15A = Last MESX*
F148, 10A = Measuring technology*
! Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
Fig. 29
No. 25 = Toggle switch, cabin
a = toggle switch for flashing beacon
b = toggle switch for front windscreen wiper/
washer
up = windscreen wiper moves to
end position and stops.
down = Switches on wiping of front
windscreen.
Push button = Front windscreen is sprayed
during wiping.
c = toggle switch for rear windscreen wiper/
washer
up = windscreen wiper moves to
end position and stops.
down = Switches on wiping of rear
windscreen.
Push button = Rear windscreen is sprayed
during wiping.
** DASA = Data Collector
*** ESX = BDC-remote control
**** MESX = BMU-measuring technology control
*****EMR = engine control
d = toggle switch for rear windscreen heating
Fig. 30
No. 26 = Fuse box, cabin
! Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
(1), 15A = (F43) wiper/washer, rear
(2), 15A = (F44) wiper/washer, front
(3), 10A = (F130) relay for rear windscreen
heating, reading light
(4), 25A = (F31) cabin fan
(5), 10A = (F41) flashing beacon
(6), 15A = (F144) cab socket
(7), 15A = (F143) rear windscreen heating
(8), 5A = (F42) potential 30, cab light
Fig. 31
No. 27 = Control panel for ventilator, air condi-
tioning, heating
e = Rotary switch for cabin ventilator
Position Off = cabin ventilator switched off.
Position 1, 2 and
3 = ventilator stages of different
strengths
f = Push button for air conditioning
*
press = air conditioning switched on.
(only with fan in stage 1, 2 or 3)
i
Note
The light above the push button lights up.
With rotary switch (g) the air conditioning unit can
be regulated within the blue range.
press again = air conditioning switched off.
i
Note
The light goes out.
g = Rotary switch for cabin heater (tempera-
ture selector switch)
Position Off = cabin heater switched off.
Position blue
range = temperature selection for air
conditioning.
Position red
range = Temperature selection for cab-
in heater.
Fig. 32
No. 28 = Cabin light
i = reading and dashboard light
j = toggle switch for reading and dashboard
light
k = toggle switch for cabin light
l = cabin light
Fig. 33
No. 29 = Main fuse for battery
125A = (F00)
i
Note
The battery with the main fuses is located in the
engine compartment.
3.3 Display and control ele-
ments
Variocontrol
Fig. 34
1 E
VIB
display
2 Display for jump operation
3 Push button F5 START
4 Push button F6 STOP
5 Push button F7 PRINT
6 Push button F8 DELETE
7 Vibration frequency display
8 Rotary switch to set the nominal value (auto-
matic operation)
9 Push button F14 nominal value increase
10 Push button F13 nominal value decrease
11 Rotary switch to select operating mode (auto-
matic/manual)
12 Push button F12 automatic operation
13 Push button F11 manual operation
14 Rotary switch for manual setting of amplitude
direction
15 Push button F10 vertical effective direction
16 Push button F9 horizontal effective direction
17 Speed display
18 Amplitude display
19 Printer for measuring values
20 Fault light
21 Amplitude limitation active
3.4 Description of indicating
and control elements
Variocontrol
No. 1 = E
VIB
-display
Display of the dynamic soil stiffness in MN/m
2
.
No. 2 = Display for jump operation
yellow
symbol = Drum jumps
red
symbol = Drum jumps excessively or
tumbles
Select a smaller amplitude, if necessary!
No. 3 = Button F5 START
press = Starts recording of measuring
values
Control field "F5" flashes green on the screen.
No. 4 = Button F6 STOP
press = Stops recording of measuring
values
The red control field "F6" on the screen lights up.
i
Note
Depending on the measuring result the green con-
trol field "F5" may stay on.
No. 5 = Button F 7 measuring value printer
To print out the measuring data saved during the
last pass press button F7 PRINT.
short actuation = Line diagram
long actuation 5
sec. = Bar chart
Control field F7 goes out and the measuring value
printer starts to print out measuring data.
i
Note
After the printing process has finished any amount
of diagrams can be printed out by pressing the
same button F7 (PRINT).
No. 6 = Button F8 DELETE
press = All stored faults are deleted.
! Caution
If the increase of the measuring value is to be
calculated on a track press button F8 DELETE
only when changing the track.
No. 7 = Frequency display (only BTM 05)
with vibration switched on this instrument shows
the frequency (rotating speed) of the exciter shaft.
No. 8 = Rotary switch P3 pre-setting of nomi-
nal values
For "Automatic" mode
In dependence on the stiffness of the soil the ef-
fective direction of the amplitude will adjust auto-
matically. The desired maximumdynamic stiffness
module E
VIB
[MN/m
2
] can be preselected in 6
stages (45, 80, 100, 120,150 and Max.).
The selected value is shown on the screen in field
"P3"
No. 9 = Button F14 increase of nominal value
With each actuation of the button the presetting is
raised by one stage.
"P3"
No. 10 = Button F13 reduction of nominal val-
ue
With each actuation of the button the presetting is
reduced by one stage.
"P3"
No. 11 = Rotary switch P2 operating mode
Position Auto-
matic E
VIB
= The machine automatically
chooses the optimal effective
direction of the amplitude in
dependence on the stiffness of
the ground and the adjusted
nominal E
VIB
-value (switch
P3).
Position E
VIB
-
Manual = The effective direction of the
amplitude is set in 6 fixed stag-
es (switch P1), when changing
the travel direction the vibra-
tion will adapt automatically
and change to other quadrant.
The selected operating mode is shown on the
screen in field "P2".
No. 12 = Button F12 automatic operation
Pressing this button changes the operating mode
to "Automatic".
No. 13 = Button F11 manual operation
Pressing this button changes the operating mode
to Manual.
No. 14 = Rotary switch P1 manual setting of ef-
fective direction of amplitude
This switch is used to specify the vertical ampli-
tude in "Manual" mode and is only available in this
operating mode.
Position 1 (left) = Horizontal, 0 mm amplitude
Position 2 = 0,7 mm amplitude
Position 6
(right) = Vertical, 2,4 mm amplitude
Field P1 on the screen shows graphically with
which amplitude the machine is currently working.
i
Note
In travel lever position "0" the vibrator system re-
mains in position "horizontal" for safety reasons.
On bridges or in sensitive areas it is recommended
to use "Manual Horizontal".
No. 15 = Button F10 vertical effective direction
With each actuation of the button the effective di-
rection is changed by one step towards vertical.
P1
No. 16 = Button F9 horizontal effective direc-
tion
With each actuation of the button the effective di-
rection is changed by one step towards horizontal.
P1
No. 17 = Speed display
Shows the travel speed of the machine.
No. 18 = Amplitude display
This gauge shows the current vertical amplitude of
the machine.
No. 19 = Printer for measuring values
To print out the measuring data saved during the
last pass press button (7) "PRINT".
No. 20 = Fault light
Inform the BOMAG After Sales Service if it lights
up.
No. 21 = Amplitude limitation active
In automatic operation the amplitude limitation en-
ables a limitation of the effective amplitude.
no symbol dis-
played = Amplitude limitation inactive
Symbol shaded = Amplitude limitation active, but
inactive because of the param-
eter setting (e.g. manual
mode)
Symbol bright = Amplitude limitation active
3.5 Line diagram Automatic
(E
VIB
)
Fig. 35
1 Pass-No.
2 Travel direction
3 Machine equipment (BTM 05/BTM-E)
4 Software status of the measuring equipment
5 Machine number
6 Machine type
7 Operating mode
8 Setting of nominal E
VIB
value
9 Maxiumum E
VIB
value
10 Miniumum E
VIB
value
11 Mean E
VIB
-value
12 E
VIB
-change
13 Medium frequency
14 Mean travel speed
15 Track length
16 Raster division in longitudinal direction
17 Longitudinal raster line
18 Identification of nominal value line
19 Measuring value raster line
20 Diagram line
3.6 Description of line diagram
Automatic (E
VIB
)
No. 1 = Pass
Total number of measured passes on this track.
No. 2 = Travel direction
No. 3 = Machine equipment
No. 4 = Software status of the measuring
equipment
No. 5 = Machine number
No. 6 = Machine type
No. 7 = Operating mode
Shows the setting of the operating mode (Auto)
and the presetting of nominal value (150).
No. 8 = Setting of nominal E
VIB
value
Shows the preset nominal E
VIB
-value.
No. 9 = Maximum E
VIB
value
No. 10 = Minimum E
VIB
value
No. 11 = Mean E
VIB
-value
shows the mean value of the E
VIB
-values for the
tracks driven between START and STOP.
No. 12 = E
VIB
-change
E
VIB
-change in %. They always relate to the previ-
ous pass.
No. 13 = Medium frequency
No. 14 = Mean travel speed
shows the mean value of speed driven during this
pass.
i
Note
Always shows the same travel speed in order to
avoid a falsification of the measuring results.
No. 15 = Track length
Measured track length between START and
STOP.
No. 16 = Raster division in longitudinal direc-
tion
Is used to pinpoint individual measuring values on
the measuring curve.
i
Note
The raster lines mark measuring track sections of
5 m length.
Graduation of the measuring track (track length in
printout) into fixed sections.
No. 17 = Longitudinal raster line
No. 18 = Identification of nominal value line
Show the setting of nominal value (150).
No. 19 = Measuring value raster line
No. 20 = Diagram line
Shows the E
VIB
-value at any point of the rolled
track. The raster line enables the location related
assignment of the E
VIB
-value and the location of a
fault (over or under compaction).
3.7 Line diagram Manual (E
VIB
)
Fig. 36
1 Pass-No.
2 Travel direction
3 Machine equipment
4 Software status of the measuring equipment
5 Machine number
6 Machine type
7 Operating mode
8 Amplitude
9 Maxiumum E
VIB
value
10 Miniumum E
VIB
value
11 Mean E
VIB
-value
12 E
VIB
-change
13 Medium frequency
14 Mean travel speed
15 Track length
16 Raster division in longitudinal direction
17 Marking (thick line) excessive jumping, tum-
bling of the drum
18 Longitudinal raster line
19 Measuring value raster line
20 Diagram line
21 Marking (thin line) jumping of the drum
3.8 Description of line diagram
Manual (E
VIB
)
No. 1 = Pass
Total number of measured passes on this track.
No. 2 = Travel direction
No. 3 = Machine equipment
No. 4 = Software status of the measuring
equipment
No. 5 = Machine number
No. 6 = Machine type
No. 7 = Operating mode
Shows the setting of the operating mode (Auto)
and the presetting of nominal value (150).
No. 8 = Amplitude
Shows the amplitude which was adjusted during
the E
VIB
measuring pass.
No. 9 = Maxiumum E
VIB
value
No. 10 = Miniumum E
VIB
value
No. 11 = Mean E
VIB
-value
shows the mean value of the E
VIB
-values for the
tracks driven between START and STOP.
No. 12 = E
VIB
-change
E
VIB
-change in %. They always relate to the previ-
ous pass.
No. 13 = Medium frequency
No. 14 = Mean travel speed
shows the mean value of speed driven during this
pass.
i
Note
Always shows the same travel speed in order to
avoid a falsification of the measuring results.
No. 15 = Track length
Measured track length between START and
STOP.
No. 16 = Raster division in longitudinal direc-
tion
Is used to pinpoint individual measuring values on
the measuring curve.
i
Note
The raster lines mark measuring track sections of
5 m length.
Graduation of the measuring track (track length in
printout) into fixed sections.
No. 17 = Marking of jump information
Indicates excessive jumping/tumbling of the drum
on the marked track section (thick line).
i
Note
Select a smaller amplitude, if necessary!
No. 18 = Longitudinal raster line
No. 19 = Measuring value raster line
No. 20 = Diagram line
Shows the E
VIB
-value at any point of the rolled
track. The raster line enables the location related
assignment of the E
VIB
-value and the location of a
fault (over or under compaction).
No. 21 = Marking of jump information
Indicates jumping of the drum on the marked track
section (thin line).
3.9 Bar diagram
*
(E
VIB
)
The bar diagram differs from the line diagram only
by the graphic representation of measuring val-
ues. In the bar diagram the mean values of 5 m
sections are shown as bars. In addition, the E
VIB
changes of the individual 5 m sections are speci-
fied in percent after the second pass in the same
travel direction.
* only BTM prof
4 Operation
Operation
4.1 General notes
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
you are not yet fully familiar with the indicators and
control elements of the machine.
All indicators and control elements are described
in detail in this chapter.
4.2 Tests before taking into op-
eration
The following inspections must be carried out be-
fore each working day or before a longer working
period.
! Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
l Park the machine on ground as level as possi-
ble.
Check:
l fuel tank and fuel lines for leaks
l screw joints for tight fit
l function of steering
l machine for cleanliness, damage
l presence of the appropriate operating and
maintenance instructions,
l check whether the machine has been properly
serviced.
i
Note
For a description of the following tasks refer to the
chapter "maintenance every 10 operating hours".
l Engine oil level
i
Note
In hydraulic systems filled with Panolin HLPSynth.
46 always use the same oil to top up. With other
ester based oils consult the lubrication oil service
of the respective oil manufacturer.
l Check the hydraulic oil level, top up if neces-
sary.
l Check the coolant level, top up if necessary.
! Danger
Fire hazard!
Do not refuel in closed rooms.
l Check the fuel level, top up if necessary.
