Bomag Roller Bw202ad-4 Operation Manual c452e

Operating instructions Maintenance instructions

BW 161 AD-4 / BW 202 AD-4 BW 161 ADH-4 / BW 203 AD-4 S/N 101 920 02 ....> S/N 101 920 03 ....> S/N 101 920 04 ....> S/N 101 920 05 ....>

Tandem Vibratory Roller

Catalogue number

008 111 81

11/2004

Foreword BOMAG machines are products from the wide range of BOMAG compaction equipment. F oreword

BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your 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 Engineering Liability Association ”Safety Rules for the Operation of Road Rollers and Soil Compactors” and all relevant accident prevention regulations.

This manual comprises: l

Safety regulations

l

Operating instructions

l

Maintenance instructions

l

Trouble shooting

For your own personal safety you should only use original spare parts from BOMAG. In the course of technical development we reserve the right for technical modifications without prior notification. These operating and maintenance instructions are also available in other languages.

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 construction sites,

l

prolong the lifetime of the machine,

l

reduce repair costs and downtimes.

BOMAG 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 mentioned in these instructions.

Apart from that, the spare parts catalogue is available from your BOMAG dealer against the serial number of your machine. Your BOMAG dealer will also supply you with information 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 of business of BOMAG. We wish you successful work with your BOMAG machine. BOMAG GmbH Printed in Copyright by BOMAG

No warranty claims can be lodged in case of damage resulting from l

operating errors,

l

insufficient maintenance and

l

wrong fuels and lubricants.

Please note! This manual was written for operators and maintenance 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 maintenance instructions are part of the machine.

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Foreword Please fill in ............................ Machine type (Fig. 1) ............................ Serial-number (Fig. 1 and 2) ............................ Engine type (Fig. 3) ............................ Engine number (Fig. 3)

i

Note

Fig. 1

Supplement the above data together with the commissioning protocol. During commissioning our organisation will instruct you in the operation and maintenance of the machine. Please observe strictly the safety regulations and all notes on risks and dangers!

Fig. 2

Fig. 3

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Table of Contents

Technical Data Safety regulations Indicators and Controls Operation

Maintenance

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7 13 21

3.1 General notes 3.2 Description of indicators and control elements

24 24

4.1 General notes 4.2 Tests before taking into operation 4.3 Starting the engine 4.4 Starting with jump wires 4.5 Driving the machine 4.6 Stopping the machine, operating the parking brake 4.7 Shutting the engine down 4.8 Switching the vibration on and off 4.9 Operating the crabwalk 4.10 Switching the pressure sprinkling system on and off 4.11 Sprinkling of edge cutter 4.12 Actuating the emergency stop switch 4.13 Adjusting the rotation stop for travel lever movement 4.14 Adjusting the driver’s seat 4.15 Opening or closing the cabin window 4.16 Towing 4.17 Transport

40 40 41 45 46 48 49 50 53 54 55 55 56 56 57 57 59

5.1 General notes on maintenance 5.2 Fuels and lubricants 5.3 Fuels, lubricants and filling capacities 5.4 Running-in instructions 5.5 Maintenance chart 5.6 Check the engine oil level 5.7 Check the fuel level 5.8 Check the hydraulic oil level 5.9 Check the coolant level 5.10 Check / empty the fuel pre-cleaner (water separator) / bleed 5.11 Check the water level 5.12 Check, clean radiator, fuel cooler, hydraulic oil cooler and intercooler 5.13 Checking the oil level in vibrator shaft tube 5.14 Change the engine oil 5.15 Change the engine oil filter cartridge 5.16 Checking the anti-freeze concentration 5.17 Servicing the air conditioning (summer operation)

62 63 66 67 68 70 70 71 72 72 74 75 76 77 78 78 79

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61

5

Table of Contents

Trouble shooting

6

5.18 5.19 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34 5.35 5.36 5.37 5.38 5.39

Service the battery Cleaning the fuel pre-cleaner, replacing, bleeding the filter if necessary Change the fuel filter cartridge Changing the oil in the drum drive gear Checking, tensioning, lubricating the steering chain Check the engine mounts Checking the V-belt, tighten, if necessary replace the V-belt Changing the oil in the vibrator shaft tube Check, adjust the valve clearance Changing hydraulic oil and breather filter Changing the hydraulic oil filter Grease the articulated t Change the coolant Replace the injection valve Check, clean, change the combustion air filter Clean the water tank Clean the water filter Water sprinkler system, maintenance in the event of frost Fill the provision tank for the windscreen washer system Adjust the scrapers Tightening torques Engine conservation

6.1 General notes 6.2 Engine

81 83 85 86 87 88 88 92 93 95 96 97 98 99 101 103 104 105 106 107 107 108

109

110 111

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1 Technical Data

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Technical Data

Fig. 4

Dimensions in mm

A

B

C

D

H

H2

K

L

O

W

BW 161 AD-4

3300

1840

715

1220

2320

3000

400

4520

80

1680

BW 202 AD-4

3300

2295

715

1220

2320

3000

400

4520

80

2135

*

BW 161 AD-4

BW 202 AD-4

kg kg

9600 10100

11300 11800

kg kg kg/cm

5050 5050 30,1

5900 5900 27,6

kg/cm

30,1

27,6

Dimensions Oscillation angle Inner track radius

+/-° mm

6 4400

6 4170

8

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Weights Operating weight (CECE) Operating weight (CECE) with ROPS-cabin Front axle load (CECE) Rear axle load (CECE) Static linear load front (CECE) Static linear load rear (CECE)

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Technical Data *

Travel characteristics Travel speed (1) Travel speed (2) Max. gradability without/ with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Electrical equipment Battery Drive system Driven drum

km/h km/h %

kW (PS) 1 rpm V V/AH

Brakes Service brake Parking brake Steering Type of steering Steering operation Steering angle Crabwalk, lateral offsetting of drum (right/left)

+/- degree mm

Vibration system Drive system Frequency 1/2 Amplitude 1/2 Vibrating drum

Hz mm

Water sprinkler system Type Interval control Filling capacities Fuel (diesel) Water Hydraulic oil Engine oil *

l l l l

BW 161 AD-4

BW 202 AD-4

0-6 0-11 40/35

0-6 0-11 40/35

Deutz BF4M 2012 Water 4 74,9 2300 12 12/100 hydrost. front + rear

Deutz BF4M 2012 C Water 4 98 2300 12 12/100 hydrost. front + rear

hydrost. mechanical

hydrost. mechanical

Oscill.-articul. hydrost. 30 170

Oscill.-articul. hydrost. 30 170

hydrost. 40/50 0,91/0,39 front + rear

hydrost. 40/50 0,83/0,35 front + rear

Pressure (+)

Pressure (+)

200 1000 60 13,5

200 1000 60 13,5

The right for technical modifications remains reserved

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Technical Data

Fig. 5

Dimensions in mm

A

B

C

D

H

H2

K

L

O

W

BW 161 ADH-4

3300

1840

715

1220

2320

3000

400

4520

80

1680

BW 203 AD-4

3300

2300

715

1220

2320

3000

400

4520

80

2135

*

BW 161 ADH-4

BW 203 AD-4

kg kg

10200 10700

12700 13200

kg kg kg/cm kg/cm

5300 5400 31,5 32,1

6600 6600 30,9 30,9

Dimensions Oscillation angle Inner track radius

+/-° mm

6 4400

6 4170

10

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Weights Operating weight (CECE) Operating weight (CECE) with ROPS-cabin Front axle load (CECE) Rear axle load (CECE) Static linear load front (CECE) Static linear load rear (CECE)

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Technical Data *

Travel characteristics Travel speed (1) Travel speed (2) Max. gradability without/with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Electrical equipment Battery Drive system Driven drum

km/h km/h %

kW (PS) rpm V V/AH

Brakes Service brake Parking brake Steering Type of steering Steering operation Steering/oscillation angle Crabwalk, lateral offsetting of drum (right/left)

+/- degree mm

Vibration system Drive system Frequency 1/2 Amplitude 1/2 Frequency 1/2 (US-version) Amplitude 1/2 (US-version) Vibrating drum

Hz mm Hz mm

Water sprinkler system Type Interval control Filling capacities Fuel (diesel) Water Hydraulic oil Engine oil *

l l l l

BW 161 ADH-4

BW 203 AD-4

0-6,0 0-11,0 40/35

0-6,0 0-11,0 40/35

Deutz BF4M 2012 C Water 4 98 2300 12 12/100 hydrost. front + rear

Deutz BF4M 2012 C Water 4 98 2300 12 12/100 hydrost. front + rear

hydrost. mechanical

hydrost. mechanical

Oscill.-articul. hydrost. 30/6 170

Oscill.-articul. hydrost. 30/6 170

hydrost. 40/50 0,91/0,39 45/60 0,91/0,39 front + rear

hydrost. 40/50 0,70/0,30

front + rear

Pressure (+)

Pressure (+)

200 1000 60 13,5

200 1000 60 13,5

The right for technical modifications remains reserved

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Technical Data The following noise and vibration values according to the EC-directive for machines, edition (98/37/ EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with the vibration switched on. The machine was standing on an elastic base. During operation these values may vary because of the existing operating conditions.

Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level at the work place of the operator (with cabin): LpA =79,7 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: LWA = 103,3 dB(A) These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO 11204 for sound pressure level (LpA) at the place of the operator.

Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire boy (driver’s seat) The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2. Hand-arm vibration values The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2.

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2 Safety regulations

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Safety regulations General notes

Unintended use

This BOMAG machine is built in accordance with the latest technical standard and the valid technical rules and regulations. There is, however, a risk of danger for persons and property if:

Dangers may, however, arise from the machine if it is used by untrained personnel in an unprofessional way or if it is used for purposes other than those mentioned in these instructions.

l

the machine is used for purposes other than those it is intended for

Starting and operation of the machine in an explosive environment is prohibited.

l

the machine is operated by untrained personnel

l

the machine is modified or converted in an unprofessional way

l

the applicable safety regulations are not observed.

Each person involved in operation, maintenance and repair of the machine must therefore read and apply these safety regulations. This should be confirmed by obtaining the signatures of the customer, if necessary. Furthermore the following regulations and instructions 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 material, e.g. road surface layers.

l

medium to heavy compaction work in earth construction (road sub-bases)

l

You should only operate the machine with fully functional safety equipment.

l

Have the machine inspected by an expert once every year.

14

Do not work with vibration on hard concrete, on a cured concrete layer or heavily frozen ground.

Who is allowed to work with the machine? 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 complied with. Persons under the influence of alcohol, medication 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 machine Unauthorized conversions to the machine are prohibited for safety reasons. Original parts and accessories have been specially designed for this machine. We wish to make expressly clear that we have not tested or authorized any original parts or special equipment not supplied by us. The installation and/or use of such products can impair the active and/or ive driving 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 maintenance instructions: Danger Sections marked like this point out possible dangers for persons. !

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Safety regulations Caution Sections marked like this point out possible dangers for the machine or for parts of the machine. !

i

Towing the machine You should generally use a tow bar. Max. towing speed 1 km/h, max. towing distance 500 m. Before releasing the parking brake secure the machine against rolling.

Note

Sections marked like this provide technical information concerning the optimal economical use of the machine.

Checking the Roll Over Protection Structure (ROPS) The machine frame must not be distorted, bent or cracked in the area of the ROPS fastening points.

Environment Sections marked like this highlight activities for the safe and environmental disposal of fuels and lubricants as well as replaced parts.

The ROPS must not show any signs of corrosion, damage, hairline cracks or open fractures.

Observe all environment protection regulations.

Information and safety stickers/decals on the machine Keep stickers/decals complete (see spare parts catalogue) and fully legible and observe their meaning.

The ROPS must not rattle about when driving. This would indicate that it is not sufficiently fastened. All screw connections must be in accordance with the respective specifications and correctly tightened (observe the tightening torques). Screws and nuts must not be damaged, bent or deformed. 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 impair the strength of the structure.

Replace damaged or illegible stickers/decals immediately.

Starting the machine

Loading the machine

Before starting

Use only stable loading ramps of sufficient load bearing capacity. The ramp inclination must be less than the gradability of the machine.

The machine must only be operated from the driver’s seat.

Switch only to first speed range (do not activate the crabwalk).

Use only machines which are serviced at regular intervals.

Secure the machine against tipping or slipping off.

Become acquainted with the equipment, the control elements, the working principle of the machine and the working area.

Secure the machine on the transport vehicle against rolling, slipping and turning over.

Wear your personal protective outfit (hard hat, safety boots, etc.).

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 an instruction and during loading.

