Operating instructions Maintenance instructions

Transcription

1 Operating instructions Maintenance instructions Origina operating instructions S/N > / S/N Reversibe Vibrating Pate Cataogue No /2012

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3 Foreword 1 Foreword BOMAG manufactures machine for earth, asphat and refuse compaction, stabiizers/recycers as we as miing machine and finishers. BOMAG s vast experience in connection with state-of-the-art production and testing methods, such as ifetime tests of a important components and highest quaity demands guarantee maximum reiabiity of your machine. This manua comprises: Safety reguations Operating instructions maintenance instructions Troube shooting Using these instructions wi hep you to become famiiar with the machine. avoid mafunctions caused by unprofessiona operation. Compiance with the maintenance instructions wi enhance the reiabiity of the machine on construction sites, proong the ifetime of the machine, reduce repair costs and downtimes. BOMAG wi not assume iabiity for the function of the machine if it is handed in a way not compying with the usua modes of use, if it is used for purposes other than those mentioned in these instructions. These operating and maintenance instructions are part of the machine. You shoud ony operate the machine after you have been instructed and in compiance with these instructions. Stricty observe the safety reguations. Pease observe aso the guideines of the Civi Engineering Liabiity Association Safety Rues for the Operation of Road Roers and Soi Compactors and a reevant accident prevention reguations. For your own persona safety you shoud ony use origina spare parts from BOMAG. For your machine BOMAG offers service kits to make maintenance easier. In the course of technica deveopment we reserve the right for technica modifications without prior notification. These operating and maintenance instructions are aso avaiabe in other anguages. Apart from that, the spare parts cataogue is avaiabe from your BOMAG deaer against the seria number of your machine. Your BOMAG deaer wi aso suppy you with information about the correct use of our machines in soi and asphat construction. The above notes do not constitute an extension of the warranty and iabiity conditions specified in the genera terms of business of BOMAG. We wish you successfu work with your BOMAG machine. BOMAG GmbH Copyright by BOMAG No warranty caims can be odged in case of damage resuting from operating errors, insufficient maintenance and wrong fues and ubricants. Pease note! This manua was written for operators and maintenance personne on construction sites. BOMAG 3

4 Foreword Pease fi in Machine type (Fig. 1) Seria-number (Fig. 1 and 2) Engine type (Fig. 3) Engine number (Fig. 3) i Note Suppement the above data together with the commissioning protoco. During commissioning our organisation wi instruct you in the operation and maintenance of the machine. Pease observe stricty the safety reguations and a notes on risks and dangers! Fig. 1 Fig. 2 Fig. 3 4 BOMAG

5 Tabe of Contents 1 Foreword 3 2 Technica Data 7 3 Safety reguations 11 4 Indicators and Contros Genera notes Description of indicators and contro eements Function of the Economizer 22 5 Operation Genera Tests before taking into operation Foding down the steering rod Operating the ow oi eve safety device Starting the engine Emergency starting with safety crank hande Operation of Economizer Work/operation Backup protection Stopping the vibratory pate, shutting down the engine Loading/transport 36 6 Maintenance Genera notes on maintenance Fues and ubricants Tabe of fues and ubricants Running-in instructions Maintenance tabe 43 Maintenance every day Cean the machine Check the engine oi eve Check the fue eve Check the hydrauic oi eve Check the air fiter service indicator 47 Maintenance every month Cean the cooing fins and the cooing air intake openings Drain the sudge from the fue tank 50 Maintenance every 6 months Check the battery condition, grease the poes Check, adjust the vave cearance 52 BOMAG 5

6 Tabe of Contents 6.15 Check the oi eve in the exciter housing 53 Maintenance every year Change engine oi and oi fiter Repacing the fue fiter Changing the oi in the exciter housing Check the rubber buffers Check the V-bet tension, if necessary repace the V-bet 59 Maintenance every 2 years Change hydrauic oi and fiter 61 As required Check, cean the air fiter, repace if necessary Tightening the screws Engine conservation 65 7 Troube shooting Genera notes Starting with jump wires Engine probems Troube shooting Economizer 72 8 Disposa Fina shut-down of machine 74 6 BOMAG

7 2 Technica Data BOMAG 7

8 Technica Data Fig. 4 Dimensions H H 1 H 2 L L 1 W W 1 W 2 (mm) (in) Weights Operating weight (CECE) W 556 kg 1226 bs Operating weight (CECE) W1 579 kg 1277 bs Operating weight (CECE) W2 595 kg 1312 bs Basic weight 570 kg 1257 bs Economizer kg + 11 bs Safety crank hande kg + 7 bs Trave characteristics Working speed max. 28 m/min 92 ft/min Max. gradabiity (depending on soi) 35% 35% Drive Engine manufacturer Hatz Hatz Type 1D 81 1D 81 Cooing Air Air Number of cyinders BOMAG