Operation
l Check water separator in fuel system, drain if
necessary.
l Check the scrapers, adjust if necessary
l Check the air pressure in the tires For values
refer to the technical data.
! Caution
Ensure equal pressure in both tires.
If the machine is to be operated with padfoot
drum shell the attachment plates must be de-
coupled!
Danger of damage to the drive axle.
4.3 Starting the engine
! Danger
Danger of accident!
Always wear your seat belt.
Fig. 37
l Check, whether the travel lever (Fig. 37) is en-
gaged to the right in brake position.
Fig. 38
l Turn the rotary vibration switch (Fig. 38) to po-
sition "0", vibration off.
Operation
Fig. 39
l Check, whether the emergency stop switch
(Fig. 39) is unlocked.
Fig. 40
l Turn rotary switch (Fig. 40) to position "Min"
(idle speed).
Fig. 41
l Turn the ignition key (Fig. 41) to position "I".
Fig. 42
All control and warning lights (Fig. 42) in the fault
monitoring board light up for a moment.
The battery control (l) and brake warning lights (u)
light up, the engine oil pressure warning light (e)
flashes.
l Wait until the pre-heating light (k) has gone
out.
i
Note
The length of the pre-heating period depends on
the engine temperature.
! Caution
Perform the starting process for maximum 20
seconds without interruption and pause for a
minute between starting attempts.
If the engine has not started after two attempts
perform trouble shooting.
Operation
Fig. 43
l Turn the ignition key to position "II" (Fig. 43),
the starter cranks the engine.
l As soon as the engine ignites return the igni-
tion key to position "I".
! Caution
Do not allow the engine to run longer than 10
minutes with idle speed.
4.4 Starting with jump wires
Fig. 44
! Caution
A wrong connection will cause severe damage
in the electric system.
l Bridge the machine only with a 12 Volt auxilia-
ry battery.
l When jump starting with an external battery
connect both plus poles first.
l Then connect the ground cable first to the mi-
nus pole of the current supplying auxiliary bat-
tery and then to engine or chassis ground, as
far away from the battery as possible (Fig. 44).
l Start as described under 'Starting the engine'.
l Once the engine is running switch on a power-
ful consumer (working light, etc.).
! Caution
If no powerful consumer is switched on volt-
age peaks may occur when separating the con-
necting cables between the batteries, which
could damage electrical components.
l After starting disconnect the negative poles
(ground cable) first and the positive poles af-
ter.
l Switch off the consumer.
Operation
4.5 Driving the machine
! Danger
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclina-
tions and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive up and down inclinations exceed-
ing the maximum gradability of the machine
(see technical data).
Do not drive without wearing your seat belt.
Always give way to loaded transport vehicles!
Before starting to drive make sure that the
drive range is absolutely safe.
! Caution
Always keep the cabin door closed while driv-
ing with the machine. With the door opened
and the machine fully articulated extreme os-
cillations of the machine may damage the
door.
i
Note
The machine is equipped with an armrest monitor-
ing system and a seat contact switch (safety fea-
ture).
If the armrest is raised or the driver gets up from
his seat while driving, the warning horn is activated
and the machine is decelerated to standstill after
four seconds. If the armrest is lowered again or the
driver sits down again within four seconds the ma-
chine will continue the travel.
Lower the armrest or sit down on the seat again
before resuming operation, engage the travel le-
ver in "0"-position (brake position), then operate
the travel lever again to the desired travel direc-
tion.
Fig. 45
l Close the cabin door (Fig. 45).
Fig. 46
l Sit on the driver's seat (Fig. 46) and fold down
the armrest (if applicable).
Fig. 47
l Fasten your seat belt (Fig. 47).
l "Start engine", see previous sections.
Operation
Fig. 48
l Select the desired travel speed range (Fig.
48).
play unit in form of a green ring segment.
Fig. 49
l Turn the rotary switch (Fig. 49) to position
"ECO" or "MAX".
Fig. 50
l Push the travel lever (Fig. 50) to the left out of
braking position and move it slowly to the de-
sired travel direction.
i
Note
Shift the travel lever out of "0"-position slowly to
forward or reverse, the machine will drive forward
or reverse at a speed which corresponds with the
displacement of the travel lever.
Returning the travel lever towards neutral will
brake the machine and in "0"-position of the travel
lever the machine will stop.
! Danger
Danger of accident!
When stopping on inclinations and slopes pull
the travel lever to the right and lock it in brak-
ing position.
Important notes on travel operation
! Caution
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!
When driving up and down inclinations move
the travel lever slowly back towards neutral to
brake the machine.
If the engine speed drops when driving up ex-
treme inclinations move the ravel lever slightly
Operation
back, if necessary change to the lower speed
range.
4.6 Switching the vibration on
and off
! Danger
Risk of damage!
When compacting with vibration you must
check the effect of nearby buildings and un-
derground supply lines (gas, water, sewage,
electric power), if necessary stop compaction
with vibration.
Do not activate the vibration on hard (frozen,
concrete) ground. Danger of bearing damage!
Fig. 51
l Pre-select the travel range for max. working
speed (Fig. 51).
play unit in form of a green ring segment.
Operation
Pre-selecting the vibration
Fig. 52
l Pre-select vibration with rotary switch (Fig.
52).
Switch the vibration on
i
Note
Vibration is only possible in the range of 0 ... 8 km/
h.
Fig. 53
l Turn the rotary switch (Fig. 53) to position
"ECO" (Automatic) or "MAX" (full throttle).
! Caution
Switch the vibration on only at ECO max. en-
gine speed.
Fig. 54
l Press the push button (Fig. 54) in the travel le-
ver while driving, the drum will vibrate.
Switching the vibration off
l Press the push button again and after work
switch the rotary vibration switch to position
"0".
Operation
4.7 Operating the parking
brake, stopping the ma-
chine
Fig. 55
l Return the travel lever (Fig. 55) slowly to "neu-
tral"-position and engage it to the right parking
brake position.
The machine is automatically braked by the hydro-
static drive and parking brake closes.
i
Note
The parking brake also closes automatically when
shutting the engine down.
4.8 Shutting the engine down
! Caution
Straighten the articulated joint to provide easi-
er access to the machine.
Fig. 56
l Return the travel lever (Fig. 56) slowly to "neu-
tral"-position and engage it to the right in brak-
ing position.
Fig. 57
l Turn rotary switch (Fig. 57) to position "ECO"
or "MIN" (idle speed).
i
Note
Do not shut the engine down all of the sudden from
full speed, but let it idle for a while for temperature
equalization.
Operation
Fig. 58
l Turn the ignition switch (Fig. 58) to position "0"
or "P" and pull the ignition key out.
i
Note
The parking brake closes automatically when
shutting the engine down.
! Danger
Danger of accident!
Secure the machine against unauthorized use,
pull the ignition key out, lock the cabin door.
4.9 Changing the LCD-display
Switching the middle display over
i
Note
Switching over possible while machine is operated
Fig. 59
l Press Info-button 1 (Fig. 59) (back of travel le-
ver).
Fig. 60
With each actuation of the button the display
changes from operating hours to mean fuel con-
sumption or vice versa (Fig. 60).
Switching the bottom display over
i
Note
Switching over possible while machine is operated
Operation
Fig. 61
l Press Info-button 2 (Fig. 61).
Fig. 62
With each actuation of the button the values for in-
clination, vibration frequency, voltage, engine oil
pressure, hydraulic oil temperature
*
and ambient
temperature* are successively displayed (Fig. 62).
Activating input mode and changing
display fields (brief instructions)
i
Note
In input mode the following can be changed:
- Display of time/coolant temperature
- Setting of time / date
- Metric/imperial units
- Brightness of display
- Input codes for service
Fig. 63
l Set the travel lever (Fig. 63) to braking position
Fig. 64
l Press both Info-buttons (Fig. 64) longer than
three seconds to access the input mode.
"UHR" or "CLOCK" appears in the display.
Operation
Fig. 65
l Select the desired field with the selection key
F3 (Fig. 65).
i
Note
With function key F5 you can only jump back with-
in the display, e.g. fromminutes to hours. It cannot
be used to jump from one field function to the pre-
vious one, e.g. from changing the upper display
back to the time.
Fig. 66
Sequence of changeable fields (Fig. 66):
Setting of time / date,
upper display changing of time / coolant tempera-
ture
Changing units from metric/imperial
Adapting brightness of display,
Entering input codes for service
Fig. 67
l To change the field press keys F2 or F4 (Fig.
67).
i
Note
F2 = reduces the value or changes the display
F4 = increases the value or changes the display
Fig. 68
l To quit the input mode press both Info-buttons
(Fig. 68) longer than three seconds or press
the F3-key as often as required to re-establish
normal condition.
Operation
Example of changing "Time/Date"
Fig. 69
Fig. 70
"UHR" or "CLOCK" appears in the display and the
figures representing the hours are flashing (Fig.
70).
Fig. 71
l Set the hours with keys F2 or F4 (Fig. 71).
Fig. 72
l Press key F3 to select "Minutes" (Fig. 72) and
set the displayed minutes with keys F2 or F4
(Fig. 71).
Fig. 73
The figures representing minutes flash (Fig. 73)
l Set the minutes with keys F2 or F4 (Fig. 71).
Fig. 74
l Press key F3 to select "Day" (Fig. 74) and set
the display keys F2 or F4 (Fig. 71).
Operation
Fig. 75
l Press key F3 to select "Month" (Fig. 75) and
set the displayed month with keys F2 or F4
(Fig. 71).
Fig. 76
l Press key F3 to select "Year" (Fig. 76) and set
the year with keys F2 or F4 (Fig. 71).
Fig. 77
normal condition.
Switching over the upper display
"Time / Coolant Temperature"
Fig. 78
Fig. 79
l Press selection key F3 (Fig. 79) as often as re-
quired to quit the setting mode for time/date.
Operation
Fig. 80
The display "UHR" or "CLOCK" flashes (Fig. 80).
Fig. 81
l Press keys F2 or F4 (Fig. 81).
Fig. 82
The coolant temperature is displayed (Fig. 82).
Fig. 83
l Press selection key F3 (Fig. 83) once to con-
firm.
Fig. 84
normal condition.
Operation
Changing the display units to "Metric /
Imperial"
Fig. 85
Fig. 86
l Press selection key F3 (Fig. 86) as often as
required to reach the "Metric/Imperial" setting
mode.
Fig. 87
The display will show "DEU" or "ENG" (Fig. 87).
Fig. 88
firm.
Fig. 89
normal condition.
Operation
Setting the day/night brightness of the
LCD-display
Fig. 90
Fig. 91
l Press selection key F3 (Fig. 91) as often as re-
quired to reach the "Brightness" setting mode.
Fig. 92
The symbol "Lamp" and the brightness value (day)
in percent flashes (Fig. 92).
Fig. 93
l Adjust the value with the keys F2 or F4 (Fig.
93).
Fig. 94
l Switch on the light (Fig. 94).
Operation
Fig. 95
The brightness percentage (night) appears flash-
ing (Fig. 95).
i
Note
Standard setting for day = 100 %
Standard setting for night = 50 %
Fig. 96
l Adjust the value with the keys F2 or F4 (Fig.
96).
Fig. 97
firm.
Fig. 98
normal condition.
Operation
Entering input codes for service
Fig. 99
Fig. 100
l Press selection key F3 (Fig. 100) as often as
required to reach the "Service Codes" setting
mode.
Fig. 101
The figures to enter the code are displayed (Fig.
101).
Fig. 102
l Adjust the value of the first digit with the keys
F2 or F4 (Fig. 102).
Fig. 103
l Select the following code digits with the keys
F3 or F5 (Fig. 103) and adjust these with the
function keys F2 or F4 (Fig. 102).
Operation
4.10 Emergency exit
If the machine should turn over and the cabin door
is closed, the right hand side cabin window can be
used as an emergency exit.
4.11 Adjusting the seat
Fig. 104
l To adjust the seat in longitudinal direction dis-
engage lever a (Fig. 104).
l To adjust the weight turn lever (b) and read the
weight in sight glass (c).
l Operate lever (d) to adjust the backrest.
Fig. 105
l To adjust the height of the seat lift the seat up
(Fig. 105) until it engages at the desired level.
When lifting the seat completely it will sink down to
lowest position.
Operation
Fig. 106
l To slide the seat pull up lever (Fig. 106) and
slide the seat to the desired position.
When releasing the lever the seat is fixed in posi-
tion.
Fig. 107
l To turn the seat press down lever (Fig. 107)
and turn the seat to the desired direction.
When releasing the lever the seat is fixed in posi-
tion.
4.12 Operating the hood
! Danger
Danger of accident!
If the hood needs to be opened further for
maintenance or repair work, support it safely.
Bottom position
Fig. 108
l Unlock the lock (Fig. 108).
l To open the hood press in the button and turn
the handle.
Fig. 109
l Pull the support out of the bracket and support
the hood (Fig. 109).
Top position
l Push the hood to top position.
Operation
Fig. 110
l Pull the spring pin (Fig. 110) out of the bracket.
l Secure the hood in the protection tube with
spring plug.
4.13 Towing in case of an engine
failure
! Danger
Secure the machine with wheel chocks against
unintentional rolling.
Danger of accident!
When using towing ropes tow the machine
only uphill.