Before mounting the machine check whether: l

persons or obstructions are beside or under the machine

The machine must not swing about when being lifted.

l

the machine is free of oily and combustible material

Use only safe lifting gear of sufficient load bearing capacity

l

all grips, steps and platforms are free of grease, oils, fuel, dirt, snow and ice

Fasten the lifting gear only at the specified lifting points.

l

Maintenance doors must be closed and locked.

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Safety regulations Use steps and grips to mount the machine.

Give warning signals, if necessary. Stop work immediately if persons remain in the danger zone, despite the warning.

Before starting the machine check whether: l

the machine shows any obvious faults

l

all guards and safety elements are in place

l

steering, brakes, control elements, light system and warning horn work correctly

l

the seat is correctly adjusted

l

mirrors (if present) are clean and correctly adjusted.

Do not step or stand in the articulation area of the machine when the engine is running. Danger of squashing! Driving

Do not start the machine with defective gauges, control lights or control elements.

In events of emergency and in case of danger actuate the emergency stop switch immediately. Do not use the emergency stop switch as service brake. Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.

Do not take any loose objects with you or fasten them to the machine.

If the machine has ed high-voltage power lines:

On machines with roll over protection system you must always wear your seat belt!

l

do not leave the operator’s stand

l

warn others from coming close to or touching the machine

l

if possible drive the machine out of the danger zone

l

have the power switched off

Starting Start and operate the machine only from the driver’s seat (seat switch). For starting set all control levers to 'neutral position'. Do not use any starting aids like start pilot or ether. After starting check all gauges and control lights.

Operate the machine only from the operator’s stand.

Starting with jump wires

Keep the cabin doors closed.

Connect positive with positive and negative with negative (ground cable) – always connect the ground strap last and disconnect it first! A wrong connection will cause severe damage in the electric system.

Do not adjust the driver’s seat while driving.

Do not start the engine by shorting the electric terminals on the starter motor, because the machine may start to drive immediately.

Do not use the machine to transport persons.

Starting in closed rooms

Do not climb onto or off the machine while the machine is driving. Change the travel direction only at standstill. In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected.

Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!

Always keep a sufficient distance to excavation walls and embankments and do not use working methods that could impair the stability of the machine.

Driving the machine

Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground.

Persons in the danger area

Always keep a sufficient distance when ing through subways, under bridges, tunnels, electric power lines etc.

Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions, especially when driving in reverse.

Driving on inclinations and slopes Do not drive on gradients exceeding the maximum gradability of the machine.

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Safety regulations On slopes drive extremely careful and always directly up or down the slope. Change to a lower gear before starting to drive.

No open fire, do not smoke.

Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes. Higher risk of accident!

Wipe off spilled fuel. Keep dirt and water away from the fuel.

Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.

Match the speed to the working conditions.

A leaking fuel tank can cause an explosion. Ensure tight fit of the fuel tank cover, if necessary replace immediately.

Always give way to loaded transport vehicles.

Fire protection measures

Switch the lights on if the visibility is poor.

Familiarise yourself with the location and the operation of fire fighting equipment. Observe all fire reporting and fire fighting possibilities.

Behaviour in traffic

Keep away from edges and embankments. Checking the effect of vibration When compacting with vibration you must check the effect on nearby buildings and underground supply lines (gas, water, sewage, electric power), if necessary stop compaction work with vibration. Do not activate the vibration on hard (frozen, concrete) ground. Danger of bearing damage!

Parking the machine Park the machine on horizontal, level, firm ground. Before leaving the machine:

Maintenance work Comply with the maintenance work described in the operating and maintenance instructions, including the information concerning the replacement of parts. Maintenance work must only be performed by qualified and authorized persons. For overhead maintenance and assembly work use the access steps and working platforms provided or other secure means. Do not use machine parts as access steps.

l

return the control lever to neutral position

l

apply the parking brake

l

shut the engine down, pull the ignition key off

l

close the cabin

Do not perform maintenance work while the machine is driving or the engine is running.

l

secure the machine against unauthorized use.

Park the machine on horizontal, level, firm ground.

l

pull the key off the main battery switch.

Keep unauthorized persons away from the machine.

Pull the key out of the ignition switch. pull the key off the main battery switch.

Do not jump off the machine, but use hand grips and access steps.

Work on hydraulic lines

Mark machines, which could be in the way, with a clearly visible sign. Parking on slopes and inclinations Secure the machine against rolling, place metal chocks in front of and behind the wheels.

Do not step in front of or behind the drums/wheels when performing adjustment work in the hydraulic system.

Filling in fuel Do not inhale any fuel fumes. Refuel only with the engine stopped and the auxiliary heater switched off. Always use access steps.

Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. When being injured by hydraulic oil consult a medical doctor immediately, as otherwise this may cause severe infections.

Do not change the setting of pressure relief valves. Drain the hydraulic oil at operating temperature – danger of scalding!

Do not refuel in closed rooms.

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Safety regulations Catch running out hydraulic oil and dispose of environmentally. Always catch and dispose of hydraulic oils separately.

Do not leave and tools or other objects, that could cause damage, in the engine compartment.

Do not start the engine after draining the hydraulic oil.

Check and change coolant only when the engine is cold.

Once all work is completed (with the system still depressurized!) check all connections and fittings for leaks.

Catch coolant and dispose of environmentally. Working on electric parts of the machine

Changing hydraulic hoses Hydraulic hoses must be visually inspected at regular intervals. 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 hydraulic hose

l

Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material. Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fire hazard!

Hydraulic hoses must be immediately replaced if: l

Store used filters and other oil contaminated materials in a separate, specially marked container and dispose of environmentally.

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 with hands or clothes! When injured by acid flush off with clear water and seek medical advice.

the hose shows deformations in bends, e.g. squeezing, buckling, layer separation, formation of blisters

Metal objects (e.g. tools, rings, watch straps) must not come in with the battery poles – danger of short circuit and burning!

l

parts of the hose are leaking.

l

hoses are not correctly installed.

l

the hydraulic hose has separated from the fitting

When recharging serviceable batteries remove all plugs, to avoid the accumulation of explosive gases.

l

the fitting shows corrosion that impairs both function and strength.

Observe the applicable instructions when starting with an auxiliary battery.

l

hoses are mixed up by mistake.

Dispose of old batteries according to regulations.

l

fittings are damaged or deformed, whereby the function and strength of the hose/hose connection is impaired.

Switch off the charging current before removing the charging clamps.

Only genuine BOMAG replacement hydraulic hoses ensure that the correct hose type (pressure range) is used at the right location. Working on the engine Shut the engine down before opening the service doors. Drain the engine oil at operating temperature – danger of scalding! Wipe off spilled oil, catch running out oil and dispose of environmentally.

18

Ensure sufficient ventilation, especially if the battery is to be charged in a closed room. Working on the fuel system Do not inhale any fuel fumes. No open fire, do not smoke, do not spill any fuel. Catch running out fuel, do not let it seep into the ground and dispose off environmentally. Cleaning work Do not perform cleaning work while the engine is running.

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Safety regulations Do not use gasoline or other easily inflammable substances for cleaning. When cleaning with steam cleaning equipment do not subject electrical parts and insulation material to the direct jet of water, or cover it beforehand. l

Do not guide the water jet into the exhaust and into the air filter.

After maintenance work After all maintenance work is completed reinstall all guards and safety installations.

Repair Attach a warning tag to the steering wheel if the machine is defective. Repairs must only be performed by qualified and authorized persons. Refer to our repair instructions. Exhaust fumes are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms! Test Depending on the type of application and the operating conditions vibratory equipment has to be examined by a specialist whenever required, but at least once every year.

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Safety regulations

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3 Indicators and Controls

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Indicators and Controls

Fig. 6

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Indicators and Controls 1

Omegameter (E-Vib display)*

18 Rotary switch for lighting (StVZO)*

2

Instrument cluster, left

19 Rotary switch for working head lights*

3

Emergency stop push button

20 Lever, swivelling of driver’s seat

4

Push button for hazard light system*

5

Instrument cluster, right

21 Momentary push button to raise the edge cutter

6

Speedometer*

7

Ignition switch

8

Rotary switch for chip spreader*

9

Rotary momentary switch for chipping quantity control*

22 Momentary push button to lower the edge cutter 23 Travel lever, right

27 Interval switch for pressure sprinkler system

11 Rotary switch for speed range selection

28 Travel lever, left

12 Riotary switch for tire sprinkling system (only AC-4)

29 Momentary push button for crabwalk, left

13 Rotary switch for sprinkling pumps 14 Rotary switch for vibration, drum pre-selection 15 Rotary switch for vibration, manual - zero - automatic 17 Rotary switch for direction indicators left/right*

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30 Momentary push button for crabwalk, right 31 Push buttin for manual vibration 32 Lever, lateral sliding of driver’s seat

16 Rotary switchfor amplitude pre-selection Optional equipment

25 Push button for warning horn 26 Rotary momentary switch for edge cutter sprinkling system*

10 Rotary momentary switch for engine speed

*

24 Push buttin for manual vibration

33 Rotation stop for travel lever movement 34 2-pole socket

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Indicators and Controls 3.1

General notes

3.2

Description of indicators and control elements

Please read this section thoroughly before operating 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 descriptions of the individual operating steps.

Fig. 7

No. 1 = Omega-meter* a compaction measuring instrument, which continually shows the load bearing values during the compaction . Omega value increase

= higher load bearing capacity

constant

= end of compaction

1 digit

= 20 Omega values

Fig. 8

No. 2 = Instrument cluster, left

i

Note

With the ignition switch in position I all gauges and instruments are switched on for 3 seconds.

*

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Indicators and Controls a red flashing = Overheating of engine, higher than 110°C, warning buzzer sounds. Switch off vibration, run engine with idle speed or shut down engine if necessary, clean engine oil cooler and radiator, if necessary repair engine.

m

= Operating hour meter, counts the operating hours while the engine is running. All maintenance work must be performed according to the indicated operating hours.

n

= Fuel tank filling level

i

Note

b red flashing = Engine oil pressure too low, engine is shut down after 10 seconds. Check engine oil level, repair the engine if necessary.

When falling below the lowest filling level the last green LED will light and the red LED will additionally come on.

c yellow = Engine air filter, air filter cartridge soiled, clean or replace if necessary.

When the fuel tank is empty only the red LED will flash.

Nine green and one red LED.

d yellow = Charge control mlight, batteries are not being charged, check V-belt, repair the generator if necessary e yellow = Hydraulic oil filter, check hydraulic system, replace hydraulic oil filter. f yellow = Seat monitoring while machine is travelling, warning buzzer sounds, engine is shut down after 4 seconds. g red

= Parking brake, with lever shifted to parking brake position, with driver’s seat unoccupied.

h green flashing = Travel direction indicator, with travel direction lever actuated.

Fig. 9

No. 3 = Emergency stop push button

i yellow = Water separator in fuel pre-filter, if the water proportion in the transparent section of the fuel pre-filter reaches the s. j red flashing = Optional; coolant provision (filling level) *

k yellow = Pre-heating and after-heating = Between -30°C and +10°C pre-heating in ignition switch position I and momentary switch for engine speed in idle speed position. After light goes out start within 14 seconds. l red flashing = Hazard light, with hazard light switch depressed

*

!

Danger

Danger of accident! Use only in events of emergency during operation. Do not use as parking brake. Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated. The machine is braked immediately, the engine is shut down. actuate

switch off/unlock

= press the button completely down, it automatically locks in fully pressed position. = Turn button clockwise. Restart the engine.

Optional equipment

BW 161/202/203 AD-4

BOMAG

25

Indicators and Controls e yellow = Crabwalk, with crabwalk actuated to left/right, goes out in middle position f yellow = Air condition failure. g red flashing = Fault light/ failure of Asphalt Manager control* h green = Chip spreader switched on. i empty

= not used

j green

= maximum speed switched on.

k yellow = Minimum fuel filling level, reserve Fig. 10

l red flashing = no function; hydraulic oil temperature

No. 4 = Hazard light button

m

pressed = hazard light system switched on, warning light (l) in left hand instrument cluster flashes red press again

= hazard light switched off, warning light (l) goes out

i

= Water tank filling level Note

Nine green and one red LED. When falling below the lowest filling level the last green LED will light and the red LED will additionally come on. When the fuel tank is empty only the red LED will flash.

Fig. 11

No. 5 = Instrument cluster, right

i

Note

With the ignition switch in position I all gauges and instruments are switched on for 3 seconds. a red flashing = No function; immobilizer b empty = not used

Fig. 12

No. 6 = Speedometer* Shows the travel speed of the machine. black display scale

=

km/h

red display scale

=

M.P.H.

c yellow = Remaining water quantity, warning buzzer sounds d yellow = Fast travel range, vibration goes out or cannot be switched on

26

BOMAG

BW 161/202/203 AD-4

Indicators and Controls i

Note

Perform the starting process for maximum 15 – 20 seconds without interruption and pause for about a minute between starting attempts. Should the engine not start in this time, perform trouble shooting and rectify the cause. ! Caution Run the engine warm for a short while before starting work. Do not allow the engine to run longer than 10 minutes with idle speed.

Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization.

Fig. 13

No. 7 = Ignition switch Position "P"/"0" =

Ignition off, key can be pulled out

Position "I"

Ignition on, all instruments in the instrument cluster light up for 3 seconds. The lighting system can be switched on.

i

=

Note

The engine can only be started if both travel levers are in “neutral”. The ignition switch is designed with a lock to prevent repetitive starting. For a new starting attempt the ignition key must first be turned back to position "0". With a cold-start system installed* and at temperatures between -30°C and 10°C run a pre-heating process. *

= Turn the rotary momentary switch for engine speed once to idle speed position. Control light (k) in the instrument cluster will only light up if fuse F 15 is installed. Once the control light (k) in the left hand instrument cluster has gone out start the engine within 14 seconds.

Position "II" (Start)

*

=

Fig. 14

No. 8 = Rotary switch for chip spreader** Position left = Chip spreader switched off Position right = Chip spreader switched on

i

Note

Control light (h) in right hand instrument cluster lights up.

turn further against spring pressure, start engine, return ignition key to position "I".

Optional equipment

BW 161/202/203 AD-4

**

BOMAG

Optional equipment

27

Indicators and Controls i

Note

Control light (j) in right hand instrument cluster lights up. To start under cold ambient temperatures: with ignition switch in position "I" turn rotary momentary switch clockwise. The engine can be started with max. speed. !

Caution

Always drive and vibrate with max. engine speed! Control the travel speed with the travel lever.

Fig. 15

No. 9 = Rotary momentary switch for chip quantity* Position left

= Reduce chip quantity

Position right

= Increase chip quantity

Fig. 17

No. 11 = Rotary switch for speed range selection Position left

= Ist travel range 0 ... 6 km/h

Fig. 16

i

Note

No. 10 = Rotary momentary switch for engine speed

Vibration is only possible in speed range 1.

Electric engine speed adjustment

Position right

turn clockwise = Idle speed position, pre-heating**

i

= IInd travel range 0 ... 11 km/h, control light (d) in right hand instrument cluster lights up.

Note

Normal position for engine start. turn clockwise = Full load position, operating position for driving and vibration

* **

28

Optional equipment Optional equipment

BOMAG

BW 161/202/203 AD-4

Indicators and Controls

Fig. 18

Fig. 20

No. 12 = Rotary momentary switch for tire sprinkling system (only AC-machines)

No. 14 = Rotary switch for vibration, drum preselection

Position "left"

= 5 sec. on / 20 sec. off (interval) emulsion sprinkling

Position "0"

= Sprinkler system switched off

Momentary switch "right" = 5 sec. emulsion sprinkling on

i

Note

Vibration change-over is only activated if the vibration is switched off beforehand. Position "left"

= Vibration of front drum

Position "middle" = Vibration of front and rear drums Position "right" = Vibration of rear drum

Fig. 19

No. 13 = Rotary switch for sprinkling pumps Position left

= Sprinkling pump I switched on

Position middle = Sprinkling pumps switched off Position right

= Sprinkling pump II switched on

Fig. 21

No. 15 = Rotary switch for vibration, manual or automatic Position "left"

i

Note

Sprinkling pumps I and II switched on alternately

= Pre-selection for vibration activation during travel via the vibration push button in the travel lever

Position "right" = Pre-selection for automatic activation and deactivation of vibration when exceeding or

BW 161/202/203 AD-4

BOMAG

29

Indicators and Controls falling below a certain slow travel speed. Position "middle" = Vibration off

Fig. 24

No. 18 = Rotary switch for light system (StVZO)** Position "left"

Position "middle" = Sidelights on, with ignition switch in position "I" or with only ignition on.

Fig. 22

No. 16 = Rotary switch for vibration, amplitude selection Position "left"

= Light off

= low amplitude, high frequency

Position "right" = high amplitude, low frequency

Position "right" = Travel light on, with ignition switch in position "I"

Fig. 23

Fig. 25

No. 17 = Rotary switch for direction indicators left / right*

No. 19 = Rotary switch for working lights*** Position "left"

Position "middle" = Direction indicators disabled

= Light off

Position "right" = Working lights on, with ignition switch in position "I"

Position "left or right" = The front and rear direction indicators for the corresponding side of the machine light up, the control light (h) in the instrument cluster flashes

*

30

Optional equipment

** Optional equipment *** Optional equipment

BOMAG

BW 161/202/203 AD-4

Indicators and Controls

Fig. 26

Fig. 28

No. 20 = Lever, swivelling of driver’s seat

No. 22 = Momentary push button to lower the edge cutter**

Danger Danger of accident!

press

= Edged cutter is lowered.

release

= Edge cutter remains in position reached last.

!

Always lock the driver’s seat in one of the locking positions while driving. Do not swivel the driver’s seat while driving. swivel

= Stop he machine, apply the parking brake. Pull the lever and swivel the driver’s seat to the desired position. Let lever click securely into place.

Fig. 29

No. 23 = Travel lever, right

Fig. 27

Position „0“

= start forward and backward travel from position ’’0“. From forward or backward travel to position ’’0“ = service brake

Position "I"

= Forward travel

Position "II"

= Backwards travel

No. 21 = Momentary push button to raise the edge cutter*

i

press

= Edged cutter is raised.

release

= Edge cutter remains in position reached last.

*

Optional equipment

BW 161/202/203 AD-4

Note

The right hand travel lever is mechanically linked with the left hand travel lever. When leaving the seat (seat switch) with the engine is running and/or the machine driving, the engine will be shut down after the 4 seconds, **

BOMAG

Optional equipment

31

Indicators and Controls the warning buzzer will sound and warning light (f) in the instrument cluster will light up. 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. Position "III"

i

= notched position to the right = parking brake, starting of engine

Note

The parking brake control light (g) in the left hand instrument cluster lights up.

Fig. 32

No. 26 = Push button, edge cutter sprinkling system* press

i

= Edge cutter sprinkling system switched on.

Note

The edge cutter sprinkler system works when the rotary switch has been switched to sprinkling pump I or II. press again

= Edge cutter sprinkling system switched off

Fig. 30

No. 24 = Momentary push button for manual vibration, right press

= to switch manual vibration on and off.

Fig. 33

No. 27 = Interval switch for pressure sprinkler system Position 12 left = permanent sprinkling when pressure sprinkling is enabled Fig. 31

No. 25 = Push button for warning horn

*

32

BOMAG

Optional equipment

BW 161/202/203 AD-4

Indicators and Controls i

i

Note

In travel lever position ’’0“ the sprinkling system is switched off, except in position 12 (permanent sprinkling).

Note

The parking brake control light (g) in the left hand instrument cluster lights up.

further positions to the right, between 11 and 1 = various sprinkling intervals

Fig. 35

No. 29 = Momentary push button for crabwalk, left press Fig. 34

= the crabwalk is infinitely adjusted to left.

No. 28 = Travel lever, left Position „0“

i

= start forward and backward travel from position ’’0“. From forward or backward travel to position ’’0“ = service brake

Note

Control light (e) in right hand instrument cluster lights up.

Position "I"

= Forward travel

Control light goes out when middle position is reached.

Position "II"

= Backwards travel

release

i

= Crabwalk remains in position reached last.

Note

The left hand travel lever is mechanically linked with the right hand travel lever. When leaving the seat (seat switch) with the engine is running and/or the machine driving, the engine will be shut down after the 4 seconds, the warning buzzer will sound and warning light (f) in the instrument cluster will light up. 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. Position "III"

= notched position to the left = parking brake, starting of engine

Fig. 36

No. 30 = Momentary push button for crabwalk, right press

BW 161/202/203 AD-4

BOMAG

= the crabwalk is infinitely adjusted to right.

33

Indicators and Controls i

sliding

Note

Control light (e) in right hand instrument cluster lights up. Control light goes out when middle position is reached. release

= Stop machine, apply parking brake, pull lever and slide driver’s seat sideways to desired position. Let lever click securely into place.

= Crabwalk remains in position reached last.

Fig. 39

No. 33 = Rotation stop for travel lever movement Fig. 37

Turn anti-clockwise = long travel lever movement

No. 31 = Momentary push button for manual vibration, left press

= to switch manual vibration on and off.

i

Note

machine can be driven with max. speed. turn clockwise = short travel lever movement

i

Note

machine can be driven with reduced speed in accordance with the length the stop is screwed in.

Fig. 38

No. 32 = Lever, lateral sliding of driver’s seat

!

Danger

Danger of accident! Always lock the driver’s seat in one of the locking positions while driving.

Fig. 40

Do not slide the driver’s seat while driving.

Permanent current when main battery switch is switched on.

34

No. 34 = 2-pole socket

BOMAG

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Indicators and Controls (9), 10A =

(F14) engine solenoid

(10), 15A = (F129) MD+ (11), 5A =

(F04) gauges

(12), 10A = (F23) warning horn (13), 10A = (F03) vibration (14), 15A = (F08) direction indicators and working head lights (15), 10A = (F101) Variomatic, potential 15 (16), 10A = (F06) water sprinkling system (17), 10A = (F09) parking and tail light, left hand side

Fig. 41

No. 35 = Main battery switch

(18), 10A = (F10) parking and tail light, right hand side

The main battery switch is installed in the engine compartment.

(19), 10A = (F11) head lights, left hand side

inserted and turned in removed

(20), 10A = (F12) head lights, right hand side = machine can be started. = engine cannot be started, (anti-theft protection)

Danger Fire hazard! !

Do not use fuses with higher ampere ratings and do not bridge fuses.

Fig. 42

No. 36 = Fuses in electric junction box Fig. 43

Fuses (1), 30A =

(F01) main fuse

(2), 15A =

(F05) socket

(3), 10A =

(F93) control potential 30

(4), 20A =

(F105) engine speed

(5), 25A =

(F68) potential 30

(6), 15A =

(F07) hazard light

(7), 7,5A =

(F119) engine

(8), 5A

(F25) solenoid valve for driving and braking

=

BW 161/202/203 AD-4

No. 37 = Main fuse for battery Main fuse for battery and fuse for white fume control are located in the battery compacrtment. (1), 125A

= (F00) main fuse for battery

(2), 125A

= (F15) Fuse for white fume control

i

Note

When installing fuse F 15 the engine is after-heated. The battery is recharged by a longer running time of the engine.

BOMAG

35

Indicators and Controls Caution Gefahr der Tiefentladung der Batterie.Risk of total discharge of battery. !

down

= Switches on wiping of rear windscreen.

Push button

= Rear windscreen is sprayed during wiping.

h = toggle switch for working headlights

Fig. 44

No. 38 = Control elements, cabin* Fig. 46

d = Fuse box in cabin !

Danger

Fire hazard! Do not use fuses with higher ampere ratings and do not bridge fuses. (1), 15A = (F41) flashing beacon (2), 15A = (F27) wiper/washer, front (3), 15A = (F28) wiper/washer, rear (4), 25A = (F31) cabin fan Fig. 45

(5), 25A = (F110) working head lights, front/rear

a = toggle switch for flashing beacon

(6), 5A

b = toggle switch for front windscreen wiper/ washer

(7), 10A = (F68) potential 30

up

= windscreen wiper moves to end position and stops.

down

= Switches on wiping of front windscreen.

Push button

= Front windscreen is sprayed during wiping.

= (F90) cabin heater

(8), 20A = (F40) cabin heater

c = toggle switch for rear windscreen wiper/ washer up

*

36

= windscreen wiper moves to end position and stops. Optional equipment

BOMAG

BW 161/202/203 AD-4

Indicators and Controls Position red range

= Temperature selection for cabin heater.

Fig. 47

e = Rotary switch for cabin ventilator Position ’’Off“

= cabin ventilator switched off. Fig. 48

Position 1, 2 and 3 = ventilator stages of different strengths

i

i = reading and dshboard light j = toggle switch for reading and dashboard light

Note

k = toggle switch for cabin light

The 3rd stage cannot be switched on when the cabin mounted working headlights are switched on.

l = cabin light

f = Push button for air conditioning* press

i

= air conditioning switched on.

Note

The light above the push button and control light (f) in the instrument cluster light up. With rotary switch (g) the air conditioning unit can be regulated within the blue range. press again

i

= air conditioning switched off.

Note

The light go out. g = Rotary switch for cabin heater (temperature selector switch) Position ’’Off“ Position blue range

*

Fig. 49

No. 39 = Vents for air conditioning, ventilation and heating, left hand side**

= cabin heater switched off. = temperature selection for air conditioning.