When towing downhill you must use a rigid
towing device.
The machine cannot be steered.
l Secure the machine with wheel chocks
against unintentional rolling.
Fig. 111
l Attach chains (Fig. 111) or towing ropes to the
lifting hooks.
! Caution
Towing speed 1 km/h, max. towing distance
500 m.
l Open the tailgate.
Operation
Fig. 112
l Slacken the middle hexagon on both valves
(Fig. 112) for approx. 2 to 3 turns.
! Caution
Do not turn the valves out completely.
Fig. 113
l To release the brake turn counter nuts 1 (Fig.
113) approx. 8 mm back.
l Turn the brake releasing screws (2) complete-
ly in against the stop.
! Caution
From this stop turn the screw in for maximum
another turn to release the brake!
Turn the screws in evenly on both sides.
l Turn the screws in alternately for turn at a
time.
l Repeat this measure on the opposite wheel
side.
Fig. 114
l Turn both screws (Fig. 114) for releasing the
drum brake evenly in clockwise direction, until
the drum can turn freely.
After towing
! Caution
Before detaching the tow bar block the ma-
chine with chocks to prevent unintended roll-
ing.
l Turn the high pressure relief valve cartridges
tightly back in.
l Turn both screws for releasing the drum brake
(Fig. 114) anti-clockwise against the stop.
l Turn all brake releasing screws of the axle
evenly back out, until they are light moving
again.
Fig. 115
l Turn the brake releasing screws (Fig. 115)
back in again, until they abut against the brake
piston.
Operation
Fig. 116
l Unscrewthe brake releasing screws (Fig. 116)
for two turns and tighten the counter nuts.
l Repeat this adjustment procedure on the op-
posite wheel side.
i
Note
If necessary replace the seal ring under the coun-
ter nut if it is leaking.
For this purpose completely unscrew the brake re-
leasing screw, replace the seal ring and lubricate
the screw with silicone grease.
Reinstall the screw with a new seal ring and adjust
the protrusion as described above.
4.14 Transport
! Danger
Danger of accident!
Use only stable loading ramps of sufficient
load bearing capacity. Make sure that persons
are not endangered by the machine tipping or
sliding off.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
Do not stand or step under loads being lifted.
Always use shackles on the lifting points for
loading, tying or lifting the machine.
Fig. 117
l Pull the spring pin (Fig. 117) out.
l Engage the articulation lock and secure it with
the spring pin.
Fig. 118
l Engage the articulation lock and secure it with
the spring pin (Fig. 118).
Operation
Fig. 119
l Lash the machine on the transport vehicle
(Fig. 119), use the four lashing eyes on front
and rear frame for this purpose.
l Support the front frame to avoid overstressing
of the rubber buffers.
Fig. 120
l For lifting use also the four lifting eyes (Fig.
120) and appropriate lifting gear.
Fig. 121
l Position of centre of gravity (Fig. 121).
i
Note
The tolerances account for all possible options,
such as cabin, additional weight etc.
Weights: See technical data.
l After transport release the articulation lock
again and store it in the receptacle.
Machine L H
BW 213-4 147090 86070
Operation
4.15 Tests before starting to op-
erate
Please observe strictly the safety regulations in
chapter 2 of these operating and maintenance in-
structions and also the safety regulations for the
machine these vibratory plates are attached to.
Before each working day:
l Inspect attachment plates and hydraulic hoses
for damage, check hydraulic systemand vibra-
tor housings for leaks.
! Caution
Rectify faults before starting to operate.
4.16 Mounting the attachment
plates
! Danger
Keep a sufficient safety distance for guiding.
! Caution
Danger of axle damage!
Do not attach the plates when working with the
padfoot drum shell.
Fig. 122
l Drive the machine backwards to the plate re-
ceptacles (Fig. 122).
Fig. 123
l Lower the retaining bolt into the receptacle
guide (Fig. 123) and move it with the pushing
cylinder to the left against the stop.
Operation
Fig. 124
l Flip the lock over and insert the locking bolt
(Fig. 124).
Fig. 125
l Pull the quick connect coupling (Fig. 125) out
of the bracket.
l Check the quick connect coupling for cleanli-
ness, clean thoroughly if necessary.
Fig. 126
! Caution
Ensure strict cleanliness to keep dirt out of the
hydraulic system.
l Insert the quick connect coupling into the con-
necting block and flip the bow 1 (Fig. 126) over
to lock.
The locking button (2) must protrude when locked.
i
Note
The quick connect coupling can only be plugged in
and locked in one position.
Operation
4.17 Taking the attachment
plates into service
! Danger
The operator must make sure that no person is
in the danger area before he lowers the plates
to the ground.
! Caution
Reversing with the plates lowered will damage
the plate suspension!
Remember that the plates will swing out when
cornering.
Before using the attachment plates perform a
trial run to check whether the hydraulic con-
nections are leak tight.
Lower the plates
Fig. 127
l Operate the push button (Fig. 127), until the
attachment plates rest fully on the ground or
switch to "floating position".
Switch the vibration on
i
Note
Vibration can only be switched on when the at-
tachment plates are in floating mode.
Fig. 128
l Switch to floating position (Fig. 128).
Fig. 129
l Pre-select the vibration (Fig. 129).
Fig. 130
l Adjust the desired vibration frequency (Fig.
130).
Operation
Fig. 131
l Operate the push button (Fig. 131) in the travel
lever, the attachment plates will vibrate.
i
Note
If drum vibration is pre-selected the drum will also
vibrate.
Extending the attachment plates
! Caution
Watch out for obstructions when working with
extended plates!
Fig. 132
i
Note
When actuating the cylinder the quick connect
coupling must be unlocked.
l Pull out the locking bolt in dependence on the
desired pushing direction (Fig. 132), flip the
cylinder over and lock it again with the bolt.
Fig. 133
l Operate the push button (Fig. 133) left or right,
until the attachment plates have been extend-
ed as desired.
l Press the right hand button to extend.
l Press the left hand button to retract.
Raising the attachment plates (for
transport)
! Caution
Raise the attachment plates completely for
transport.
! Danger
Do not step or work under the raised plates.
i
Note
The attachment plates can only be raised com-
pletely in middle position (retracted).
Operation
Fig. 134
l Press the push button (Fig. 134), until the at-
tachment plates are fully raised.
4.18 Detaching the attachment
plates
Fig. 135
l Switch to floating position (Fig. 135).
Fig. 136
l Press the unlocking button (Fig. 136) and flip
the bow over.
l Pull out the quick connect coupling.
Operation
Fig. 137
l Plug the quick connect coupling (Fig. 137) into
the bracket.
Fig. 138
l Pull out bolt 1 (Fig. 138) and reinsert it in park-
ing position (3).
l Switch the lock (2) over.
Fig. 139
l Move the retaining bolt with the pushing cylin-
der to the right out of the receptacles (Fig.
139).
! Danger
Do not work under the unsecured frame.
l Lift the frame completely out of the plate re-
ceptacle by means of the lift cylinders.
l Drive the machine forward out of the plate re-
ceptacles.
Operation
4.19 Variocontrol, selecting the
operating mode
i
Note
The normal mode of operation is Variocontrol in
automatic mode. However, based on his experi-
ence and with respect to the material to be com-
pacted, the operator can set certain effective
amplitudes manually.
In travel lever position "0" the vibrator system re-
mains in position horizontal for safety reasons.
Fig. 140
l Start the engine and run it with maximum
speed or position "ECO" (Fig. 140).
l Pre-select the slow speed range .
Fig. 141
l Enable vibration (Fig. 141).
Variocontrol automatic operation
Fig. 142
l Press button F12 or turn rotary button P2
clockwise to set the operating mode to "Auto"
(Fig. 142).
The set mode appears in the display as P2. Dis-
play field A lights green.
Fig. 143
l Press button F13 or F14 or turn rotary button
P3 to set the required "nominal value" (Fig.
143).
The set nominal value appears in the display as
P3.
i
Note
Normal position "Max.". Now the machine works
with maximum compaction energy.
On problematic soils, such as sand, it may be nec-
essary to reduce the compaction energy, so that
the drum does not dig into the ground.
Operation
Also if you want to reduce the depth effect it may
be sensible to reduce the compaction energy.
Fig. 144
l Actuate the travel lever (Fig. 144).
Fig. 145
l Switch the vibration on (Fig. 145).
Fig. 146
The gauge (Fig. 146) shows the current vertical
amplitude to the corresponding travel direction.
Variocontrol manual setting (Manual)
Fig. 147
l Press button F11 or turn rotary button P2 anti-
clockwise to set the the operating mode to
"Manual" (Fig. 147).
The set mode appears in the display as P2. Dis-
play field M lights green.
Fig. 148
l Press button F9 or F10 or turn rotary button P1
to set the required "direction of vibration" (Fig.
148).
The adjusted amplitude direction appears in the
display as P1
i
Note
From position "0" switch slowly up step by step
during operation and watch the drum while doing
this. When the drum starts to jump turn the rotary
switch one step back.
The gauge shows the current vertical amplitude.
Operation
On bridges or in sensitive areas it is recommended
to use Manual Horizontal.
Fig. 149
l Actuate the travel lever (Fig. 149).
Fig. 150
Fig. 151
The gauge (Fig. 151) shows the current vertical
amplitude to the corresponding travel direction.
4.20 Measuring pass with Vario-
control
General notes
i
Note
The soil measuring values (E
VIB
) recorded during
different passes can only be compared if the re-
cording of measuring values took place in operat-
ing mode "Manual" with the same amplitude,
frequency and travel speed and on exactly the
same track.
A change in travel speed would affect the measur-
ing result, because e.g. with a slow travel speed
per pass the energy introduced into the ground is
higher and in the comparison of all passes a high-
er soil measuring value would be displayed.
The following description describes an measuring
pass in forward. Measuring passes in manual re-
verse must be performed accordingly.
Measuring values must only be compared for
passes performed in the same direction.
Measuring pass
Fig. 152
l Turn the ignition key (Fig. 152) to position "I"
The BTM-E performs a self-test.
Operation
Fig. 153
l Control field F5 (Fig. 153) lights green.
Fig. 154
l Turn the ignition key (Fig. 154) to position II
engine start.
Fig. 155
l Mark the track to be compacted (Fig. 155).
! Caution
Since the transducer unit is mounted on the
left hand side of the drum, it is necessary to ar-
range the tracks so that track 1 is processed
first, followed by further tracks offset to the
left.
i
Note
Maximum track length 150 m.
Forward:
Mark 1 = Start of track
Mark 2 = End of track
i
Note
The operator may also remember the start and the
end of the track by means of distinct points.
Operation
Fig. 156
l Choose the maximum forward speed (Fig.
156).
The adjusted travel speed is indicated by a green
ring segment in the tachometer on the LCDdisplay
unit.
Fig. 157
l In the starting distance set the rotary switch for
engine speed (Fig. 157) to "ECO" (Automatic)
or "MAX" (full throttle).
Fig. 158
l Shift the travel lever (Fig. 158) fully to position
I.
The machine accelerates up to the preadjusted
travel speed.
! Caution
Differences in the travel speeds falsify the
measuring result!
Fig. 159
! Caution
Before reaching mark 1 the nominal exciter
shaft speed and the adjusted amplitude must
have been reached and a valid E
vib
-value
should be displayed.
Operation
Fig. 160
l When mark 1 is reached, press button F5
START (Fig. 160).
Control field to the left of F5 lights green.
The E
VIB
- display shows the present value.
Fig. 161
l When the end of the track, mark 2, is reached,
press the button F6 STOP (Fig. 161).
i
Note
The first forward pass is finished.
Control field F5 lights green. This means, that the
compaction is not yet completed. One or several
passes are still required.
l Stop the machine.
4.21 Finishing compaction of a
track
Fig. 162
l Drive forward and reverse passes on a track
until the green control field to the left of F5 (Fig.
162) goes out and the red control field F6 be-
low lights up after pressing the stop button F6.
The compaction process on this track is finished.
Once the travel lever has been returned to neutral
position after recording, the printout will immedi-
ately start.
i
Note
Another pass on this track does not make any
sense, because an increase in load bearing ca-
pacity is hardly possible with this machine.
l If necessary print out the measuring data for
this track (see following section).
Operation
Fig. 163
l Repeat the complete compaction process on
the next track (Fig. 163) to record measuring
values.
4.22 Printing measuring data af-
ter completing compaction
i
Note
Measuring data can be printed after completion of
any pass.
Always check the paper provision before starting
work.
Change the paper roll if a red stripe appears on the
paper.
Fig. 164
l At the end of the track press push button F7
PRINT (Fig. 164).
short actuation = Line diagram
long actuation 5
sec. = Bar chart
Control field F7 goes out and the measuring value
printer starts to print out measuring data.
i
Note
Once the red control light to the left of field F6
lights up any amount of diagrams can be printed
out by pressing the same button F7 (PRINT).
Operation
Fig. 165
l If no further printouts of this track are needed,
press the button F8 DELETE (Fig. 165) when
the red control lamp F6 FINISHED lights up.
The red control field F6 FINISHED goes out and
the green control field F5 CONTINUE lights up.
BTM plus/prof is ready to compact the next track.
4.23 Teaching distance pulses
i
Note
The distance pulses have already been set by de-
fault when setting the correct machine type.
Due to slippage of the drums the recorded dis-
tance measurement may differ from the actually
driven distance.
An adaptation of the distances pulses in only pos-
sible within the range of +/- 10% of the default val-
ue.
l Compare the actually driven distance with the
recorded distance in the printed line diagram
*
.
l In case of different distances an adaptation to
these distances is required.
l Engine running.
Fig. 166
l Press key ? (menu) (Fig. 166).
i
Note
The menu appears on the screen.
Operation
Fig. 167
l Press key "F8" (distance pulses) (Fig. 167).
i
Note
The screen page with the pre-set distance pulses
appears.
Fig. 168
l When the machine has stopped press key
"F5" (teach mode) (Fig. 168).
i
Note
The screen page with distance pulses appears.
l Switch on vibration and drive the machine 10
m forward.
Fig. 169
l At the end of the 10 m distance press key "F6"
(quit teach mode) (Fig. 169).
i
Note
The screen page to save the distance pulses ap-
pears.
l Switch off vibration and stop the machine.
Fig. 170
l Press key "F14" (safe distance pulses) (Fig.
170).
Operation
Fig. 171
l If the screen page states that the distance
pulses cannot be saved after pressing the key
"F6" (quit teach mode) (Fig. 171), the meas-
urement must be repeated.
i
Note
The measured distance pulses are not within the
range of +/- 10% of the default value.
Saving is not possible.
l Press key "ESC" to return to the working
screen.
4.24 Amplitude limitation (BVC
only)
i
Note
The amplitude limitation in automatic mode ena-
bles a limitation of the effective and measuring
depth.
The system offers 5 regulating ranges ( 0 - 0.7
mm; 0 - 1.1 mm; 0 - 1.5 ; 0 - 1.9 mm; 0 - 2.4 mm
(max).
This is e.g. sensible when a layer on a soft or in-
stable base is to be compacted, and this base it-
self cannot be compacted or has a extremely high
stiffness.
In operating mode "Automatic" with nominal value
"MAX" the amplitude limitation is inactive.
Fig. 172
i
Note
The control unit shows the start screen.
Operation
Fig. 173
l When activating the amplitude limitation, the
symbol (Fig. 173) will appear on the screen.
i
Note
If no symbol appears, the amplitude limitation may
need to be activated (if required).
Fig. 174
l Press button F12 or turn rotary button P2
clockwise to set the operating mode to "Auto"
(Fig. 174).
Fig. 175
l Set the amplitude limitation with keys F9 or
F10, or with rotary button P1 (Fig. 175).
0 = low amplitude
1 = 0 to 0.7 mm
2 = 0 to 11 mm
3 = 0 to 1.6 mm
4 = 0 to 1.8 mm
6 = 0 to 2.5 mm, max. amplitude, ampli-
tude limitation not active
Activating/deactivating the amplitude
limitation
Fig. 176
i
Note
Operation
Fig. 177
l Press key "F3" (amplitude limitation) (Fig.
177).
i
Note
The screen page "Amplitude limitation" appears
on the screen.
Fig. 178
l Press key "F5" to activate/deactivate the limi-
tation (Fig. 178).
0 = Limitation switched off
1 = Limitation switched on
l Press key "F14" to save the changed setting.
l Press "ESC" to exit the screen page.
4.25 Changing the paper roll in
the measuring value printer
*
i
Note
Use a new paper roll if a red stripe appears on the
paper.
Fig. 179
l Unscrew the star handles (Fig. 179) and re-
move the cover.
Fig. 180
l Remove shaft 1 (Fig. 180) with the rest of the
paper roll (2).
* only BTM prof
Operation
Fig. 181
l Insert a new paper roll (Fig. 181).
l Feed the paper into the guide (1) on the print-
er.
l Actuate the toggle switch (2) in direction of ar-
row, until the paper comes out of the printer.
l Reassemble the cover.
4.26 Changing the printer ribbon
in the measuring value
printer
*
i
Note
In case of faint or poorly legible diagrams the print-
er ribbon needs to be replaced.
Fig. 182
l Unscrew the star handles (Fig. 182) and re-
move the cover.
Fig. 183
l Lift the tongue at point 1 (Fig. 183) and take
the printer ribbon (2) out of the printer.
l Insert the new printer ribbon into the printer,
then press in the tongue (1) on the right.
l Tension the printer ribbon by turning the rotary
button (3) in direction of arrow.
l Reassemble the cover.
* only BTM prof
Operation
5 Maintenance
Maintenance
5.1 General notes on mainte-
nance
When performing maintenance work always com-
ply with the appropriate safety regulations.
! Danger
Thorough maintenance of the machine guaran-
tees far longer safe functioning of the machine and
prolongs the lifetime of important components.
The effort needed for this work is only little com-
pared with the problems that may arise when not
observing this rule.
The terms right/left correspond with travel direc-
tion forward.
l Always clean machine and engine thoroughly
before starting maintenance work.
l For maintenance work stand the machine on
level ground.
l Perform maintenance work only with the en-
gine shut down.
l Relieve hydraulic pressures before working on
hydraulic lines.
l Before working on electric parts of the ma-
chine disconnect the battery and cover it with
insulation material.
l When working in the area of the articulated
joint attach the articulation lock (transport
lock).
Environment
During maintenance work catch all oils and fu-
els and do not let them seep into the ground or
into the sewage system. Dispose of oils, cool-
ant and fuels environmentally.
Notes on the fuel system
The lifetime of the diesel engine depends to a
great extent on the cleanliness of the fuel.
l Keep fuel free of contaminants and water,
since this will damage the injection elements
of the engine.
l Drums with inside zinc lining are not suitable to
store fuel.
l The fuel drum must rest for a longer period of
time before drawing off fuel.
l Do not let the hose stir up the slurry at the bot-
tom of the drum.
l Do not draw off fuel from near the bottom of
the drum.
l The rest in the drum is not suitable for the en-
gine and should only be used for cleaning pur-
poses.
Notes on the performance of the en-
gine
On diesel engines both combustion air and fuel in-
jection quantities are thoroughly adapted to each
other and determine power, temperature level and
exhaust gas quality of the engine.
If your engine has to work permanently in "thin air"
(at higher altitudes) and under full load, you should
consult the customer service of BOMAG or the
customer service of the engine manufacturer.
Notes on the hydraulic system
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that
no dirt or other contaminating substances can en-
ter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clog noz-
zles and pilot bores, thereby making expensive re-
pairs inevitable.
l 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.
l Seal external leaks immediately. If necessary
inform the responsible customer service.
l 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.
l Always use the filling and filtering unit
(BOMAG part-no. 007 610 01) to fill the hy-
draulic system. This unit is fitted with a fine fil-
Maintenance
ter to clean the hydraulic oil, thereby
prolonging the lifetime of the filter.
l Clean fittings, filler covers and the area around
such parts before disassembly to avoid enter-
ing of dirt.
l Do not leave the tank opening unnecessarily
open, but cover it so that nothing can fall in.
Notes on the cooling system
For water-cooled engines the preparation and in-
spection of the coolant is of greatest importance,
as otherwise the engine may be damaged by cor-
rosion, cavitation and freezing.
The coolant is prepared by mixing a cooling sys-
tem protection agent into the coolant.
The cooling system must be permanently moni-
tored. Besides the inspection of the coolant level
this includes also the inspection of the concentra-
tion of cooling system protection agent.
The concentration of cooling system protection
agent can be checked by means of commercial
testers (glycomat).
! Danger
Health hazard!
The mixing of nitrite based anti-freeze agents
with amine based agents results in the forma-
tion of health affecting nitrosamines.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
5.2 Fuels and lubricants
Engine oil
Quality
Lubrication oils are classified according to their
performance and quality class. Oils according to
other comparable specifications may be used.
The exact assignment of the approved oil qualities
and oil change intervals can be taken from the fol-
lowing section "Lubrication oil change intervals".
Consult your local service station if in doubt.
Oil viscosity
Multi-purpose oils should be generally used.
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class) .
Optimal operating conditions can be achieved by
using the opposite oil viscosity chart (Fig. 184) as
a reference.
Occasionally falling short of the temperature limits
will impair the cold starting ability, but will not
cause any engine damage. In order to keep the
occurring wear as low as possible, occasional ex-
ceeding of the limits should not happen over a
longer period of time.
Approved engine oils
Deutz DQC II-05 DQC II-05
ACAE E3/96/E5-02/
E7-04
E4-99/E6-04
API CG-4/CH-4/CI-
4
-
DHD DHD-1 -
Maintenance
Fig. 184
With their better temperature and oxidation stabil-
ity synthetic lubrication oils offer quite a few bene-
fits.
Oil change intervals
The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the follow-
ing oil change intervals are not reached over a pe-
riod of 1 year, the oil change should be performed
at least once per year, irrespective of the operating
hours reached.
ACEA
*
E3-96/E5-02/E7-
04/E4-99/
E6-04 = 500 operating hours
API
**
CG-4/CH-4/
CI-4 = 500 operating hours
! Caution
These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight
and for ambient temperatures higher than -10
C.
When using fuels with a sulphur content of
more than 0.5% to 1% or under ambient tem-
peratures below-10 C the oil change intervals
specified in the table must be halved. For fuels
with a sulphur content of more than 1% you
should consult the responsible service agen-
cy.
Fuels
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and
ensure strict cleanliness when filling in. A higher
sulphur content has a negative effect on the oil
change intervals. Use only winter-grade diesel fuel
under low ambient temperatures. The fuel level
should always be topped up in due time so that the
fuel tank is never run dry, as otherwise filter and in-
jection lines need to be bled.
When using fuels with a Cetan number < 49 poor
starting and white smoke can be expected, in par-
ticular in connection with low ambient tempera-
tures.
The following fuel specifications are permitted:
DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75;
BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-
D.
l DIN/EN 590
l BS 2869
l ASTM D 975-78: 1-D and 2-D.
l Nato Codes: F-54, F-34, F44 and XF63
Winter fuel
! Danger
Fire hazard!
Diesel fuels must never be mixed with gaso-
line.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At
very low temperatures disturbing paraffin separa-
* Association des Constructeurs European dAutomobiles
** American Petroleum Institute
Maintenance
tion can also be expected when using winter diesel
fuel.
In most cases a sufficient cold resistance can also
be achieved by adding flow enhancing fuel addi-
tives. Consult the engine manufacturer.
Operation with rape seed oil methyl ester (RME
Bio Diesel)
Due to the extreme quality differences of RMEW-
fuels available on the market, which are caused by
the non-existence of a standardization, BOMAG
does generally not approve any RME-fuels. If this
is neglected the warranty will become null and
void!
However, if you still intend to operate the machine
with RME-fuels you should observe the following
information:
l Reduced engine power (approx. 7%), higher
fuel consumption.
l The quality of RME-fuel should be in compli-
ance with DIN draft 51606.
l Avoid longer periods of standstill (formation of
resin, corrosion in injection system)
l RME-fuel can damage the paint finish of the
machine.
l Fuel dilution of engine oil, therefore shortening
of oil change intervals to half.
l Rubber parts, such as leak fuel return lines,
seats will be damaged in the long run and
need to be replaced on a regular basis or
should be replaced by parts made of fluorinat-
ed rubber. However, fluorinated rubber is not
resistant against normal diesel fuel.
l If the fuel filter is clogged the filter change in-
tervals must be shortened accordingly.
Coolant, anti-freeze agent
The correct quality of water is highly important
when preparing coolant. Clear and clean water
within the boundaries of the following analysis val-
ues should generally be used.
*
1
Proportion of carbonate hardness on the total
hardness min. 3 dGH
Information concerning the water quality can be
obtained from the waterworks.
A test case for checking the water quality can be
ordered from the engine manufacturer.
If the values of the analysis deviate, the water
must be treated accordingly.
l pH-value too low
Adding of caustic lye of soda or caustic potash
solution.
l Total hardness too high:
Mixing with dehardenede water.
l Total hardness or carbonate hardness too low:
Mixing with harder water.
l Chlorides and/or sulphates too high:
Mixing with dehardenede water.
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any
climatic conditions.
The proportion of cooling system protection agent
must be between min. 35% and max. 45% to the
water.
! Caution
Do not mix different coolants and additives of
any other kind.
! Danger
Health hazard!
The mixing of nitrite based anti-freeze agents
with amine based agents results in the forma-
tion of health affecting nitrosamines.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
Hydraulic oil
The hydraulic systemis operated with hydraulic oil
HV 46 (ISO) with a kinematic viscosity of
46 mm
2
/s at 40C. For topping up or for oil chang-
es use only high-quality hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils
type HV according to ISO 6743/3. The viscosity in-
Water quality
Analysis values min. max.
pH-value at 20 C 6,5 8,5
Chloride ion content [mg/dm
3
] - 100
Sulphate ion content [mg/dm
3
] - 100
Total hardness*
1
[dGH] ] 3 12
Maintenance
dex (VI) should be at least 150 (observe informa-
tion of manufacturer).
Bio-degradable hydraulic oil
On request the hydraulic system can also be filled
with ester based biodegradable hydraulic oil (Pan-
olin HLP Synth. 46). The biologically quickly de-
gradable hydraulic oil meets all demands of a
mineral oil based hydraulic oil according to DIN
51524.
In hydraulic systems filled with Panolin HLPSynth.
46 always use the same oil to top up. When
changing from mineral oil based hydraulic oil to an
ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manu-
facturer for details.