Optional equipment

BW 161/202/203 AD-4

**

BOMAG

Optional equipment

37

Indicators and Controls

Fig. 50

No. 40 = Vents for air conditioning, ventilation and heating, right hand side*

*

38

Optional equipment

BOMAG

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4 Operation

BW 161/202/203 AD-4

BOMAG

39

Operation 4.1

General notes

Please read section 3 Indicators and Control Elements thoroughly before operating the machine if you are not yet fully familiar with the indicators and control elements of the machine.

4.2

Tests before taking into operation

The following inspections must be carried out before each working day or before a longer working period.

All indicators and control elements are described in detail in this chapter. !

Danger

Danger of accident! Please observe strictly the safety regulations in chapter 2 of this instruction manual! Park the machine on ground as level as possible.

l

Check: l

fuel tank and fuel lines for leaks

l

screw ts for tight fit

l

function of steering

l

machine for cleanliness, damage

l

Presence of the appropriate operating and maintenance instructions

l

proper maintenance of the machine

l

right and left hand service doors closed and locked

i

Note

For a description of the following tasks refer to the chapter "maintenance every 10 operating hours". Engine oil level

l

i

Note

In hydraulic systems filled with Panolin HLP Synth. 46 always use the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer. l

Check the hydraulic oil level, top up if necessary.

l

Check the coolant level, top up if necessary.

!

Danger

Fire hazard! Do not refuel in closed rooms. l

40

BOMAG

Check the fuel level, top up if necessary. BW 161/202/203 AD-4

Operation l

Check water separator in fuel system, drain if necessary.

l

Fill water tanks

l

Clean the scrapers, check their condition, replace if necessary.

4.3

Starting the engine

Open the right hand service door.

l

Fig. 51 l

Insert and lock the main battery switch (Fig. 51).

l

Close the right hand service door.

Fig. 52

Always start the engine from the driver’s seat with seat switch (Fig. 52).

l

Danger Danger of accident! !

Always wear your seat belt.

BW 161/202/203 AD-4

BOMAG

41

Operation

Fig. 53 l

Fig. 56

Fasten your seat belt (Fig. 53).

l

Check, whether the emergency stop switch (Fig. 56) is unlocked.

Fig. 54 l

Fig. 57

Adjust the driver’s seat and let it click into place (Fig. 54).

l

Fig. 55 l

42

Turn the ignition key (Fig. 57) to position "I".

Fig. 58

Check, whether the travel lever (Fig. 55) is engaged in brake position (III).

All control and warning lights (Fig. 58) and (Fig. 59) in the fault monitoring board light up for approx. 3 seconds.

BOMAG

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Operation

Fig. 59

Fig. 61

Charge control light (d), engine oil pressure warning light (b) and brake warning light (g) stay on.

i

Note

Control light (j) (Fig. 61) in right hand instrument cluster lights up.

Starting with fuse F15 (pre-heating facility) installed

Fig. 60 l

To start under cold temperatures turn the rotary momentary switch (Fig. 60) for engine speed clockwise to "MAX". Fig. 62

Turn the rotary momentary switch for engine speed (Fig. 62) once to the left to engine speed ’’MIN“.

l

i

Note

The pre-heating facility is switched on.

BW 161/202/203 AD-4

BOMAG

43

Operation Caution Run the engine warm for a short while, but do not run with idle speed for more than 10 minutes. !

Fig. 63

i

Note

Control light k (Fig. 63) in the left hand instrument cluster lights as long as the pre-heating facility is in operation (between 32 ... 54 seconds).

Fig. 65

After control light goes out start within 14 seconds.

l

l

Turn the rotary momentary switch for engine speed (Fig. 65) counter-clockwise to position ”MIN” to run the engine warm.

Fig. 64

Turn the ignition key to position "II" (Fig. 64), the starter will crank the engine.

l

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. l

As soon as the engine ignites return the ignition key to position "I".

Charge control light and engine oil pressure warning light go out. The brake warning light stays on.

44

BOMAG

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Operation 4.4

Caution If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components.

Starting with jump wires

!

l

After starting disconnect the negative poles (ground cable) first and the positive poles after.

l

Switch off the consumer.

l

Fasten the battery cover again.

Fig. 66 l

Remove the battery cover (Fig. 66).

Fig. 67

! Caution A wrong connection will cause severe damage in the electric system.

l

Only use a 12 Volt battery to bridge the machine.

l

When jump starting with an external battery connect both plus poles first.

l

Then connect the ground cable first to the minus pole of the current supplying battery and then to engine or chassis ground, as far away from the battery as possible (Fig. 67).

l

Start as described under 'Starting the engine'.

l

Once the engine is running switch on a powerful consumer (working light, etc.).

BW 161/202/203 AD-4

BOMAG

45

Operation 4.5 !

Driving the machine

Danger

Danger of accident! Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes. Soil conditions and weather influences impair the gradability of the machine. Do not drive up and down inclinations exceeding the maximum gradability of the machine (see technical data).

Fig. 69

Turn the rotary momentary switch for engine speed clockwise to "MAX"(Fig. 69).

l

Always give way to loaded transport vehicles! Before starting to drive make sure that the drive range is absolutely safe.

i

Note

The engine revs up to maximum speed. Caution Always drive and vibrate with max. engine speed! Control the travel speed with the travel lever. !

Fig. 68

Caution Pre-select the travel speed range at standstill. !

l

Pre-select the desired speed range (Fig. 68). Fig. 70

i

Note

Control light j (Fig. 70) in right hand instrument cluster lights up.

46

BOMAG

BW 161/202/203 AD-4

Operation Do not operate jerkily! Control the travel speed with the travel lever. When driving up and down inclinations move the travel lever slowly back towards neutral to brake the machine. If the engine speed drops when driving up extreme inclinations move the ravel lever slightly back, if necessary change to the lower speed range.

Seat switch Fig. 71

Disengage the travel lever (Fig. 71) from notched position III towards the inside.

l

i

Note

The brake warning lamp (g) in the instrument cluster goes out. Move the travel lever form "0"-position slowly to forward or reverse.

l

i

Note Fig. 72

The machine drives forward or backward with a speed that corresponds with the actuation of the travel lever.

i

In travel lever positions "I" and "II" the seat switch is active (Fig. 72).

Move the travel lever back to "0"-position.

l

i

Note Danger Danger of accident! !

The machine is braked and stops in "0"-position. !

Note

If the seat is not occupied when the engine is running the warning horn will sound and the engine will be shut down after 4 seconds.

Danger

Danger of accident! When stopping on inclinations and slopes engage the travel lever towards the outside in parking brake position.

Important notes on travel operation 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. !

BW 161/202/203 AD-4

BOMAG

47

Operation 4.6

Stopping the machine, operating the parking brake

Fig. 73

i

Note

The warning lights for seat occupation and parking brake f and g (Fig. 73) in the left hand instrument cluster light up.

Fig. 74

Return the travel lever (Fig. 74) slowly to "0"position and engage it towards the outside in notched position "III", parking brake position.

l l

To continue travelling you must occupy the seat and put on the seat belt within 4 seconds. The warning lights go out and the warning horn stops sounding.

l

If the engine stops restarting is required.

i

Note

The machine is automatically braked by the hydrostatic drive and the parking brake is applied.

Fig. 75

The parking brake warning light g (Fig. 75) in the left hand instrument cluster lights up.

i

Note

The parking brake also closes automatically when shutting the engine down.

48

BOMAG

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Operation 4.7

Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization.

Shutting the engine down

Fig. 76

Fig. 78

Return the travel lever (Fig. 76) slowly to "0"position and engage it towards the outside in notched position "III", parking brake position.

l

i

Turn the ignition switch (Fig. 78) to position "0" or "P" and pull the ignition key out.

l

i

Note

Note

The parking brake closes automatically when shutting the engine down.

The machine is automatically braked hydrostatically. The parking brake warning light in the left hand instrument cluster lights up.

Open the right hand service door.

l

Fig. 79 Fig. 77

Turn the rotary momentary switch for engine speed counter-clockwise to "MIN" (idle speed) (Fig. 77).

l

l

Remove the main battery switch (Fig. 79) and store it in a safe place.

l

Close the right hand service door.

Danger Danger of accident! !

i

Note

The control light for maximum engine speed j in the right hand instrument cluster goes out.

BW 161/202/203 AD-4

Secure the machine against unauthorized use, pull the ignition key out, lock the cabin door.

BOMAG

49

Operation 4.8

Switching the vibration on and off

i

Note

Vibration is only possible in speed range 1.

Pre-selecting the vibration

i

Note

Switch the vibration on only at maximum engine speed. Vibration at standstill causes transverse ruts, therefore: l

switch the vibration on only after shifting the travel lever to the desired travel direction.

l

Switch the vibration off before stopping the machine.

Caution Danger of bearing damage! !

Do not activate the vibration on hard (frozen, concrete) ground.

!

Fig. 81

Pre-select amplitude/frequency with the rotary switch (Fig. 81).

l

Danger

Risk of damage! When compacting with vibration you must check the effect of nearby buildings and underground supply lines (gas, water, sewage, electric power), if necessary stop compaction with vibration.

Fig. 82

Preselect the desired drum or drums with the rotary switch (Fig. 82).

l

i

Note

The drum pre-selection "front/ both/ rear" can only be changed after switching the vibration off. Fig. 80 l

50

Turn the rotary speed range selector switch (Fig. 80) anti-clockwise to the first speed range.

BOMAG

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Operation Vibration in manual mode

Fig. 85

Actuate the vibration push button (Fig. 85) in the left or right hand travel lever only after shifting the travel lever to the desired travel direction.

l

Fig. 83

Turn the rotary switch for vibration in manual or automatic mode (Fig. 83) anti-clockwise to the symbol "Manual".

l

Switching the vibration off Switch the vibration on

Press the vibration push button again.

l

Caution Switch the vibration on only at max. engine speed. !

i

Note

Always switch the vibration off before stopping the machine.

Vibration in automatic mode

i

Note

In automatic mode the vibration is switched on at a speed of more than 1.3 km/h, when riving in travel speed ranges I + II. Vibration is switched off at a speed below 1.3 km/h.

Fig. 84

Turn the rotary momentary switch for engine speed clockwise to "MAX" (Fig. 84).

l

i

Note

Control light j in right hand instrument cluster lights up.

BW 161/202/203 AD-4

BOMAG

51

Operation Switching the vibration off

Fig. 86

Turn the rotary switch (Fig. 86) clockwise to "Automatic".

l

Fig. 88

Shift the travel lever (Fig. 88) towards "0"-position to brake the machine.

l

Switch the vibration on

i

Note

The vibration switches off when falling below the slow travel speed. Vibration in automatic mode avoids the formation of transverse marks caused by vibration with the machine at standstill.

Fig. 87

Shift the travel lever (Fig. 87) in direction forward or backward.

l

i

Note

The vibration comes on at a low travel speed.

52

BOMAG

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Operation 4.9

Operating the crabwalk

Fig. 91

i

Fig. 89

i

Note

The crabwalk control light e (Fig. 91) in the right hand instrument cluster lights up.

Note

Control light goes out when middle position is reached.

The maximum offset (Fig. 89) to right and left is 170 mm. Danger Operate the crabwalk only at low travel speed, in order to stay in track. !

Fig. 92

Press and hold the right hand push button (Fig. 92) on the left hand travel lever.

l

i

Fig. 90

Press and hold the left hand push button (Fig. 90) on the left hand travel lever.

l

i

Note

the crabwalk is infinitely adjusted to right. The crabwalk operates immediately, also in standstill.

Note

The crabwalk is infinitely adjusted to left. The crabwalk operates immediately, also in standstill.

BW 161/202/203 AD-4

BOMAG

53

Operation 4.10 Switching the pressure sprinkling system on and off

Fig. 93

Turn the rotary switch for the pressure sprinkling system (Fig. 93) to position "left" (sprinkling pump I) or position ’’right“ (sprinkling pump II).

l

i

Note

The pressure sprinkler system is switched on. For sprinkling switch alternately between sprinkling pumps I and II to achieve even straining of the sprinkling pumps.

i

Note

Permanent sprinkling, stage 12, is always active in travel lever position ’’0“, stages 11 to 1 are switched off after 30 seconds when the travel lever is in ’’0“-position.

Fig. 95

i

Note

When the water tank is empty the warning light for residual water quantity in water sprinkling system c (Fig. 95) in the right hand instrument cluster will light up and the warning buzzer will sound. In the water tank filling level gauge (m) the last green and the red LED will light or the red LED will flash. l

Perform trouble shooting and rectify the cause.

Fig. 94 l

54

Set the interval switch for pressure sprinkling system to the desired sprinkling interval (Fig. 94).

BOMAG

BW 161/202/203 AD-4

Operation 4.12 Actuating the emergency stop switch

4.11 Sprinkling of edge cutter*

!