Check the filter more frequently after this change.
! Caution
Oil change bio-degradable hydraulic oil:
Perform regular oil analyses for content of wa-
ter and mineral oil.
Replace the hydraulic oil filter element every
500 operating hours.
Oil for drive axle
For the drive axle use only multi-purpose transmis-
sion oil of API-class GL5 with viscosity class SAE
90.
The additives in this oil ensure lowwear lubrication
under all operating conditions.
Lubrication grease
For lubrication use only EP-high pressure grease,
lithium saponified (penetration 2).
Maintenance
5.3 Table of fuels and lubri-
cants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention
Observe the level marks
Engine Engine oil ACEA: E3/96/E5-02/
E7-04 or
approx. 15,5 litres incl. oil
filter
API: CG-4/CH-4/CI-4
SAE 10W/40
(-20 C to +40 C)
SAE 15W/40
(-15 C to +40 C)
Fuel
Diesel Winter diesel fuel approx. 340 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm
2
/s at 40 C
Vario exciter drum Engine oil SAE 15W/40 approx. 16,5 litres
Exciter housing attach-
ment plates
Engine oil SAE 15W/40 2.7 litres each
Drive axle Gear oil SAE 90, API GL5 approx. 12,5 litres
Wheel hubs Gear oil SAE 90, API GL5 approx. 0,7 per side
Axle reduction gear Gear oil SAE 90, API GL5 approx. 1,9 litres
Drum drive gear Gear oil SAE 90, API GL5 approx. 3,2 litres
Air conditioning system Refrigerant R134A approx. 1400 g
Engine cooling system Cooling system protection agent approx. 16 litres
Tires Water approx. 300 litres
Calcium chloride (CaCl
2
) or magnesium chloride
(MgCl
2
)
approx. 139 kg
Maintenance
5.4 Running-in instructions
The following maintenance work must be per-
formed when running in new machines or
overhauled engines:
! Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes
l Retighten the V-belt
After 250 operating hours
l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.
l Retighten all wheel fastening screws with the
specified tightening torque.
l Oil change diesel engine and engine oil filter
l 1. Oil change in Vario exciter
l Oil change in drive axle
l Oil change, axle reduction gear
l Oil change in wheel hubs
l 1. Oil change in drum drive gear
After 500 operating hours
l 2. Oil change in Vario exciter
l 2. Oil change in drum drive gear
Maintenance
5.5 Maintenance chart
No. Maintenance work Remark
R
u
n
n
i
n
g
-
i
n
i
n
s
t
r
u
c
t
i
o
n
s
a
f
t
e
r
2
5
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
1
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
,
d
a
i
l
y
e
v
e
r
y
2
5
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
5
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
1
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
2
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
3
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
6
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
a
s
r
e
q
u
i
r
e
d
5.6
Check the engine oil level Dipstick mark X
5.7
Check the water separator X
5.8
Check the fuel level X
5.9
Check the hydraulic oil level Inspection glass X
5.10
Check the coolant level Inspection glass X
5.11
Check the dust separator X
5.12
Check the tire pressure X
5.13
Clean the cooling fins on engine
and hydraulic oil cooler
X
5.14
Check the oil level in the drive axle X
5.15
Check the oil level in the wheel
hubs
X
5.16
Check the oil level in the axle re-
duction gear
X
5.17
Check the oil level in the drum re-
duction gear
X
5.18
Checking the Vario exciter oil level X
5.19
Change engine oil and oil filter car-
tridge
*
min. 1x per year X X
5.20
Change the fuel filter cartridge X X
5.21
Drain the sludge from the fuel tank X
5.22
Battery maintenance Pole grease X
5.23
Change the fuel pre-filter cartridge X
Maintenance
5.24
Check, replace the refrigerant
compressor V-belt
X
5.25
Service the air conditioning X
5.26
Check, adjust the valve clearance Intake = 0,4 mm
Exhaust = 0,6 mm
X
5.27
Adjusting the control piston play X
5.28
Checking, replacing the V-belt X
5.29
Check the engine mounts X X
5.30
Oil change in drive axle min. 1x per year X X
5.31
Oil change in wheel hubs min. 1x per year X X
5.32
Oil change, axle reduction gear min. 1x per year X X
5.33
Oil change in drum drive reduction
gear**
5.34
Oil change in Vario exciter
**
see foot note, min.
1 x per year
X X
5.35
Oil change exciter shaft housing at-
tachment plates
5.36
Retighten the fastening of the axle
on the frame
X
5.37
Tighten the wheel nuts X X
5.38
Check the ROPS X
5.39
Clean the oil bath air filter min. 1x per year X
5.40
Change hydraulic oil and breather
filter
***
at least every 2
years
X
5.41
Change the hydraulic oil filter*** at least every 2
years
X
R
u
n
n
i
n
g
-
i
n
i
n
s
t
r
u
c
t
i
o
n
s
a
f
t
e
r
2
5
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
1
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
,
d
a
i
l
y
e
v
e
r
y
2
5
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
5
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
1
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
2
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
3
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
6
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
a
s
r
e
q
u
i
r
e
d
Maintenance
5.42
Change the steering oil filter*** at least every 2
years
X
5.43
Change the attachment plate oil fil-
ter***
at least every 2
years
X
5.44
Change the coolant at least every 2
years
X
5.45
Replace the crankcase ventilation
valve
at least every 2
years
X
5.46
Electronic injector test EMR X
5.47
Cleaning, changing the dry air filter
cartridge
min. 1x per year,
safety cartridge at
least every 2
years
X
5.48
Adjusting the scrapers X
5.49
Adjust the parking brake X
5.50
Change the tires X
5.51
Change the fresh air filter in the
cabin
X
5.52
Tightening torques X
5.53
Engine conservation X
* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h.
*** Also in case of repair in the hydraulic system.
R
u
n
n
i
n
g
-
i
n
i
n
s
t
r
u
c
t
i
o
n
s
a
f
t
e
r
2
5
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
1
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
,
d
a
i
l
y
e
v
e
r
y
2
5
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
5
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
1
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
2
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
3
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
e
v
e
r
y
6
0
0
0
o
p
e
r
a
t
i
n
g
h
o
u
r
s
a
s
r
e
q
u
i
r
e
d
Every 10 operating hours
5.6 Check the engine oil level
! Danger
Danger of injury!
Support the engine hood for all maintenance
and repair work.
i
Note
The machine must be parked horizontally with the
engine shut down.
Fig. 185
l Pull the dipstick (Fig. 185) out, wipe it off with
a lint-free, clean cloth and reinsert it until it bot-
toms.
l Pull the dipstick back out again.
l If the oil level is below the "MAX" mark fill in oil.
l If the oil level is above the Max mark deter-
mine the cause and drain the oil off.
! Caution
Before longer work periods you should always
top the oil up to the "MAX"-mark.
For quality and quantity of oil refer to the table
of fuels and lubricants.
5.7 Check, clean the water sep-
arator
! Danger
Danger of injury!
Support the engine hood for all maintenance
and repair work.
i
Note
The service intervals for the water separator de-
pend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should therefore
check the water separator every day for signs of
water.
If a to high quantity is drained off, the filter must be
refilled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.
Environment
Catch running out fuel and dispose of environ-
mentally.
Fig. 186
l Slacken the drain plug (Fig. 186) for a few
turns and catch running out fuel / water.
l Tighten the drain plug again and check for
leaks, if necessary replace the seal ring.
5.8 Check the fuel level
! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke, do not refuel in closed
rooms, do not inhale any fuel fumes.
Fig. 187
l Check the fuel level on the fuel level gauge "n"
(Fig. 187) with the ignition switched on.
i
Note
Do not drive the fuel tank dry, as otherwise the fuel
system needs to be bled.
l Clean the area around the filler opening.
Fig. 188
l Open the fuel tank cover (Fig. 188).
! Caution
Contaminated fuel can cause malfunction or
even damage of the engine.
If necessary, fill in fuel through a funnel with
screen.
l If necessary top up with fuel (diesel or winter
diesel).
For quality of fuel refer to the table of fuels and
lubricants.
5.9 Check the hydraulic oil level
! Caution
In hydraulic systems filled with Panolin HLP
Synth. 46 always use the same oil to top up.
With other ester based oils consult the lubrica-
tion oil service of the respective oil manufac-
turer.
Fig. 189
l Check the hydraulic oil level in the inspection
glass (Fig. 189).
Normal level
approx. 3 cm below the top edge of the inspection
glass.
Minimum level
Middle of inspection glass.
! Caution
If, during the daily inspection of the oil level
the hydraulic oil level is found to have
dropped, check all lines, hoses and compo-
nents for leaks.
l If necessary fill in hydraulic oil through the filler
neck.
5.10 Check the coolant level
! Danger
Danger of scalding!
Fill up coolant only when the engine is cold.
Fig. 190
l Check the coolant level (Fig. 190).
! Caution
If, during the daily inspection the coolant level
is found to have dropped, check all lines, hos-
es and engine for leaks.
l To top up unscrew the filler cap and fill in cool-
ant up to the MAX-mark.
For quality of coolant refer to the chapter 5.2,
fuels and lubricants.
5.11 Checking the dust separa-
tor on the oil bath air filter
*
Fig. 191
l If the dust reaches the mark loosen the clamp
(Fig. 191), take the cover off and clean the
bowl.
* Option
5.12 Checking the tire pressure
! Caution
Since the tires are filled with water, you should
always turn the inflation valve to top position
to check the tire pressure!
Always close the valves with the dust cap.
Fig. 192
l Check the tire pressure with a pressure gauge
and the tire inflation valve 1 (Fig. 192) in top
position.
Nominal value see "technical data".
i
Note
Ensure even pressure in all tires.
l Screw the valve caps back on.
5.13 Clean the cooling fins on
engine and hydraulic oil
cooler
! Danger
Danger of injury!
Perform cleaning work only after the engine
has cooled down and with the engine stopped.
! Caution
Do not damage any cooling fins on the cooler
core when cleaning.
i
Note
Dirt on fan blades and oil cooler reduce the cooling
effect. Dirt deposits in these areas are substantial-
ly supported by oil and fuel on these surfaces. For
this reason you should always seal any oil or fuel
leaks in the vicinity of the cooling fan or the oil
cooler and clean the cooling surfaces after.
Cleaning with compressed air
Fig. 193
i
Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 193) out with com-
pressed air.
Cleaning with cold cleansing agent
! Caution
Protect electrical equipment such as genera-
tor, regulator and starter against the direct wa-
ter jet.
l Spray the engine with a suitable cleansing
agent, e.g. cold cleanser, let it soak in for a
while and spray it off with a strong water jet.
l Run the engine warm for a while to avoid cor-
rosion.
5.14 Check the oil level in the
drive axle
l Park the machine on level ground.
Fig. 194
l Unscrewthe oil level inspection plug (Fig. 194)
and check the oil level.
i
Note
The second level inspection plug as at the back.
After filling in oil wait until the oil has evenly distrib-
uted inside the axle.
The oil level must reach the bottom edge of the
level bore.
l Top up oil, if necessary.
For quality of oil refer to the table of fuels and
lubricants.
l Turn the level inspection plug tightly back in.
5.15 Checking the oil level in left/
right wheel hubs
Fig. 195
l Move the machine until the oil level inspection
plug 1 (Fig. 195) is in horizontal position.
l Clean and unscrew the plug.
bore.
l Top up oil, if necessary.
lubricants.
l Screw the plug back in tightly.
l Repeat this inspection on the other side.
axle reduction gear
Fig. 196
l Unscrew the filler and oil level inspection plug
(Fig. 196) and check the oil level.
bore, top up oil if necessary.
lubricants.
l Retighten the filler and level inspection plug.
drum reduction gear
Check
Fig. 197
l Unscrewthe oil level inspection plug (Fig. 197)
and check the oil level.
bore, top up oil if necessary.
Filling up
l Move the drum until drain and filler plugs are
exactly vertically in line.
Fig. 198
l Unscrew the filler plug at the top (Fig. 198) and
fill in oil, until it reaches the bottom edge of the
inspection bore.
! Caution
Investigate the cause for the oil loss, if neces-
sary seal the gearbox
lubricants.
5.18 Checking the Vario exciter
oil level
i
Note
Check only at operating temperature after running
the machine approx. 1/2 hour with vibration.
Fig. 199
l Move the drum, until oil level inspection plug 1
(Fig. 199) on the left hand side of the drum is
in bottom position.
l Unscrew level inspection plug (1).
Some oil should run out of the inspection bore.
l If necessary unscrew oil filler plug (2) and fill in
some oil through the oil filler bore (2), until oil
starts to drip out through the inspection bore.
lubricants.
l Screw oil filler (2) and level inspection plug (1)
back in tightly.
l Repeat this inspection on the other side.
! Caution
If a loss of oil is found perform trouble shoot-
ing, repair the drum if necessary.
5.19 Changing engine oil and oil
filter cartridges
! Caution
The oil change at 500 operating hours refers to
the use of oils of oil quality class API CG-4/CH-
4 or ACAE E3-96/E5-02 respectively.
Refer also to the chapter 5.2, fuels and lubri-
cants.
Drain the engine oil only when the engine is
warm.
! Danger
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil fil-
ter.
Environment
Catch running out oil and dispose of environ-
mentally together with the engine oil filter car-
tridge.
Fig. 200
l Unscrew the drain plug (Fig. 200) and catch
running out oil.
l Turn the drain plug tightly back in.
Fig. 201
l Thoroughly clean the outside of both filter car-
tridges (Fig. 201).
l Unscrew both filter cartridges using an appro-
priate filter wrench.
i
Note
The filter cartridges are fitted with a valve that pre-
vents engine oil from running out during removal
and installation.
l Clean the sealing face on the filter carrier from
any dirt.
l Slightly oil the rubber seal on the new filter car-
tridges.
Fig. 202
l Turn the new filter cartridges (Fig. 202) on by
hand, until the seal contacts.
l Tighten the filter cartridges for another half
turn.
Fig. 203
l Fill in new engine oil (Fig. 203).
l Tighten the oil filler cap properly.
! Caution
Before starting crank the engine with the start-
er motor until the oil pressure warning light
goes out.
l After a short test run check the oil level on the
dipstick, if necessary top up to the top dipstick
mark.
l Check filter cartridge and drain plug for leaks
after a short test run.
l Shut the engine down and wait for about 15
minutes, so that all oil can flowback into the oil
sump.
l Check the oil level again, if necessary fill up to
the Max.-mark.
5.20 Change the fuel filter car-
tridge
! Danger
Fire hazard!
open fire, do not smoke and do not spill any fu-
el.
Catch running out fuel, do not let it seep into
the ground.
Fig. 204
l Loosen and unscrew the fuel filter cartridge
(Fig. 204) using an appropriate filter wrench.
any dirt.
Fig. 205
l Slightly oil the rubber seal (Fig. 205) on the
new filter cartridge.
l Fill the filter cartridge with clean diesel fuel.
l Turn the new filter cartridge on by hand, until
the seal contacts.
l Tighten the filter element for another half turn.
l Check the filter cartridge for leaks after a short
test run.
5.21 Draining the sludge from
the fuel tank
! Danger
Fire hazard!
open fire, do not smoke!
Do not spill any fuel.
the ground.
Fig. 206
l Unscrew the cap (Fig. 206) and drain off ap-
prox. 5 litres of fuel.
l Turn the cap tightly back in.
5.22 Service the battery
! Danger
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!
Environment
Dispose of the old battery environmentally.
i
Note
Maintenance free batteries also need care. Main-
tenance free only means that the fluid level does
not need to be checked. Each battery suffers un-
der self-discharge, which may, in not checked oc-
casionally, even cause damage to the battery as a
result of exhaustive discharge.
The following therefore applies for the service
life:
l Switch off all consumers (e.g. ignition, light, in-
side light, radio).
l 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% discharged.
l Recharge the battery immediately after an
open-circuit voltage of 12.25 V or less is
reached. Do not perform boost charging.
The open-circuit voltage of the battery occurs ap-
prox. 10 hours after the last charging process or
one hour after the last discharge.
l After each charging process allow the battery
to rest for one hour before taking it into service.
l For resting periods of more than one month
you should always disconnect the battery. Do
not forget to perform regular open-circuit volt-
age measurements.
! Caution
Exhausted batteries (batteries with formation
of sulphate on thge plates are not covered un-
der warranty!
l Open the engine hood and remove the cover-
ing.
Fig. 207
l Remove the battery (Fig. 207) and clean the
battery compartment.
l Clean the outside of the battery.
l Clean battery poles and pole clamps and
grease them with pole grease (Vaseline).
l Check the fastening of the battery.
l On serviceable batteries check the acid level,
if necessary top up to the filling mark with dis-
tilled water.
Charging voltage recommendation
Fig. 208
5.23 Change the fuel pre-filter
cartridge
! Danger
Fire hazard!
open fire, do not smoke and do not spill any fu-
el.
the ground.
Fig. 209
l Pull off the cable and unscrew the fuel filter
cartridge (Fig. 209) using an appropriate filter
wrench.
any dirt.
Fig. 210
l Unscrew the water separator from the filter
cartridge (Fig. 210).
Fig. 211
l Apply a thin coat of oil to the rubber seal of the
water separator 1 (Fig. 211).
l Screwthe water separator on by hand (2), until
the seal contacts.
l Tighten the water separator for another half
turn (3).
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter el-
ement (5) and screw it on by hand, until the
seal contacts.
l Tighten the filter element for another half turn
(6).
l Plug the water sensor cable back on.
l Check the filter cartridge for leaks after a short
test run.
i
Note
Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the en-
gine and makes starting impossible.
Therefore bleed the fuel systemafter changing the
fuel pre-filter.
Environment
Catch running out fuel and dispose of environ-
mentally.
Fig. 212
l Slacken the bleeding screw (Fig. 212) on the
fuel pre-filter for 2 to 3 turns.
l Operate the hand pump manually, until fuel
flows out of the slackened bleeding screw(Fig.
212) without air bubbles.
l Then tighten the bleeding screw while pump-
ing.
5.24 Checking, replacing the re-
frigerant compressor V-belt
! Danger
Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.
Check the V-belt
Fig. 213
l Inspect the entire circumference of the V-belt
(Fig. 213) visually for damage and cracks. Re-
place damaged or cracked V-belts.
l 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.
Tighten the V-belt.
Fig. 214
l Slightly slacken fastening screws 1, 2 and 3
(Fig. 214).
l Press the compressor in direction of arrow, un-
til the correct V-belt tension is reached.
l Retighten all fastening screws.
Changing the V-belt
l Slightly slacken the fastening screws 1, 2 and
3.
l Press the compressor against the direction of
arrow completely against the engine.
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
! Caution
Check the V-belt tension after a running time of
30 minutes.
5.25 Service the air conditioning
*
Cleaning the condenser
! Caution
A soiled condenser results in a considerable
reduction of air conditioning power.
Under extremely dusty conditions it may be
necessary to clean the condenser several
times per day.
If, during operation of the air conditioning sys-
tem, the warning buzzer sounds switch the air
conditioning off and clean the condenser.
In case of formation of foam have the air con-
ditioning system inspected by the service de-
partment.
! Danger
Danger of accident!
Do not clean with a hot water jet. Heat will
cause extreme overpressure, which could
cause damage or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 215
l Unscrewthe condenser fastening screws (Fig.
215) and fold the condenser forward.
l Clean the condenser fins on front and back
with compressed air or cold water .
Checking the refrigerant level
l Start the engine.
Fig. 216
l Switch the air conditioning (Fig. 216) on.
Fig. 217
l Choose a cooling temperature with the rotary
switch for cabin heater (Fig. 217) in the blue
section.
l Open the air outlet nozzles.
l Check, whether the outflowing air is noticeably
cooler.
i
Note
The adjusted temperature must be below the actu-
al temperature inside the cabin, so that the com-
pressor will be switched on.
l Open the hood.
Fig. 218
l Check whether the white float (Fig. 218) inside
the inspection glass of the drier/collector unit
floats right at the top.
i
Note
The refrigerant level is correct.
Fig. 219
l If the white float (Fig. 219) inside the inspec-
tion glass of the drier/collector unit floats at the
bottom, inform the service department.
i
Note
The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary
check the air conditioning system for leaks.
Checking the moisture level of the dry-
ing agent
Fig. 220
l Check the moisture indication pearl (Fig. 220)
inside the inspection glass of the drier/collec-
tor unit.
orange = drying agent o.k.
colorless = moisture level of drying agent too
high.
l Inform the service department. Replace drier/
collector unit, check air conditioning system.
! Caution
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.
Checking the condition of the drier/col-
lector unit
! Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeated-
ly inspected by a specialist. In this sense
repeated inspections are external examina-
tions, normally on pressure reservoirs in oper-
ation. In connection with this inspection the
drier/collector unit must be visually examined
twice every year. During these inspections
special attention must be paid to corrosion
and mechanical damage. If the reservoir is not
in proper condition it must be replaced for
safety reasons, as a precaution to protect op-
erators and third parties against any danger
arising from the handling and operation of
pressure reservoirs.
! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be re-
placed, to avoid bursting and further damage.
Fig. 221
l Check the drier/collector unit (Fig. 221) for me-
chanical damage or rust.
Every 1000 operati ng hours
5.26 Adjusting the valve clear-
ance
! Caution
We recommend to have this work carried out
by trained personnel or our after sales service.
Before checking the valve clearance let the en-
gine cool down for at least 30 minutes. The en-
gine oil temperature must be less than 80 C.
After a short test run check the engine for
leaks.
l Attach the cranking device over the V-belt pul-
ley fastening screws.
l Remove the valve covers.
l Crank the engine, until the valves on cylinder
1 overlap.
l The individual cylinder positions can be taken
from the section "valve adjustment schemat-
ic".
Adjusting the valve clearance
Fig. 222
l Loosen counter nut 1 (Fig. 222).
Fig. 223
Fig. 224
l Attach the rotation angle disc 3 (Fig. 224) and
the spanner socket (4) to the valve adjustment
screw 2 (Fig. 223).
l Fix the magnet (5) of the rotation angle disc.
l Turn the rotation angle disc clockwise against
the stop (rocker arm no clearance) and set the
scale to zero.
l Turn the rotation angle disc clockwise, until the
specified angle is reached.
Intake valve IN = 90 (0,4 mm)
Exhaust valves
EX = 150 (0,6 mm)
l Hold the rotation angle disc tight, so that it
does not turn, and tighten counter nut 1 (Fig.
222).
l Repeat this adjustment procedure an all other
cylinders, after cranking the crankshaft ac-
cordingly.
l Assemble the cylinder head cover with a new
gasket.
Intake valve clearance adjustment in
case of exhaust gas recirculation
Fig. 225
Fig. 226
Fig. 227
l Attach the rotation angle disc 3 (Fig. 226) with
the special spanner (8) to the valve setscrew 7
(Fig. 227) on the intake valve.
l Fix the magnet 5 (Fig. 226) of the rotation an-
gle disc.
l Turn the rotation angle disc 3 (Fig. 226) clock-
wise against the stop (rocker arm no clear-
ance) and set the scale to zero.
l Turn the rotation angle disc 3 (Fig. 226) anti-
clockwise, until the specified angle is reached
(90).
225).
l Repeat the adjustment procedure on each in-
take valve.
Valve adjustment schematic
l Firing order 1-3-4-2
Overlapping of valves:
Exhaust valve not yet closed,
intake valve starts to open.
! Caution
With the intake valve opened, the exhaust
valve will temporarily open for about 2 mm.
This is no valve overlap condition!
Valves Cylinder
overlapping
1 3 4 2
adjustment 4 2 1 3
5.27 Adjusting the control piston
play
! Caution
This work must be performed after adjusting
the valve clearance.
l Crank the engine, until the valves on cylinder
1 overlap.
l The cylinders to be adjusted can be taken from
the section "Adjustment Schematic".
Adjusting the control piston play
Fig. 228
Fig. 229
l Plug rotation angle disc and socket onto the
setscrew 2 (Fig. 229).
l Fix the magnet of the rotation angle disc.
l Turn the rotation angle disc clockwise against
the stop (rocker arm no clearance) and set the
scale to zero.
l Turn the rotation angle disc anti-clockwise, un-
til the specified angle is reached.
228).
l Repeat this adjustmennt procedure on each
control piston according to the crankshaft po-
sition.
l Assemble the cylinder head cover with a new
gasket.
Adjustment schematic
l Firing order 1-3-4-2
Overlapping of valves:
Exhaust valve not yet closed,
intake valve starts to open.
! Caution
With the intake valve opened, the exhaust
valve will temporarily open for about 2 mm.
This is no valve overlap condition!
Valves Cylinder
overlapping
1 3 4 2
adjustment 4 2 1 3
5.28 Checking / replacing the
ribbed V-belt
! Danger
Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.
Checking the wear limit of the ribbed V-
belt
Fig. 230
l Check the distance between the tongue of the
moveable tensioner arm and the fixed tension-
er housing (Fig. 230).
l If measurement "a" is smaller than 3 mm, re-
place the ribbed V-belt.
Changing the ribbed V-belt
Fig. 231
l Unscrew the fastening screws (Fig. 231) and
slide the fan forward.
Fig. 232
l Release the idler pulley (Fig. 232) in direction
of arrow until the ribbed V-belt is free.
l Pull the ribbed V-belt first to the smallest pul-
ley.
l Install the new ribbed V-belt.
l Release the idler pulley against the direction
of arrow until the V-belt is tensioned.
l Measure the V-belt tension, tighten if neces-
sary.
i
Note
Retighten the new fan V-belt after a running time
of 20 minutes.
5.29 Check the engine mounts
Fig. 233
l Tighten fastenings of intake and exhaust man-
ifolds (Fig. 233) on the cylinder heads.
l Check sockets and clamps between air filter,
exhaust turbocharger and charge air line as
well as the lubrication air line for tight fit and
leaks.
l Retighten the fastening screws for oil sump
and engine mounts.
5.30 Change the oil in the drive
axle
i
Note
On other axle versions drain and filler plugs are of
slightly different design. Performthe oil change ac-
cordingly.
! Caution
Drain oil only at operating temperature.
Environment
Catch old oil and dispose of environmentally.
Fig. 234
l Clean and unscrew all level inspection and
drain plugs (Fig. 234).
l Drain and catch all oil.
l Clean the drain plug and turn it back in with a
new seal ring.