Danger

Danger of accident! In events of emergency and in case of danger actuate the emergency stop switch immediately. Start travel operation of the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated. Caution Do not use as service brake. The deceleration is extremely high. In case of frequent use the wear on the multi-dics brakes will be very high. !

Fig. 96

Turn the rotary sprinkling system switch (Fig. 96) to left or right.

l

Fig. 97

Fig. 98

Press push button for edge cutter sprinkling system (Fig. 97).

l

i

Note

The edge cutter is sprinkled in the same interval as the drums.

*

Press the button of the emergency stop switch (Fig. 98) completely down, it automatically locks in fully pressed position.

l

i

Note

Shuts the engine down and closes the brake. l

Turn the button clockwise to unlock the emergency stop switch.

l

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

Optional equipment

BW 161/202/203 AD-4

BOMAG

55

Operation 4.13 Adjusting the rotation stop for travel lever movement

4.14 Adjusting the driver’s seat !

i

Danger

Danger of accident!

Note

Use the rotation stop only to adjust a predetermined travel speed, then release the full travel lever movement again.

Do not adjust the driver’s seat while driving.

Fig. 100 Fig. 99

a

= Pull the lever and lock the driver's seat (Fig. 100) in one of 9 possible rotary positions.

l

Loosen the fastening nut.

l

Turn the rotary stop (Fig. 99) in or out, until the desired travel lever movement is reached.

b

= Disengage the lever and adjust the seat in longitudinal direction.

l

Retighten the fastening nut.

c

= Operate the lever and adjust the back rest.

d

= Pull the lever and lock the driver's seat in one of 9 possible lateral positions.

e

= read the adjusted driver’s weight in the window.

f

= Adjust the weight of the driver with the lever.

56

BOMAG

BW 161/202/203 AD-4

Operation 4.15 Opening or closing the cabin window

4.16 Towing !

!

Danger

Danger of accident!

Caution

Always keep the cabin doors closed while driving.

Before releasing the brake secure the machine against unintended rolling.

Always lock the cabin windows in open position or close them.

!

Caution

Tow the machine only after releasing the parking brake. Towing speed 1 km/h, max. towing distance 500 m.

Fasten the towing hitch

Fig. 101 l

Open the locking (Fig. 101) of the cabin window.

l

Swing out and lock the cabin window.

Fig. 103 l

Fasten the towing hitch at front (Fig. 103) or rear with a tightening torque of 578 Nm (426 ft.lb).

Fig. 102 l

To close the cabin window press the locking button (Fig. 102), swing the cabin window back and lock it.

BW 161/202/203 AD-4

BOMAG

57

Operation Releasing the parking brake in case of a battery failure

i

Note

The pump lever extension is stored in the tool box in the cabin.

Fig. 104 Fig. 106

Open the left hand maintenance door (Fig. 104).

l

Release the brake by operating the hand pump (Fig. 106).

l

After towing Caution Before detaching the tow bar block the machine with chocks to prevent unintended rolling. !

l

Unlock the emergency control button and lock it with the clamp.

Fig. 105 l

Loosen clamp 1 (Fig. 105).

l

Press the emergency control button (2) in and turn it clockwise against the end stop.

Danger Danger of accident! !

If the emergency control button remains pressed in, the automatic parking brake is out of function. Once the function of the machine has been reestablished unlock the emergency control button and assemble the clamp.

58

BOMAG

BW 161/202/203 AD-4

Operation 4.17 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. 108 l

After driving the machine onto the low loader take the transport locks out of the brackets on both sides of the articulated t (Fig. 108).

Fig. 107

Turn the rotary speed range selector switch(Fig. 107) to low speed range.

l

Fig. 109 l

Place the articulation t lock (Fig. 109) on both sides over the piston rods and lock with bolts and split pins.

Danger Danger of accident! !

Do not drive with crabwalk onto the transport vehicle.

BW 161/202/203 AD-4

BOMAG

59

Operation

Fig. 110 l

Lash the machine to the transport vehicle, fasten the lashing gear (Fig. 110) to the front and rear legs.

Fig. 111 l

Use the four lifting eyes (Fig. 111) to lift the machine.

Loading weight: see technical data.

60

BOMAG

BW 161/202/203 AD-4

5 Maintenance

BW 161/202/203 AD-4

BOMAG

61

Maintenance 5.1

General notes on maintenance

l

Do not let the suction hose disturb the sludge on the bottom of the drum.

l

Fuel left in the fuel drum is not suitable for the engine and should only be used for cleaning purposes.

When servicing the machine pay careful attention to all applicable safety instructions. Thorough maintenance of the machine ensures maximum reliability and prolongs the lifetime of important components. The necessary effort can by no means be compared with the faults which may occur when not observing these instructions.

Notes on the engine performance

The left/right are always related to travel direction forward.

Combustion air and fuel injection rates of the diesel engine have been carefully adjusted and determine the engine's performance and temperature level as well as the quality of the exhaust gas.

l

Clean machine and engine thoroughly before starting maintenance work.

If your machine has to work permanently in "thin air" (at high altitudes) and with full load you should consult or service department or the service department of the engine manufacturer.

l

For maintenance work park the machine on level ground.

Notes on the hydraulic system

l

Maintenance work must generally be carried out with the engine shut down.

l

Depressurize hydraulic lines before working on them.

l

Disconnect the battery and cover it with insulation material before starting to work on electrical components.

l

Always attach the articulation lock (transport lock) before starting to work in the articulation area of the machine.

Environment During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils and fuel environmentally.

When servicing the hydraulic system cleanliness if of utmost importance. make sure that no dirt or other contaminating systems can enter the system. Small particles can flute valves, cause pumps to seize and block restrictors and pilot bores, thereby causing costly repairs. l

If during the daily oil level check the oil level is found to have dropped, check all lines, hoses and components for leakages.

l

Seal leakages immediately. If necessary inform the responsible service department.

l

Always use the filling and filtering unit (BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is equipped with a fine filter which cleans the hydraulic oil and prolongs the lifetime of the filter.

l

Clean fittings, filler caps and their immediate surrounding area before removing them, so that no dirt can fall in.

l

Do not leave the tank opening unnecessarily open, cover it so that no dirt can fall in.

Store used filters in a special waste container and dispose of environmentally. Always catch biodegradable oil separately.

Notes on the fuel system The lifetime of the diesel engine is decisively depending on the cleanliness of the fuel. l

Keep the engine free of dirt and water as this could damage the injection elements of the engine.

l

When choosing the storage location for fuel make sure that spilled fuel will not harm the environment.

62

BOMAG

BW 161/202/203 AD-4

Maintenance 5.2

fect the cold starting ability of the engine, but will not cause any engine damage.

Fuels and lubricants

Temperature related lubrication oil changes can be avoided by using multi-purpose oils. The following oil change intervals apply also when using multi-purpose oils.

Engine oil l

Use winter grade engine oil for winter operation!

Regular lubrication oil changes The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operating hours reached.

Oil quality Preferably use oils of ACEA-classification E3-96/ E5-02. This enables utilization of the longest oil change intervals. Oil of ACEA-classification E2-96 may also when reducing the period between oil changes by 50 percent. Oils of API-quality class CG-4/CH-4 enable utilization of the longest oil change intervals. Oils of APIquality classes CF/CF-4 may also be used when reducing the period between oil changes by 50 percent.

Lubrication oil change intervals Fig. 112

Oil change intervals with oil quality

In order to assure perfect cold starting it is import to chose the viscosity (SAE-class) of the engine oil according to the ambient temperature. For winter operation below -10 °C the oil change intervals must be shortened.

ACEA E2-96

= 250 operating hours

API

Lubrication oil with a too high viscosity index causes starting difficulties. The temperature when starting the engine is therefore of highest importance when choosing the viscosity of engine oil for winter operation.

API CF/CF-4

= 250 operating hours

ACEA E3-96/E5-02

= 500 operating hours

API CG-4/CH-4

= 500 operating hours

Oil viscosity Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAEclass) (Fig. 112). Occasional falling short of the temperature limit (e.g. use of SAE 15W/40 down to -15 °C) may ef-

BW 161/202/203 AD-4

!

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-

BOMAG

63

Maintenance peratures below -10 °C the oil change intervals specified in the table must be halved. When using fuels with a sulphur content higher than 1% to 1.5% the engine oil must have a TBN of approx. 12 x the S-content in % by weight when halving the oil change intervals.

46 mm2/s at 40 °C. For topping up or for oil changes use only high-quality hydraulic oil, type HVLP according to DIN 51524, part 3, or hydraulic oils of type HV according to ISO 6743/3. The viscosity index (VI) must be at least 150 (observe information provided by manufacturer).

Lubrication oil quality classes

Bio-degradable hydraulic oil

The oil manufacturer is solely responsible for asg a product to a certain quality class.

On request the hydraulic system can also be filled with ester based biodegradable hydraulic oil, Panolin HLP Synth. 46. This biologically quickly degradable hydraulic oil Panolin HLP Synth.46 meets all demands of a mineral oil based hydraulic oil according to DIN 51524. In hydraulic systems filled with Panolin HLP Synth. 46 always use the same oil to top up.

i

Note

When changing to a higher alloyed oil quality after a longer period of operation, it is recommended to perform the first oil change of the higher quality oil already after 20 operating hours. The lubrication oil filter cartridge must be changed at the same time.

When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details.

Fuels

Check the filter more frequently after this change.

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 injection lines need to be bled. The following fuel specifications are permitted: DIN 51601; Nato Codes: F-54, F-75; BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-D; VV-F-800 a: DF-A, DF-1 and DF-2.

Winter fuel For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel. In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel additives. Consult the engine manufacturer.

Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of

64

Drum drive gear oil For the gearbox use only multi-purpose transmission oil of API-class GL5 with viscosity class SAE 80W-90.

Lubrication grease For lubrication purposes use an EP-high pressure grease, calcium and/or lithium saponified (penetration 2), acc. to DIN 51502 KP 2G. Coolant High performance diesel engines require a well balanced coolant mixture of water, anti-freeze and supplementary coolant additives. For coolant mixtures use only soft tap water with a water hardness between 3 and 20 °dGH. The water should not contain more than 100 mg/dm3 of chlorine and sulphate. Prepare and check coolant with highest care, since otherwise the engine may be damaged by corrosion, cavitation and freezing. As a protection against frost and boiling point antifreeze agents must be used under any climatic conditions. Mixing of coolant water and cooling system protection agent must be performed at a concentration

BOMAG

BW 161/202/203 AD-4

Maintenance level of the cooling system protection agent of minimum 35% and maximum 45%. !

Caution

Do not mix different coolants and additives of any other kind. Environment Cooling system protection agents must be disposed of environmentally.

BW 161/202/203 AD-4

BOMAG

65

Maintenance 5.3

Fuels, lubricants and filling capacities

Assembly

Fuel or lubricant Summer

Winter

Quantity approx. Attention Observe the level marks

Engine

Engine oil ACEA: E3-96/E5-02

8.5 litres without oil filter, 10 litres with oil filter

API: CG-4/CH-4 SAE 10W/40 (-20 °C to +30 °C) SAE 10W/40 (-10 °C to +40 °C) SAE 30

SAE 10W

(+5 °C to +30 °C)

(-5 °C to -30 °C)

SAE 40

SAE 20W/20

(+25 °C to +40 °C)

(-10 °C to +10 °C) Fuel

Diesel

Winter diesel fuel (down to -12 °C)

200 litres

Coolant Mixture of water and anti-freeze agent Hydraulic system

Sprinkler system Drum

Hydraulic oil (ISO), HV46, kinem. viscosity 46 mm 2/s at 40 °C or ester based biodegradable hydraulic oil Water

Anti-freeze mixture water * SAE 15W/40

- Exciter shaft tube Travel gear, drum

approx. 15 litres 60 litres

1000 litres 7.5 litres (BW 161 AD-4) 9.5 litres (BW 202 AD-4)

SAE 80W-90, API GL5

approx. 1.5 litres

Steering chains

High pressure grease (lithium saponified)

as required

Oscillating articulated t

High pressure grease (lithium saponified)

as required

*

66

Mix water and anti-freeze agent by following the instructions of the manufacturer

BOMAG

BW 161/202/203 AD-4

Maintenance 5.4

Running-in instructions

The following maintenance work must be performed 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. Maintenance after 50 operating hours l

Check the engine for leaks.

l

Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts.

l

Retighten the bolted connections on the machine.

Maintenance after 250 operating hours l

Engine oil change

l

1st oil change in drum drive gear.

l

1. Oil change in the exciter shaft tube

Maintenance after 500 operating hours l

2. Oil change in drum drive gear.

l

2. Oil change in the exciter shaft tube

Special intervals l

l

*

BW 161/202/203 AD-4

BOMAG

Switch the heating system* on every month for about 10 minutes. Switch the air conditioning* on every month for about 10 minutes.

Optional equipment

67

Maintenance 5.5

Maintenance chart

With all maintenance intervals perform also the work for shorter preceding service intervals. No.

Designation

Note

Every 10 operating hours 5.6 5.7 5.8 5.9 5.10 5.11

Check the engine oil level Check the fuel level Check the hydraulic oil level Check the coolant level Check/empty the fuel pre-cleaner (water separator) Check the water level

Observe the dipstick marks Inspection glass Inspection glass Inspection glass Summer: Water, winter: Anti-freeze agent

Every 250 operating hours 5.12 5.13

Check, clean radiator, fuel cooler, hydraulic oil cooler and intercooler Check the oil level in vibrator shaft tube

Every 500 operating hours 5.14 5.15 5.16 5.17 5.18

Change the engine oil (at least 1x per year)* Change the engine oil filter cartridge Check the coolant concentration Service the air conditioning Check the battery condition, grease the poles

Dipstick mark

Every 1000 operating hours 5.19 5.20 5.21 5.22 5.23 5.24 5.25

Clean the fuel pre-cleaner, replace, bleed the filter if necessary Change the fuel precleaner, bleed the fuel system Change the oil in the drum drive gear Check, tension, lubricate the steering chain Check the engine mounts Check the V-belt, tighten, if necessary replace the Vbelt Change the oil in the vibrator shaft tube

Every 1500 operating hours 5.26

Check, adjust the valve clearance

on cold engine

Every 2000 operating hours 5.27 5.28 5.29 5.30

68

Change the hydraulic oil** Replace the hydraulic oil filter element Grease the articulated t Change the coolant

at least every 2 years at least every 2 years High pressure grease at least every 2 years

BOMAG

BW 161/202/203 AD-4

Maintenance No.

Designation

Note

Every 3000 operating hours 5.31

Replace the injection valve

As required 5.32 5.33 5.34 5.35 5.36 5.37 5.38 5.39 * **

Clean, change the dry air filter cartridge Clean the water tank Clean the water filter Sprinkler system Fill the windscreen washer tank Check the scrapers Engine conservation Tightening torques for screws with metric unified thread

at least 1x per year

Maintenance in case of frost

Retighten bolted connections

When using diesel fuel with a sulphur content of more than 0,5 % by weight the engine oil change intervals must be halved. The same applies when using engine oil of API-class CF/CF-4 and engine oil of ACEA-class E2-96 Also in case of repairs in the hydraulic system

BW 161/202/203 AD-4

BOMAG

69

Every 10 operating hours Every 10 oper ating hours

5.6

Check the engine oil level

5.7 !

Check the fuel level

Danger

Fire hazard! When working on the fuel system do not use open fire, do not smoke. Catch running out fuel. Do not refuel in closed rooms. Do not inhale any fuel fumes.

Fig. 113

i

Note

Park the machine horizontally, shut down the engine and wait for 5 minutes. l

Open the right hand service door.

l

Pull the dipstick (Fig. 113) out, wipe it off with a lint-free, clean cloth and reinsert it until it bottoms.

l

Pull the dipstick back out again.

l

Check the oil level, top up to MAX-mark if necessary.

l

If the oil level is too low top up oil immediately.

Fig. 114

Check the fuel level on the fuel gauge (Fig. 114).

l

For quality of oil refer to the table of fuels, lubricants and filling capacities. Check the oil level again after running the engine for approx. 1 minute.

l

i

Note

Do not drive the fuel tank empty, since this may damage the engine. Always bleed the fuel system after running the tank empty.

Caution Before longer work periods you should always top the oil up to the "MAX"-mark. !

70

BOMAG

BW 161/202/203 AD-4

Every 10 operating hours 5.8

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 lubrication oil service of the respective oil manufacturer.

Fig. 115

Use access steps (Fig. 115).

l

Fig. 117

Check the oil level in the oil level inspection glass (Fig. 117).

l

i

Fig. 116 l

Clean the area around the filler opening.

l

Open the fuel tank cover (Fig. 116).

l

If necessary top up with fuel (diesel or winter diesel).

At a room temperature of approx. 20°C the oil level should reach approx. 2/3 way up the inspection glass.

Caution

Contaminated fuel can cause malfunction or even damage of the engine. If necessary, fill in fuel through a funnel with screen filter.

BW 161/202/203 AD-4

If the oil level is too low top up hydraulic oil immediately.

l

For specified fuel refer to the table of fuels, lubricants and filling capacities. !

Note

For quality of oil refer to the table of fuels, lubricants and filling capacities. Caution 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. !

BOMAG

71

Every 10 operating hours 5.9 !

Check the coolant level

5.10 Check / empty the fuel precleaner (water separator) / bleed

Danger

Danger of scalding! Fill up coolant only when the engine is cold.

Danger Fire hazard! !

When working on the fuel system do not use open fire, do not smoke. Environment Catch running out fuel and dispose of environmentally.

i

The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should check the filter bowl initially every day, later as required, for signs of water.

Fig. 118

Check the coolant level (Fig. 118) only when the engine is cold.

l

Note

Caution If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks. !

l

To top up unscrew the filler cap and fill in coolant up to the MAX-mark.

For quality of coolant refer to the chapter 5.2, fuels and lubricants.

Fig. 119

If the water separator control light (Fig. 119) in the left hand instrument cluster lights up during starting or operation, drain the water from the prefilter.

l

i

Note

Open the service flap on the right hand side.

72

BOMAG

BW 161/202/203 AD-4

Every 10 operating hours

Fig. 120 l

Fig. 122

Unscrew the bleeding screw (Fig. 120) on the filter cover.

Drain the fuel off until there is no water or dirt left (Fig. 122). Close the drain tap.

l

Environment Dispose of catched fuel environmentally.

i

Note

After draining the water separator the control light must go out and the fuel pre-cleaner must be bled.

Bleeding

Fig. 121 l

Place a collecting vessel (Fig. 121) under the drain opening.

l

Press the drain cock to the valve body and open it.

Fig. 123 l

Operate the manual pump (Fig. 123) until fuel runs out of the bleeding screw without air bubbles.

Environment Dispose of catched fuel environmentally. l

BW 161/202/203 AD-4

BOMAG

Open the bleeding screw .

73

Every 10 operating hours 5.11 Check the water level ! Caution Risk of damage!

Do not step on the water tank and do not place any heavy objects on it.

Fig. 126

Open the caps on both water tanks and top up with water (Fig. 126) and screw the caps back on.

l

i

Fig. 124

i

Note

Note

If there is a risk of frost observe the special service instructions under "water sprinkler system, maintenance in case of frost". Make sure that the ventilation bore in the filler cap is free.

In case of a pressure drop and when the water tank is empty the warning light for residual water quantity in water sprinkling system c (Fig. 124) in the right hand instrument cluster will light up and the warning buzzer will sound. In the water tank filling level gauge (m) the last green and the red LED will light or the red LED will flash.

Fig. 125 l

74

Use access steps (Fig. 125).

BOMAG

BW 161/202/203 AD-4

Every 250 operating hours Every 250 oper ating hours

5.12 Check, clean radiator, fuel cooler, hydraulic oil cooler and intercooler

i

Note

Dirty operating conditions, particularly lubrication oil and fuel deposits on the cooling fins reduce the cooling effect. You should therefore immediately seal any oil or fuel leaks near cooling fan, cylinder or oil cooler and subsequently clean the cooling fins. Danger Danger of injury!

Fig. 128 l

Remove dried on dirt from the cooling fins with a suitable brush.

l

Blow coolers (Fig. 128) out with compressed air. Remove all dirt that has been blown into the engine compartment.

l

In case of oily dirt spray the cooler with a cold cleansing agent and let it soak in for about 10 minutes.

!

Perform cleaning work only with engine stopped and cooled down!

Environment Catch running off fluid and dispose of environmentally. l

Clean off with water or steam jet.

l

Repeat the process if necessary.

Fig. 127 l

Unscrew the fastening screws from the radiator covering plate (Fig. 127) and fold the covering plate back.

BW 161/202/203 AD-4

BOMAG

75

Every 250 operating hours 5.13 Checking the oil level in vibrator shaft tube !

Caution

Check the oil level in both drums, rear right and front left.

Fig. 129 l

Move the machine so that the level inspection plug is exactly behind bore (Fig. 129).

l

Clean and unscrew oil level inspection plug (1).

l

The oil level must reach the bottom edge of the bore, top up oil if necessary.

For quality of oil refer to the table of fuels, lubricants and filling capacities.

76

BOMAG

BW 161/202/203 AD-4

Every 500 operating hours Every 500 oper ating hours

5.14 Change the engine oil !

Danger

Danger of scalding! Danger of scalding when draining off hot engine oil!

i

Note

Drain the oil only when the engine is warm. For quality and quantity of oil refer to the section on fuels and lubricants as well as the section on fuels, lubricants and filling capacities.

Fig. 131 l

Fill in new engine oil (Fig. 131) through the oil filler neck.

l

Screw the cover back on.

Environment Do not let old oil seep into the ground, but dispose off environmentally. l

Open the right hand service door.

l

Unscrew the oil filler cap .

Fig. 132 l

After a short test run check the oil level on the dipstick (Fig. 132). The oil level should reach the MAX-mark, top up oil if necessary.

Fig. 130 l

Unscrew the drain plug (Fig. 130), catch running out oil.

l

Screw the plugs back in.

BW 161/202/203 AD-4

BOMAG

77

Every 500 operating hours 5.15 Change the engine oil filter cartridge !

5.16 Checking the anti-freeze concentration

Danger

!

Danger of scalding!

In order to avoid damage to the engine e.g. by corrosion, cavitation and freezing, particular attention must be paid to the inspection of the coolant.

Danger of scalding by hot oil when unscrewing the filter cartridge. Caution Catch running out oil, e.g. with a cloth. !

Danger Danger of scalding! !

Environment Do not let old oil seep into the ground, but dispose off environmentally. l

Open the right hand service door.

Caution

Check the anti-freeze concentration only when the engine is cold. l

Perform the inspection with conventional test equipment.

l

The anti-freeze concentration (additive) must be at least 35 Vol% and maximum 45 Vol%.

!

Danger

Health hazard! The mixing of nitrite based anti-freeze agents with amine based agents results in the formation of health affecting nitrosamines. Environment Catch all anti-freeze agent and dispose of environmentally. Fig. 133 l

l

Loosen and unscrew the fuel filter cartridge (Fig. 133) using an appropriate filter wrench. Wipe the sealing face clean.

l

Cover the rubber seal of the new filter cartridge slightly with clean oil.

l

Spin the new fuel filter cartridge on and tighten it hand tight.

l

Perform a short test run and inspect the engine for leaks and check the oil level, top up oil if necessary.

78

BOMAG

BW 161/202/203 AD-4

Every 500 operating hours 5.17 Servicing the air conditioning* (summer operation) Caution Under very dusty conditions clean every day in order to maintain the cooling power of the air conditioning system. !

Danger Danger of accident! !

Fig. 135

Do not clean with a hot water jet. Heat will cause extreme overpressure, which could cause damage or explosion of the system.

Clean the condenser fins on front and back with compressed air or cold water (Fig. 135).

l

Caution During cleaning work do not damage the cooling fins and realign bent fins. !

Cleaning the condenser

Checking the refrigerant level l

Start the engine.

Fig. 134 l

Unscrew the fastening screws from the radiator covering plate (Fig. 134) and fold the covering plate back. Fig. 136 l

*

Switch the air (Fig. 136) conditioning on.

Optional equipment

BW 161/202/203 AD-4

BOMAG

79

Every 500 operating hours

Fig. 137 l

Choose a cooling temperature with the rotary switch for cabin heater (Fig. 137) in the blue section.

l

Open the air outlet nozzles.

l

Check, whether the outflowing air is noticeably cooler.

Fig. 139

i

Note

The refrigerant level is not correct. l

i

If the white float (Fig. 139) inside the inspection glass of the drier/collector unit floats at the bottom, inform the service department.

l

Note

The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.

Refrigerant must be filled up, if necessary check the air conditioning system for leaks.

Checking the moisture level of the drying agent

Open the right hand service door.

l

Fig. 140 Fig. 138

Check whether the white float (Fig. 138) inside the inspection glass of the drier/collector unit floats right at the top.

l

i

Check the moisture indication pearl (Fig. 140) inside the inspection glass of the drier/collector unit.

blue

= drying agent o.k.

purple

= moisture level of drying agent too high.

Note

The refrigerant level is correct.

80

l

l

BOMAG

Inform the service department. Replace drier/ collector unit, check air conditioning system.