Fig. 235
l Fill in oil through the oil level inspection bores
(Fig. 235), until it has reached the bottomedge
of the bore.
i
Note
The second level inspection plug as at the back.
After filling in oil wait until the oil has evenly distrib-
uted inside the axle.
5.31 Changing the oil in the
wheel hubs
! Caution
Change the oil on both sides of the axle.
Environment
Fig. 236
l Move the drive wheel, until the plug (Fig. 236)
is in bottom position.
l Clean and unscrew the plug.
l Drain and catch all oil.
Fig. 237
l Move the drive wheel, until the plug (Fig. 237)
is in horizontal position on the housing.
l Fill in oil, until it reaches the bottomedge of the
bore.
l Turn the plug tightly back in.
5.32 Changing the oil in the axle
reduction gear
! Caution
Drain the oil only at operating temperature.
Environment
Catch the old oil and dispose of environmetal-
ly.
Fig. 238
l Unscrew the filler plug (Fig. 238).
l Unscrew the oil drain plug and catch the run-
ning out oil.
l Once the oil has run out clean the drain plug
and screw it tightly back in.
l Fill in oil through the filler and control bore until
it reaches the lower edge of the control bore.
l Clean the filler plug and screw it back in tightly
with a new sealing ring.
5.33 Change the oil in the drum
reduction gear
! Caution
Environment
l Move the drum until drain and filler plugs are
exactly vertically in line.
Fig. 239
l Unscrew the filler plug at the top (Fig. 239).
l Unscrew the drain plug at the bottom and
catch running out oil.
l Turn the oil drain plug back in tightly after all oil
has run out.
Fig. 240
l Unscrew the level inspection plug (Fig. 240).
Fig. 241
l Fill in oil through the filler bore (Fig. 241), until
it reaches the bottom edge of the inspection
bore.
l Clean filler and level control plugs and screw
them tightly back in with new sealing rings.
5.34 Vario exciter oil change
! Caution
Change the oil at operating temperature. For
this purpose run the machine approx. half an
hour with vibration.
Environment
mentally.
Fig. 242
l Move the drum, until the drain plug 1 (Fig. 242)
is in bottom position.
l Unscrew the drain plug, let the oil run out and
catch it.
l Turn the oil drain plug back in tightly after all oil
has run out.
Fig. 243
l Unscrew oil level inspection plug 1 (Fig. 243)
on the drum and fill in oil through the filler
opening (2), until it starts to drip out from the
level inspection bore.
l Screw oil filler (2) and level inspection plug (1)
back in tightly.
l Check the oil level once again at operating
temperature (after running the machine for
about half an hour with vibration).
! Caution
Overfilling causes overheating and destruc-
tion of the vibration bearings!
5.35 Change the oil in the exciter
shaft housing of the attach-
ment plates
! Caution
Tilt the machine to the side with the oil drain
plug and support it safely.
Environment
Catch running out old oil, do not let it seep into
the ground.
Fig. 244
l Unscrew oil drain plugs on both sides (Fig.
244), drain and catch running out old oil.
l Turn the oil drain plugs back in with a new seal
rings.
Fig. 245
l Stand the plates on level ground and fill in oil
(Fig. 245).
l Screw the filler plug back in with a new seal
ring.
5.36 Tightening the fastening of
the axle to the frame
Fig. 246
l Check all fastening nuts for the axle retaining
bolts (Fig. 246) for tight fit.
5.37 Tightening the wheel nuts
Fig. 247
l Tighten the wheel nuts (Fig. 247) in a cross-
type pattern.
5.38 Check the ROPS
i
Note
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.
Fig. 248
l Inspect the cabin, especially the ROPS (Fig.
248), for cracks, corrosion, damage and miss-
ing fastening parts.
i
Note
Unusual movements and noises (vibrations) dur-
ing operation are signs for damage or loosened
fastening elements.
l Check the fastening screws for the cabin
(ROPS) to the operators stand for tight fit.
l Check the rubber buffers of the operators plat-
form suspension for condition and tight fit.
l Check the condition and fastening of the seat
belts.
5.39 Cleaning the oil bath air fil-
ter
*
Fig. 249
l Loosen the quick locks (Fig. 249), take the fil-
ter bowl off and empty it.
l Clean the filter mesh by repetitive dipping into
diesel fuel.
l Clean the filter bowl with diesel fuel and fill in
engine oil up to the level mark.
l reinstall the filter bowl.
* Option
5.40 Changing hydraulic oil and
breather filter
i
Note
See also chapter 5.1 "Notes on the hydraulic sys-
tem".
! Caution
Apart from the normal oil change intervals, the
hydraulic oil must also be changed after major
repairs in the hydraulic system.
Perform the oil change when the hydraulic oil
is warm.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not use any detergents to clean the system.
Do not start the engine after draining the hy-
draulic oil.
Replace the hydraulic oil filter element with
every hydraulic oil change.
! Danger
Danger of scalding!
Danger of scalding by hot oil.
Environment
mentally.
i
Note
Generally replace the hydraulic oil filter element
after the test run.
Fig. 250
l Unscrew the plug (Fig. 250) and drain off all
hydraulic oil.
l Turn the plug tightly back in.
Fig. 251
l Remove the filler cap (Fig. 251).
l Fill in new hydraulic oil through the screen.
i
Note
We recommend to use the filling and filtering unit
(BOMAG part-no. 079 930 35) with fine filter to fill
the hydraulic system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the hy-
draulic oil filter and protects the hydraulic system.
l Check the oil level in the inspection glass.
Nominal value:
approx. 3 cm below the upper edge of the inspec-
tion glass
i
Note
The breather filter for the hydraulic oil tank is inte-
grated in the filler cap, you must therefore replace
the complete filler cap.
l Close the tank with a new filler cap.
5.41 Changing the hydraulic oil
filter
! Danger
Danger of scalding!
There is a danger of scalding by hot oil when
unscrewing the filter.
! Caution
If the filter has to be changed together with the
hydraulic oil, the filter should in any case be
changed after the oil change and the test run.
Do not use the oil in the filter bowl.
Environment
Catch running out oil, dispose of oil and filter
element environmentally.
i
Note
The filter element must be changed with every hy-
draulic oil change and after major repairs in the hy-
draulic system.
Fig. 252
l Unscrew the cap nut 4 (Fig. 252) and take the
filter bowl (5) with the filter element (3) off.
l Examine the sealing face on the filter element
thoroughly for any visible dirt.
! Caution
Visible impurities may be an early indicator for
a failure of systemcomponents and predict the
possible malfunction of important parts. In
such a case you should perform trouble shoot-
ing and replace or repair the defective compo-
nents. Nonobservance may lead to total
damage of the hydraulic system.
Do not clean or reuse the filter element.
l Take the old filter element (3) out and clean
the filter bowl and the thread.
l Reinstall the filter bowl with the new filter ele-
ment, check the condition of the O-rings (1)
and (2), replace if necessary.
l After a test run check the filter for leaks.
5.42 Changing the steering oil fil-
ter
! Danger
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter.
! Caution
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.
Environment
i
Note
Apart from the normal oil change intervals, the fil-
ter element must also be changed after major re-
pairs in the hydraulic system.
Fig. 253
l Unscrew spigot nut 4 (Fig. 253) and take off fil-
ter bowl (5) with filter element (3).
l Examine the surface of the filter element thor-
oughly for any visible dirt.
! Caution
Visible dirt may be an early sign for the failure
of system components and indicate the possi-
ble failure of components. In this case deter-
mine the cause and replace or repair the
defective components, if necessary. Negli-
gence may cause destruction to the entire hy-
draulic system.
l Take the old filter element (3) out, clean the fil-
ter bowl and thread.
l Assemble the filter bowl with new filter ele-
ment, check the condition of O-rings (1) and
(2), if necessary use new ones.
l After a short test run check the filter for leaks.
5.43 Changing the attachment
plate oil filter
! Danger
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter.
! Caution
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.
Environment
i
Note
Apart from the normal oil change intervals, the fil-
ter element must also be changed after major re-
pairs in the hydraulic system.
Fig. 254
l Unscrew spigot nut 4 (Fig. 254) and take off fil-
ter bowl (5) with filter element (3).
l Examine the surface of the filter element thor-
oughly for any visible dirt.
! Caution
Visible dirt may be an early sign for the failure
of system components and indicate the possi-
ble failure of components. In this case deter-
mine the cause and replace or repair the
defective components, if necessary. Negli-
gence may cause destruction to the entire hy-
draulic system.
l Take the old filter element (3) out, clean the fil-
ter bowl and thread.
l Assemble the filter bowl with new filter ele-
ment, check the condition of O-rings (1) and
(2), if necessary use new ones.
l After a short test run check the filter for leaks.
5.44 Change the coolant
! Danger
Danger of scalding!
Change the coolant only when the engine is
cold.
Environment
Catch running out coolant and dispose of envi-
ronmentally.
Fig. 255
l Set the cock valve for the cabin heater to posi-
tion "warm".
Fig. 256
l Unscrew the plug, let the coolant run out and
catch it.
l Screwthe plug back in once all coolant has run
out.
Fig. 257
l Unscrew the cap and fill in coolant up to the
MAX-mark (Fig. 257).
For quality of coolant refer to the chapter 5.2,
fuels and lubricants.
l Start the diesel engine and run it warm to op-
erating temperature.
l Let the engine cool down and check the cool-
ant level again, top up if necessary.
5.45 Replacing the crank case
ventilation valve
Fig. 258
l Replace the crank case ventilation valve (Fig.
258).
5.46 Electronic injector test EMR
i
Note
This work must only be performed by authorized
service personnel.
As required
As required
5.47 Service the combustion air
filter
! Caution
Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter ele-
ment.
Fig. 259
Maintenance of the dry air filter is due when con-
trol light 1 (Fig. 259) in the fault monitoring board
lights permanently when the engine is running, but
at the latest after 2 years.
i
Note
Once the air filter service indicator lights up, work
may be continued until the end of the day.
Fig. 260
l Open the engine hood (Fig. 260) completely
and secure it.
Removing the main filter element
Fig. 261
l Loosen both locking hooks (Fig. 261) on the
housing cover and take the cover off.
Fig. 262
l Pull out the main filter element (Fig. 262) with
light turning movements.
Cleaning the main filter element
! Caution
If necessary, the main filter element may be
cleaned up to five times. It must be renewed at
the latest after a maximum utilization period of
two years.
The number of cleaning intervals of the main
filter element can be marked on the safety ele-
ment with a ball pen or a felt pen.
Cleaning does not make sense if the main filter
element is covered with a sooty deposit. Use a
new filter cartridge.
As required
Incorrectly handled inserts may be ineffective
because of damage (e.g. cracks) and cause
damage to the engine.
Replace the safety cartridge if the main filter el-
ement is defective!
Additional cleaning intervals between two fil-
ter services signalized by the fault monitoring
board are not necessary.
Fig. 263
l Blow the filter cartridge out from inside to out-
side with dry compressed air (max. 5 bar) (Fig.
263), until all dust has been removed.
Fig. 264
l Examine the filter cartridge with a torch for
cracks and holes in the paper bellows (Fig.
264).
! Caution
Do not continue to run the machine with a
damaged main filter element. If in doubt use a
new main filter element.
Cleaning the dust bowl
Fig. 265
l Pull the internal part (Fig. 265) out and remove
the dust from the cover.
l Reinsert the inner part.
! Caution
When assembling the inner part make sure
that the notch in the cover engages in the
opening of the inner part.
Installing the main filter element
l Slide the main filter element carefully into the
housing.
When closing the housing cover the main filter el-
ement is automatically forced in the correct posi-
tion.
Changing the safety filter element
! Caution
The safety filter element must not be cleaned
and should not be used again after it has been
removed.
Break the seal only to replace the safety filter
element.
The safety filter element must be replaced:
If the main filter element is defective.
after five service intervals of the filter car-
tridge,
at the latest after 2 years,
As required
if the warning light comes on again after serv-
icing the main filter cartridge.
l Remove the housing cover and pull the main
filter element off.
Fig. 266
l Pull the safety element (Fig. 266) out by slight
turning movements.
l Push in a new safety filter element.
l Reassemble main filter element and cover.
! Caution
Make sure that the cover locks engage correct-
ly.
5.48 Adjust the scrapers
Smooth drum
l Check adjustment and condition of front and
rear scrapers, if necessary adjust or replace
the scraper rubber.
Fig. 267
l In order to adjust the scrapers 2 (Fig. 267),
slacken the fastening screws (1) in the slots
and push the scraper towards the drum to con-
tact.
l Retighten the fastening screws.
Padfoot drum
l Check adjustment and condition of front and
rear scrapers, if necessary adjust or replace
the scraper rubber.
As required
Fig. 268
l Check adjustment and condition of scrapers
(Fig. 268), adjust or replace the teeth if neces-
sary.
l To adjust the scrapers slacken the clamping
screws and push the scrapers towards the
drum, leaving a gap of about 25 mm.
l Retighten the clamping screws.
5.49 Adjust the parking brake
! Caution
Have adjustment work on the brakes only car-
ried out by a specialist! Always adjust both
sides.
l Secure the machine with wheel chocks
against rolling.
l Start the diesel engine to relieve the brake.
Fig. 269
l Disengage the travel lever (Fig. 269) to the
left, but do not move to position "I" or "II".