BW 161/202/203 AD-4

Every 500 operating hours Caution Have the drier/collector unit replaced by the service department every year before the operating season.

5.18 Service the battery

Checking the condition of the drier/collector unit

Danger of cauterisation ! Danger of explosion!

!

!

Caution According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with this inspection the drier/collector unit must be 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 operators and third parties against any danger arising from the handling and operation of pressure reservoirs. !

!

Danger

When working on the battery do not use open fire, do not smoke! The battery contains acid. Do not let acid come in 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. Maintenance free only means that the fluid level does not need to be checked. Each battery suffers under self-discharge, which may, in not checked occasionally, even cause damage to the battery as a result of exhaustive discharge. The following therefore applies for the service life:

Danger

Danger of injury! In case of mechanical damage or corrosion on this drier/collector unit this unit must be replaced, to avoid bursting and further damage.

l

Switch off all consumers (e.g. ignition, light, inside 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 approx. 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 voltage measurements.

Fig. 141 l

Check the drier/collector unit (Fig. 141) for mechanical damage or rust.

BW 161/202/203 AD-4

BOMAG

81

Every 500 operating hours Charging voltage recommendation

Fig. 144 l

Clean the outside of the battery (Fig. 144).

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 distilled water.

Fig. 142

!

Caution

Exhausted batteries (batteries with formation of sulphate on thge plates are not covered under warranty!

Fig. 143 l

Disassemble the battery compartment cover (Fig. 143).

l

Clean the battery compartment.

82

BOMAG

BW 161/202/203 AD-4

Every 1000 operating hours Every 1000 operating hours

5.19 Cleaning the fuel pre-cleaner, replacing, bleeding the filter if necessary Danger Fire hazard! !

No open fire, do not smoke, do not spill any fuel. Do not inhale any fuel fumes. Fig. 146

Environment Catch running out fuel, do not let it seep into the ground. l

l

Place a collecting vessel (Fig. 146) under the drain opening.

l

Press the drain cock to the valve body and open it.

Open the service flap on the right hand side.

Cleaning the fuel pre-cleaner

Fig. 147

Drain the fuel off until there is no water or dirt left (Fig. 147). Close the drain tap.

l

Fig. 145 l

Unscrew the bleeding screw (Fig. 145) on the filter cover.

Environment Dispose of catched fuel environmentally.

i

Note

After draining the fuel pre-cleaner must be bled.

BW 161/202/203 AD-4

BOMAG

83

Every 1000 operating hours Changing the fuel precleaner

Fig. 149 l

Fig. 148 l

Unscrew the hexagon screws (Fig. 148) from the filter cover and take the cover off.

l

Take the filter element out of the filter housing.

l

Insert the new filter element into the filter housing.

l

Check the seal of the filter cover, replace if necessary.

l

Install the filter cover with seal and tighten the hexagon screws crosswise.

Slacken the bleeding screw (Fig. 149) on the fuel prefilter for 2 to 3 turns.

Bleeding the fuel prefilter

i

Note

Fig. 150

Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.

l

Operate the hand pump (Fig. 150) manually, until fuel flows out of the bleeding screw without air bubbles.

Therefore bleed the fuel system after changing the fuel prefilter.

l

Then tighten the bleeding screw while pumping.

84

BOMAG

BW 161/202/203 AD-4

Every 1000 operating hours 5.20 Change the fuel filter cartridge !

Danger

Fire hazard! No open fire, do not smoke, do not spill any fuel. Do not inhale any fuel fumes. Environment Catch running out fuel, do not let it seep into the ground. l

Fig. 152

Open the right hand engine compartment doors.

l

Slightly oil the rubber seal on the new filter cartridge (Fig. 152).

l

Fill the filter cartridge with clean diesel fuel.

l

Turn the new filter cartridge on by hand, until the seal s.

l

Then tighten hand-tight.

l

Check for leaks after a short test run.

Fig. 151 l

Loosen fuel filter (Fig. 151) using a suitable filter wrench and screw it off.

l

Clean the sealing face on the filter carriers from any dirt.

BW 161/202/203 AD-4

BOMAG

85

Every 1000 operating hours 5.21 Changing the oil in the drum drive gear

i

Note

Drain oil only at operating temperature. Change the oil in front right and rear left hand travel gears. Danger Danger of scalding! !

Danger of scalding when draining off hot gear oil! Environment Environmental damage! Catch old oil and dispose of environmentally.

Fig. 154 l

Fill in oil through the oil filler opening (Fig. 154), until it reaches the bottom edge of the oil level inspection bore.

For quality and quantity of oil refer to the table of fuels, lubricants and filling capacities. l

Clean filler and level plug and screw it back in tightly fitted with a new sealing ring.

Fig. 153 l

Clean and unscrew filler and drain plugs (Fig. 153).

l

Drain and catch all oil.

l

Once all oil has run out clean the drain plug and screw it back in fitted with a new sealing ring.

86

BOMAG

BW 161/202/203 AD-4

Every 1000 operating hours 5.22 Checking, tensioning, lubricating the steering chain l

Unscrew the dashboard from the drive console and lay down to the front.

Check

Fig. 157 l

Check the condition of the left hand sliding block (Fig. 157), replace if necessary.

Fig. 155 l

Unscrew the cover plate (Fig. 155) from the steering chain and take it off.

Fig. 158 l

Check the condition of the right hand sliding block (Fig. 158), replace if necessary.

Tension l

Loosen four fastening screws on the steering column.

l

Press the steering columns towards the outside and retighten the fastening screws.

Fig. 156 l

Check the entire circumference of chain and sprockets (Fig. 156).

Lubricating l

Cover the entire circumference of the chain with grease.

For quality of grease refer to the table of fuels, lubricants and filling capacities.

BW 161/202/203 AD-4

BOMAG

87

Every 1000 operating hours 5.23 Check the engine mounts

5.24 Checking the V-belt, tighten, if necessary replace the V-belt Danger Danger of injury! !

Work on the V-belt must only be performed with the engine shut down.

Checking the V-belt for the air conditioning compressor Fig. 159 l

Tighten fastenings of intake and exhaust manifolds (Fig. 159) on the cylinder heads.

l

Check sockets and clamps between air filter, exhaust turbocharger and charge air line as well as the lubrication air lines for tight fit and leaks.

l

Retighten the fastening screws for oil sump and engine mounts.

Fig. 160

88

l

Inspect the entire circumference of the V-belt (Fig. 160) visually for damage and cracks. Replace 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.

BOMAG

BW 161/202/203 AD-4

Every 1000 operating hours Tighten the V-belt.

Checking the generator V-belt

Fig. 161

Fig. 162

l

Slightly slacken the fastening screws 1, 2 and 3 (Fig. 161).

l

Press the compressor in direction of arrow, until the correct V-belt tension is reached.

l

Retighten all fastening screws.

Inspect the entire circumference of the V-belt (Fig. 162) visually for damage and cracks. Replace damaged or cracked V-belts.

l

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.

Fig. 163

Caution Check the V-belt tension after a running time of 30 minutes.

l

Press the indicator arm of the tester a (Fig. 163) into the gap of the measuring scale.

l

Lay the measuring unit loosely onto the back of the fan V-belt.

!

i

Note

To measure the V-belt tension a free length of at least 200 mm is required.

BW 161/202/203 AD-4

BOMAG

89

Every 1000 operating hours Tightening the generator V-belt

Fig. 164 l

i

Operate measuring unit b (Fig. 164) with a finger (I or II or III), until the pressure spring disengages audibly or noticeably.

Fig. 166 l

Slacken the fastening screws 1,2 and 3 (Fig. 166) slightly.

Note

l

Press the generator towards the outside until the correct tension is achieved. Check with the tester.

l

Retighten all fastening screws.

The indicator arm remains in the measured position. l

take the measuring unit carefully off, without moving the indicating arm.

Replacing the generator V-belt l

Slightly slacken fastening screws 1,2 and 3.

l

Press the generator towards the engine.

l

Take the old V-belt off the V-belt pulley.

l

Fit the new V-belt to the V-belt pulleys.

l

Tension the V-belt as previously described.

Fig. 165 l

Read the V-belt tension where the upper edge of the indicating arm intersects with the measuring scale (Fig. 165).

First installation = approx. 450±50 N Retighten after 15 minutes = approx. 300±50 N

90

BOMAG

BW 161/202/203 AD-4

Every 1000 operating hours Checking the V-belt for coolant pump and fuel pump

Replacing the V-belt for coolant pump and fuel pump l

Disassemble the generator and compressor V-belts

l

Slightly slacken fastening screw 1 and 2.

l

Press the fuel towards the engine.

l

Take the old V-belt off the V-belt pulley.

l

Fit the new V-belt to the V-belt pulleys.

l

Tension the V-belt as previously described.

l

Reassemble and tighten generator and compressor V-belts.

Fig. 167 l

Inspect the entire circumference of the pump V-belt (Fig. 167) visually for damage and cracks. Replace damaged or cracked V-belts.

Tightening the V-belt for coolant pump and fuel pump

Fig. 168 l

Slightly slacken fastening screws 1 and 2 (Fig. 168) on the fuel pump.

l

Press the fuel pump towards the outside until the correct tension is achieved. Check with the tester.

First installation = 450±50 N After 15 minutes of operation = 300 ±50N l

Retighten all fastening screws.

BW 161/202/203 AD-4

BOMAG

91

Every 1000 operating hours 5.25 Changing the oil in the vibrator shaft tube !

Caution

Change the oil in both drums. Environment Catch running out oil and dispose of environmentally. Fig. 170 l

Clean and unscrew the oil level inspection plug (Fig. 170).

l

Fill in oil through the filler bore, until it starts to run out through the level inspection bore.

For quality and quantity of oil refer to the table of fuels and lubricants. l

Turn oil filling and level inspection plugs tightly back in.

Fig. 169 l

Move the drum until drain and filler plugs (Fig. 169) are exactly vertically in line.

l

Clean and unscrew drain and filler plugs.

l

Drain off and catch old oil.

l

Clean and turn the oil drain plug back in tightly after all oil has run out.

92

BOMAG

BW 161/202/203 AD-4

Every 1500 operating hours Overlapping means: Exhaust valve not yet closed, intake valve starts to open.

Every 1500 operating hours

5.26 Check, adjust the valve clearance !

Caution

l

Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 1", black mark.

l

For control purposes mark the respective rocker arm with while chalk once the corresponding valve is adjusted.

Before checking the valve clearance let the engine cool down for at least 30 minutes. The engine oil temperature must be less than 80 °C. After a short test run check the engine for leaks.

Valve adjustment schematic

Fig. 173

Crankshaft position 2 (Fig. 173)

Fig. 171

l

Turn the crankshaft one revolution (360 °) further.

l

Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 2", black mark.

Valve 1 (Fig. 171) white = not adjustable Valve (2) black = adjustable

Check the valve clearance l

Loosen the crankcase ventilation valve and swing it to the side.

l

Remove the valve cover (2).

l

Crankshaft position as per "valve adjustment schematic".

Fig. 172

Crankshaft position 1 (Fig. 172) l

Crank the engine with the starter or a spanner by the V-belt pulley until both valves on cylinder 1 are “overlapping”.

BW 161/202/203 AD-4

BOMAG

93

Every 1500 operating hours l

Swivel the ventilation valve back to correct position and fasten it.

l

Fasten the air filter again and ensure correct fit of combustion air hoses and clamps.

Fig. 174 l

Check valve clearance 2 (Fig. 174) between rocker arm (1) and valve (3) with a feeler gauge.

Intake valve

= 0,3 mm

Exhaust valve = 0,5 mm The feeler gauge must fit with little resistance. l

If the gap is too narrow or too wide for the feeler gauge, the valve must be adjusted.

Adjusting the valve clearance

Fig. 175 l

Slightly slacken the counter nut. Adjust setscrew 7 (Fig. 175) with a screwdriver, until the feeler gauge (6) can be inserted and pulled out with little resistance after retightening the counter nut.

l

Perform tests and adjustments on all other adjustable valves.

l

Check the gasket of the valve cover, replace it if necessary.

l

Reassemble the cylinder head cover.

94

BOMAG

BW 161/202/203 AD-4

Every 2000 operating hours Every 2000 operating hours

5.27 Changing hydraulic oil and breather filter

i

Note

See also chapter 5.1 "Notes on the hydraulic system". Caution Apart from the normal oil change intervals, the hydraulic oil must also be changed after major repairs in the hydraulic system. !

Fig. 176 l

Perform the oil change when the hydraulic oil is warm.

Remove the filler cap (Fig. 176).

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 hydraulic oil. Replace the hydraulic oil filter element with every hydraulic oil change.

!

Danger

Danger of scalding! Danger of scalding by hot oil.