The parking brake is released
Fig. 270
l Unscrew locking plate 2 (Fig. 270).
l Turn the square (1) in anti-clockwise direction
against the stop.
As required
Fig. 271
l In order to adjust the brake clearance turn the
square 1 (Fig. 271) three turns back in clock-
wise direction.
l Fasten the locking plate again.
l Pull the plug off the brake solenoid valve and
perform the drive test.
The machine must be braked.
5.50 Change the tires
! Danger
Danger of accident!
Observe all safety regulations for the lifting of
loads.
l Place a jack (min. 5 t bearing capacity) under
the rear frame and jack the machine up until
the wheel is off the ground.
l Unscrew the wheel nuts and take the wheel
off.
Fig. 272
l Attach a new wheel (Fig. 272) and tighten the
wheel nuts crosswise with 550 Nm (405 ft. lb.
lb.).
l Check the tire pressure, see technical data.
As required
5.51 Change the fresh air filter in
the cabin
Fig. 273
l Unscrew fastening screws for the ventilation
grid (Fig. 273) and remove the filter.
l Insert a new filter and reassemble the ventila-
tion grid.
5.52 Tightening torques
Fig. 274
* Strength classes for screws with untreated, non-
lubricated surface. Screw quality designations are
stamped on the screw heads.
8.8 = 8G
10.9 = 10K
12.9 = 12K
l Axle - frame
M 22x1.5 = 710 Nm
l Wheel nuts
M 22x1.5 = 550 Nm
The values result in a 90% utilization of the screw
yield point at a coefficient of friction total = 0,14.
When using lubricant MOS
2
the specified tighten-
ing torques do not apply.
i
Note
Self-locking nuts must always be replaced once
they have been unscrewed.
As required
5.53 Engine conservation
If the engine is to be shut down for a longer period
of time (e.g. over winter), please consult the serv-
ice department of the engine manufacturer for fur-
ther details.
6 Trouble shooting
Trouble shooting
6.1 General notes
The following work must only be carried out by
qualified and trained personnel or by the sales
service.
Please observe strictly the safety regulations
in chapter 2 of these operating and mainte-
nance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serv-
iced. Therefore, whenever a fault occurs, read
through these instructions on correct operation
and maintenance. If you cannot locate the cause
of the fault or eliminate it yourself by following the
trouble shooting charts, you should contact our
customer service departments at our branch office
or dealers.
! Danger
Danger of injury!
Keep away from rotating parts of the engine.
6.2 Reading out faults BVC/
BTM05
Fig. 275
Fig. 276
i
Note
Trouble shooting
Fig. 277
l Press key "F5" (diagnostics) (Fig. 277).
i
Note
The screen with the currently available fault codes
is displayed.
Fig. 278
l Currently present faults are indicated by a cor-
responding fault code in the field "Actual Er-
rors".
l Press key "ESC" (Fig. 278) to leave the screen
page with the actual fault codes.
Trouble shooting
6.3 Engine
Faults Possible cause Remedy
The engine
does not start
Starter defective or pinion not engaging Have examined by a specialist
Fuel tank empty Fill and bleed the tank
Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.
Fuel filter clogged, in winter due to paraf-
fin separation.
Change the filter. use winter fuel
Fuel lines leaking Check all line connections for leakages
and tighten the fittings.
Battery discharged or not connected Tighten the pole clamps, check the cable
connections
Injection valves or injection pump defec-
tive
Have examined by a specialist
The engine
starts poorly and
works irregularly
with poor power
Battery power too low, battery clamps
loose or oxidized, causing the starter to
turn too slowly
Have the battery checked, clean the ter-
minal clamps, tighten them and cover
them with acid free grease
Especially during winter: the use of too
viscous engine oil
Use engine oil suitable for the ambient
temperature
Fuel supply restricted, in winter fuel sys-
tem clogged due to paraffin separation
Change the fuel filter. Check the line con-
nections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Incorrect valve clearance Adjust the valve clearance
Injection valve defective Have examined by a specialist
Injection lines leaking Check the lines for leakages
Turbo charger defective Have examined by a specialist
Dry air filter dirty clean, replace if necessary
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary
Trouble shooting
Excessive ex-
haust smoke
Engine oil level too high Drain the oil to the upper dipstick mark
Dry air filter dirty clean, replace if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Poor compression due to burned or bro-
ken compression rings or incorrect valve
clearance
Have compression rings and pistons ex-
amined by a specialist, adjust the valve
clearance
Engine over-
heats, shut
down immedi-
ately!
Cooling fins on radiator extremely soiled
(the warning light "engine oil temperature"
lights)
Clean the cooling fins
Engine oil level too low Top up engine oil to the upper dipstick
mark
Filling capacity of the injection pump not
correctly adjusted
Have adjusted by a specialist
Cooling air flow restricted Clean the cooling air duct
V-belt loos or broken Tension or replace the V-belt
Poor engine
power
Engine oil level too high Drain the engine oil down to the upper dip-
stick mark
Dry air filter dirty clean, change if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Charge air hose leaking Check fastening and connections
Engine oil pres-
sure too low
Engine oil level too low (control light "en-
gine oil pressure" lights, the warning
buzzer sounds)
Top up oil
Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
The charge con-
trol light lights
during opera-
tion, the warning
buzzer sounds
Generator speed too low Check the V-belt tension, replace the V-
belt if necessary
The generator does not charge the bat-
tery, because generator or regulator is de-
fective
Have examined by a specialis
Faults Possible cause Remedy
Trouble shooting
7 Cab assembly before initial start-up
Cab assembly before initial start-up
General safety regulations for assem-
bly
When installing the cabin to your BOMAG ma-
chine you must strictly comply with the valid
accident prevention instructions or the coun-
try specific regulations. However, dangers for
persons and property may still arise, if:
l the lifting gear used has a too low bearing ca-
pacity
l damaged or worn lifting tackle is used
l unqualified personnel is entrusted with the in-
stallation
l the safety instructions are not observed
Each person involved in the installation of the
cabin must therefore read and comply with
these safety regulations. If necessary, the cus-
tomer must demand a written confirmation
with signature.
Moreover, the following instructions and regula-
tions must obviously also be complied with:
l applicable accident prevention instructions
l generally accepted safety and road traffic reg-
ulations
l country specific safety regulations. It is the
duty of the operator to be acquainted with
these instructions and to apply these accord-
ingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instruc-
tions be different from the regulations valid in
your country, you must comply with the safety
regulations valid in your country.
Changes and conversions to the cabin/
machine
Unauthorized changes to the cabin are prohibited
for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
plicitly 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
driving safety.
The manufacturer explicitly excludes any liability
for damage caused by the use of non-original
parts or accessories.
Notes on safety in the assembly in-
structions
! Danger
Paragraphs marked like this highlight possible
dangers for persons.
! Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
i
Note
Paragraphs marked like this contains technical in-
formation and hints for optimal assembly.
Environment
Paragraphs marked like this point out practic-
es for safe and environmental disposal of fuels
and lubricants as well as replacement parts.
Strictly observe the national regulations for
the protection of the environment.
Information and safety stickers/decals
on the cabin
Keep stickers/decals in good and legible condition
(see spare parts catalogue) and comply with their
meaning.
Replace damaged stickers/decals
Work on heating lines
Before starting work on heating pipes relieve any
pressure and let them cool down - danger of scald-
ing!
After completing work on the heating systemof the
machine check all connections and fittings for
leaks.
Working on electric parts of the ma-
chine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire haz-
ard.
7.1 Preparations
! Danger
Danger of accident!
For transport purposes the driver's seat must
be tied down with cable straps thus to operate
the seat contact switch. Before resuming oper-
ation of the machine these cable straps must
strictly be removed to ensure safe and reliable
function of the seat contact switch.
Check the 4 lifting eyes on the cabin roof for
tight fit.
Fasten the lifting gear to all four lifting eyes.
Use lifting gear (chains or ropes) of sufficient
load bearing capacity. The minimum load bear-
ing capacity of the crane must be 1000 kg.
Fig. 279
l Make sure that all fastening screws, washers,
spacers and nuts to fasten the cabin are avail-
able (Fig. 279).
l Check whether rear rack, foot mat, step plate
and fastening kit are available.
Fig. 280
l Fasten the lifting gear to the four lifting eyes 1
(Fig. 280).
l Loosen possible fastening on the transport
pallet.
l Slowly list the crane with a crane.
! Danger
Danger of accident!
7.2 Cabin assembly
! Danger
Danger of accident!
Use lifting gear (chains or ropes) of sufficient
load bearing capacity. The minimum load bear-
ing capacity of the crane must be 1000 kg.
l Clean the operator's stand of dirt, oil and mois-
ture.
Fig. 281
l Stick the supplied sealing tape 1 (Fig. 281)
along the edge of the operator's stand.
! Caution
Only unroll and stick the sealing tape on just
before mounting the cab to the operator's
stand. The sealing tape will swell a few min-
utes after being unrolled. In this case the cabin
can no longer be mounted!
Fig. 282
l Stick the sealing tape 1 (Fig. 282) all around
the operator's stand.
l Do not run the sealing tape across the front re-
cess in the operator's stand (2), since this is
the air inlet for the cabin ventilation.
i
Note
Mount the cabin immediately after sticking on the
sealing tape, because the sealing tape will swell.
Fig. 283
l Spray the sealing tape with soapsuds (Fig.
283), to be able to slide the cabin on the oper-
ator's stand.
Fig. 284
l Slowly lower the cabin vertically to the opera-
tor's stand (Fig. 284).
! Caution
The cabin must be lowered vertically onto the
operator's stand.
Fig. 285
! Caution
Take care that none of the hoses and electric
cables become squashed (Fig. 285).
l Run cables and hoses from inside the cabin
through the operator's stand to the outside.
Fig. 286
l Turn both fastening screws (Fig. 286) at the
rear of the cabin in hand tight.
Fig. 287
i
Note
If the bores do not match the cabin can be moved
into position by means of a crow bar (Fig. 287).
Fig. 288
l Tighten the bottom fastening screw on the ac-
cess side (Fig. 288) with 578 Nm.
Fig. 289
l Loosen both fastening screws (Fig. 289) at the
rear of the cabin again.
i
Note
The cabin will now slide into final assembly posi-
tion.
l Tighten both fastening screws (Fig. 289) at the
rear of the cabin with 578 Nm.
Fig. 290
l Tighten the rear lateral fastening screw on the
left hand side with 578 Nm (Fig. 290).
Fig. 291
l Tighten the rear lateral fastening screw on the
right hand side with 578 Nm (Fig. 291).
Fig. 292
l Tighten the rear inside fastening screw on the
Fig. 293
l Turn nuts with washers onto both studs and
tighten with 200 Nm (Fig. 293).
Fig. 294
l Tighten the front lateral fastening screwon the
Fig. 295
l Tighten the front lateral fastening screwon the
left hand side with 578 Nm (Fig. 295).
Fig. 296
l Cover all lateral fastening screws with plastic
caps (Fig. 296).
Fig. 297
l Insert the foot mat 1 (Fig. 297).
Fig. 298
l Attach the step plate 1 (Fig. 298) and tighten
the three fastening screws (2).
Fig. 299
l Insert the dashboard and fasten it with four
fastening screws (Fig. 299).
Fig. 300
l Remove all cable straps from the seat console
(Fig. 300) to activate the seat contact switch.
Fig. 301
l Insert the rear rack and knock both plastic fas-
teners carefully into the bores with a hammer
(Fig. 301).
Fig. 302
l Connect the feed 1 (Fig. 302) and the return
flow (2) for the air conditioning system with
quick release couplings.
l Connect the feed (4) and the return flow (3) of
the heating. (Observe the marks on the hos-
es).
i
Note
Run the connecting lines for the heating parallel to
each other (do not cross).
i
Note
Check the function of air conditioning and heating
within the scope of the function test.
Observe identical hose diameters when connect-
ing.
Fig. 303
l Plug on both connecting plugs for the washing
water pumps (Fig. 303).
Fig. 304
l Plug on the hoses for the washing water sup-
ply to front and rear windscreens 1 (Fig. 304).
i
Note
Check the function of the washing water system
within the scope of the function test.
Fig. 305
l Insert the plug 1 (Fig. 305) into the socket (2).
l Close the bayonet catch by turning the corru-
gated cap nut in clockwise direction against
the stop.
! Danger
Before starting to work on electric parts of the
machine disconnect the battery and cover it
with insulating material.
Fig. 306
l Connect the plug connection of the air condi-
tioning system (Fig. 306).
7.3 Final function tests and
checks
! Caution
Make sure that all screws have been tightened
with the specified torque.
i
Note
After the cabin assembly the following tests must
be performed to assure that all cables and lines
are correctly connected.
l Insert the ignition key and turn clockwise to po-
sition "1".
l Operate the switches for headlights, direction
indicators and interior light to check their func-
tion.
l Operate the switches for front and rear wind-
screen washer system and check their correct
function.
i
Note
If the function of the windscreen washer system is
reversed, the two washing water hoses must be in-
terchanged.
l Start the engine.
l Switch the air conditioning on by the switch.
After a five minute operation the cabin must
become noticeably cooler.
l Switch the air heater on by the switch. After a
five minute operation the cabin must become
noticeably warmer.
l Function of the seat contact switch.
! Caution
The machine must not be operated if the seat
contact switch is not functioning correctly.

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