Fig. 177 l

Unscrew the plug (Fig. 177) and drain off all hydraulic oil.

l

Check the seal ring, replace if necessary and turn the plug tightly back in.

Environment Catch running out oil and dispose of environmentally.

i

Note

Generally replace the hydraulic oil filter element after the test run.

Fig. 178 l

BW 161/202/203 AD-4

BOMAG

Fill in new hydraulic oil through the screen (Fig. 178).

95

Every 2000 operating hours 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 hydraulic oil filter and protects the hydraulic system.

!

Danger

Danger of scalding!

Check the oil level in the inspection glass.

l

5.28 Changing the hydraulic oil filter

Danger of scalding by hot oil when unscrewing the oil filter.

Nominal value: At a room temperature of approx. 20°C the oil level should reach approx. 2/3 way up the inspection glass.

Caution If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the oil change and after the test run. !

For quality and quantity of oil refer to the table of fuels and lubricants.

Do not use the oil in the filter bowl again. Environment Catch running out oil, dispose of oil and filter element environmentally.

i

Note

Apart from the normal oil change intervals, the filter element must also be changed after major repairs in the hydraulic system. l

Open the left hand maintenance door.

Fig. 179

i

Note

The breather filter (Fig. 179) for the hydraulic oil tank is integrated in the filler cap, you must therefore replace the complete filler cap. l

Close the tank with a new filler cap.

Fig. 180

96

l

Unscrew filter bowls (Fig. 180) and take off with filter elements.

l

Examine the surface of the filter element thoroughly for any visible dirt.

BOMAG

BW 161/202/203 AD-4

Every 2000 operating hours Caution Visible dirt may be an early sign for the failure of system components and indicate the possible failure of components. In this case determine the cause and replace or repair the defective components, if necessary. Negligence may cause destruction to the entire hydraulic system. !

5.29 Grease the articulated t

Do not clean or reuse the filter element. l

Clean filter bowls with threads.

l

Assemble the filter bowls with new filter elements, check the condition of the seal rings, if necessary use new ones.

l

After the test run check the filters for leaks. Fig. 181 l

Clean the grease nipple (Fig. 181) and lubricate with approx. 5 shots of high pressure grease from the grease gun.

For quality of grease refer to the section on "fuels, lubricants and filling capacities”.

BW 161/202/203 AD-4

BOMAG

97

Every 2000 operating hours 5.30 Change the coolant !

Danger

Danger of scalding! Change the coolant only when the engine is cold. Environment Catch running out coolant and dispose of environmentally. Fig. 184 l

Fill in coolant (Fig. 184) up to the MAX-mark and screw the filler cap back on.

For quality of coolant refer to the chapter 5.2, fuels and lubricants. l

Start the diesel engine and run it warm to operating temperature.

Fig. 182 l

Unscrew the cap (Fig. 182) from the coolant compensation reservoir.

Fig. 185 l

Let the engine cool down and check the coolant level (Fig. 185) again, top up if necessary.

Fig. 183 l

Unscrew the plug, let the coolant run out and catch it (Fig. 183).

l

Screw the plug back in once all coolant has run out.

98

BOMAG

BW 161/202/203 AD-4

Every 3000 operating hours Every 3000 operating hours

5.31 Replace the injection valve

i

Note

This work must only be performed by authorized service personnel.

BW 161/202/203 AD-4

BOMAG

99

Every 3000 operating hours

100

BOMAG

BW 161/202/203 AD-4

As required As r equired

i

5.32 Check, clean, change the combustion air filter

Once the air filter service indicator lights up, work may be continued until the end of the day. l

!

Note

Open the left hand maintenance door.

Caution

Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element. Do not use gasoline or hot fluids to clean the filter element. After cleaning the filter element must be inspected for damage using a torch. Air filter elements with damaged paper bellows or seal lips must be replaced in any case. The main filter element must be replaced after 3 times cleaning, but at the latest after one year, irrespective of the operating hours. Each cleaning interval must be marked with a cross on the cover of the filter element.

Fig. 187 l

Fold three clips up and take the filter hood (Fig. 187) off.

l

Clean filter hood and dust discharge valve.

Cleaning does not make sense if the air filter element is covered with a sooty deposit. Use a new filter element. Incorrectly handled filter elements may become ineffective because of damage (e.g.: cracks) and cause engine damage.

Fig. 188 l

Fig. 186

Maintenance of the dry air filter is due when control light c (Fig. 186) in the left hand instrument cluster lights permanently when the engine is running, but at the latest after one year.

BW 161/202/203 AD-4

Carefully loosen the main filter element.

The main filter element is located directly on the air intake tube, thereby providing a seal on the inside of the filter cover. Carefully remove the main filter element, in order to reduce the released amount of dust. To release the seal pull the main filter element carefully up, down and sideways or turn it (Fig. 188).

BOMAG

101

As required Caution The safety element must not be cleaned. It must be replaced after three times cleaning of the main filter element, but at least once every year. !

Do not run the engine without an intact safety and main filter element. Clean or replace the main filter element.

l

i

We generally recommend to change the filter. A new filter element is far less expensive than a possible engine damage.

Fig. 189

!

Caution

l

Avoid between main filter element and housing. l

Note

Examine the main filter element thoroughly for damage.

Before installing the new main filter element check it for possible damage from transport, cleaning or incorrect handling. Especially on the inside of the open end (sealing area). Do not install damaged filter elements.

Pull the main filter element (Fig. 189) carefully out of the housing.

l

If necessary use safety elements.

Fig. 190 l

Clean the sealing face on the outlet tube (Fig. 190). Fig. 191

Dust on the outer diameter of the outlet tube can impair effective sealing. l

l

The radial sealing area is located at the inside of the open filter edge. This critical sealing area must be under slight tension after the filter has been installed. In order to achieve a tight seal apply pressure to the outer edge of the filter and not to the moveable centre.

Check the old main filter element.

The old main filter element can be of help to discover foreign particles on the sealing face, which could lead to leaks. A line of dust on the clean air side of the filter may be a sign for such a leak. Eliminate this problem before installing a new main filter element. l

102

Insert the main filter element (Fig. 191).

l

Reinstall the filter hood with the dust discharge valve.

If the main filter element is damaged, the safety element must be replaced as well.

BOMAG

BW 161/202/203 AD-4

As required Caution The dust discharge valve must point vertically downwards. !

5.33 Clean the water tank

Dry cleaning of the main filter element !

Danger

Eye injury! Wear protective clothing (goggles, gloves).

Fig. 193 l

Unscrew both caps (Fig. 193) from the water tank.

Fig. 192

i

Note

For cleaning purposes fit a tube to the compressed air gun (Fig. 192), the end of which should be bent for approx. 90°. The length should reach down to the bottom of the element. Blow the main filter element out with compressed air (max. 5 bar) from inside to outside by moving the tube up and down inside the element, until it if free of dust.

l

Fig. 194 l

Open the maintenance cover (Fig. 194) to gain access to the water pumps.

Examine the main filter element with a torch for cracks and holes in the paper bellows.

l

!

Caution

Do not continue to use a damaged main filter element. If in doubt use a new main filter element.

BW 161/202/203 AD-4

BOMAG

103

As required 5.34 Clean the water filter

Fig. 195 l

Disconnect the quick lock coupling (Fig. 195) on the water filter.

l

Unscrew the water filter.

Fig. 196

l

Let all water with dirt run out.

l

l

Fill the water tank with clean water.

Unscrew both water tank caps (Fig. 196), take out and clean the filling screens.

i

Note

Replace damaged filling screens.

Fig. 197 l

104

BOMAG

Open the maintenance cover (Fig. 197) to gain access to the water pumps.

BW 161/202/203 AD-4

As required 5.35 Water sprinkler system, maintenance in the event of frost Caution If there is a risk of frost, the water sprinkler system must be drained. !

Fig. 198

Disconnect the quick lock coupling (Fig. 198) on the water filter.

l

In this case frost protection measures are of greatest importance in order to avoid freezing of sensitive components like pump, solenoid valve and water filter. l

Drain the water tank

Unscrew and clean the water filter.

l

i

Note

Change a damaged water filter.

Fig. 199 l

Disconnect the quick lock couplings (Fig. 199) of the water lines from the water pumps and let all water run out.

Fig. 200 l

BW 161/202/203 AD-4

BOMAG

Disconnect the water pipe connection (Fig. 200) at the articulated t and let all water run out.

105

As required 5.36 Fill the provision tank for the windscreen washer system l

Open the right hand service door.

Fig. 201 l

Open all water drain taps (Fig. 201) on the sprinkler tubes and let all water run out.

l

Unscrew all nozzles.

Fig. 202

106

l

Check the fluid level in the tank (Fig. 202), top up if necessary.

l

For winter operation fill in the appropriate amount of ant-freeze agent; refer to the specifications of the manufacturer of the ant-freeze agent.

BOMAG

BW 161/202/203 AD-4

As required 5.37 Adjust the scrapers

5.38 Tightening torques

Fig. 204 Fig. 203

Check the scrapers (Fig. 203), two each per drum.

l

* Strength classes for screws with untreated and non-lubricated surface. The quality designation of the screws is stamped on the screw heads. 8.8 = 8G

i

Note

Replace worn scrapers.

10.9 = 10K 12.9 = 12K The values result in a 90% utilization of the screws yielding point at a coefficient of friction of tot. = 0,14. The tightening torques are not valid when using MOS2 lubricants.

i

Note

Self locking nuts must always be replaced after they have been unscrewed.

BW 161/202/203 AD-4

BOMAG

107

As required 5.39 Engine conservation If the engine is to be shut down for a longer period of time (e.g. during winter) we recommend the following conservation measures for the engine to avoid corrosion: l

Clean the engine, including the cooling system. With cold cleansing agent, or, even better, with a steam cleaner.

l

Run the engine warm and shut it down.

l

Drain the still warm engine oil and fill in anticorrosion engine oil.

l

Drain the coolant and fill it back in with fresh anti-freeze agent.

l

Drain the fuel from the fuel tank, mix it well with 10% anti-corrosion oil and fill it in again.

l

Run the engine for 10 minutes until all lines, filter, pump and nozzles are filled with the conserving mixture and the new engine oil is distributed to all parts.

l

Crank the engine several times by hand (without ignition) in order to spray all combustion chamber.

l

Take the V-belt off and spray the grooves of the V-belt pulleys with anti-corrosion oil. The anti-corrosion oil must be removed before taking the machine back into service.

l

Close the air intake opening on the air filter and the exhaust opening.

i

Note

Depending on the weather condition these conserving measures will provide protection for approx. 6 - 12 months. The conserving oil must be replaced by engine oil according to the API- (MIL) classification before taking the machine into operation. Refer to the section "Fuels and lubricants". Anti-corrosion oils are those that comply with the specification MIL-L-21260 B or TL 9150037/2 resp. Nato Code C 640/642. Mark a machine with conserved engine by attaching a clearly visible warning tag.

108

BOMAG

BW 161/202/203 AD-4

6 Trouble shooting

BW 161/202/203 AD-4

BOMAG

109

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 maintenance instructions. Faults occur frequently due to the fact, that the machine has not been properly operated or serviced. 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 our customer service departments at our branch office or dealers. Danger Danger of injury! !

Keep away from rotating parts of the engine.

110

BOMAG

BW 161/202/203 AD-4

Trouble shooting 6.2

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 paraffin 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 defective

Have examined by a specialist

Battery power too low, battery clamps loose or oxidized, causing the starter to turn too slowly

Have the battery checked, clean the terminal 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 system clogged due to paraffin separation

Change the fuel filter. Check the line connections 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 necessary

The engine starts poorly and works irregularly with poor power

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BOMAG

111

Trouble shooting Faults

Possible cause

Remedy

Excessive exhaust 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 broken compression rings or incorrect valve clearance

Have compression rings and pistons examined by a specialist, adjust the valve clearance

Incorrect valve clearance

Adjust the valve clearance

Cooling fins on radiator extremely soiled (the warning light "engine oil temperature" lights)

Clean the cooling fins

Injection valve defective

Have examined by a specialist

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

Engine oil level too high

Drain the engine oil down to the upper dipstick 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

Incorrect valve clearance

Adjust the valve clearance

Injection valve defective

Have examined by a specialist

Engine oil level too low (control light "engine 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.

Generator speed too low

Check the V-belt tension, replace the Vbelt if necessary

The generator does not charge the battery, because generator or regulator is defective

Have examined by a specialis

Engine overheats, shut down immediately!

Poor engine power

Engine oil pressure too low

The charge control light lights during operation, the warning buzzer sounds

112

BOMAG

BW 161/202/203 AD-4

Trouble shooting

BW 161/202/203 AD-4

BOMAG

113

Trouble shooting

114

BOMAG

BW 161/202/203 AD-4