9 Technica Data Rated power ISO KW 13.1 hp Rated speed 2700 min min -1 Drive system mechanica mechanica Vibration system Frequency 68 Hz 4080 vpm Centrifuga force 70 kn bf Fiing capacities Fue (diese) ga us Engine oi ga us 1 Optiona equipment i Note Subject to technica aterations. BOMAG 9

10 Technica Data The foowing noise and vibration data acc. to - EC Machine Reguation edition 2006/42/EC - the noise reguation 2000/14/EG, noise protection guideine 2003/10/EC - Vibration Protection Reguation 2002/44/EC were determined during conditions typica for this type of equipment and by appication of harmonized standards. During operation these vaues may vary because of the existing operating conditions. Noise vaue Sound pressure eve on the pace of the operator: L pa = 95 db(a), determined acc. to ISO and EN 500 Guaranteed sound power eve: L WA = 109 db(a), determined acc. to ISO 3744 and EN 500! Danger Loss of hearing! Wear your persona noise protection means (ear defenders) before starting operation. Vibration vaue Hand-arm vibration: Vector tota of the weighted effective acceeration in three orthogona directions: Weighted tota vibration vaue a hv = 6.9 m/s 2 on crushed rock determined acc. to ISO 5349 and EN 500! Caution Observe the daiy vibration oad (Industria safety acc. to 2002/44/EEC). 10 BOMAG

11 3 Safety reguations BOMAG 11

12 Safety reguations Genera This BOMAG machine has been buit in compiance with the atest technica standard and compies with the appicabe reguations and technica rues. However, dangers for persons and property may arise from this machine, if: it is used for purposes other than the ones it is intended for, it is operated by untrained personne, it is changed or converted in an unprofessiona way, the safety instructions are not observed. Each person invoved in the operation, maintenance and repair of the machine must therefore read and compy with these safety reguations. If necessary, this must be confirmed by obtaining the signature of the customer. Furthermore, the foowing obviousy aso appies: appicabe accident prevention instructions, generay accepted safety and road traffic reguations, country specific safety reguations. It is the duty of the operator to be acquainted with these instructions and to appy these accordingy. This appies aso for oca reguations concerning different types of handing work. Shoud the recommendations in these instructions be different from the reguations vaid in your country, you must compy with the safety reguations vaid in your country. Intended use This machine must ony be used for: Compaction of a types of sois Repair work on a types of soi Paving of wakways Work in trenches Underfiing and compaction of hard shouders Unintended use Dangers may arise from the machine when it is used for purposes other than the one it is intended for. Any danger caused by intended use is the soe responsibiity of the customer or driver/operator, the manufacturer cannot be made iabe. Exampes for unintended use are: Dragging the machine aong as a measure of transportation Throwing the machine off the transport vehice Attaching an additiona weight to the machine It is not permitted to stand on the machine whie working. Any transport ropes fastened to the machine must be removed before operation. Starting and operation of the machine in exposive environments and in underground mining is prohibited. Remaining dangers, remaining risks Despite carefu work and compiance with standards and reguations it cannot be rued out that further dangers may arise when working with and handing the machine. Both the machine as we as a other system components compy with the currenty vaid safety reguations. Nevertheess, remaining risks cannot be rued out competey, even when using the machine for the purpose it is intended for and foowing a information given in the operating instructions. A remaining risk can aso not be excuded beyond the actua danger zone of the machine. Persons remaining in this area must pay particuar attention to the machine, so that they can react immediatey in case of a possibe mafunction, an incident or faiure etc. A persons remaining ion the area of the machine must be informed about the dangers that arise from the operation of the machine. Reguar safety inspections Have the machine inspected by an expert (capabe person) as required for the conditiosn the machine is working under, but at east once every year. 12 BOMAG

13 Safety reguations Who is aowed to operate the machine? Ony trained, instructed and authorized persons of at east 18 years of age are permitted to drive and operate this machine. For operation of the machine the responsibiities must be ceary specified and compied with. Persons under the infuence of acoho, medicine or drugs are not aowed to operate, service or repair the machine. Maintenance and repair work requires specific knowedge and must therefore ony be performed by trained speciaists. Changes and conversions to the machine Unauthorized changes to the machine are prohibited for safety reasons. Origina parts and accessories have been speciay designed for this machine. We wish to make expicity cear that we have not tested or approved any parts or accessories not suppied by us. The instaation and/or use of such products may have an adverse effect on the active and/or passive safety. The manufacturer expicity excudes any iabiity for damage caused by the use of non-origina parts or accessories. Damage, deficiencies, misuse of safety instaations Machines which are not safe to operate must be immediatey taken out of service and sha not be used, unti these deficiencies have been propery rectified. Safety instaations and switches must neither be removed nor must they be made ineffective. Notes on safety in the operating and maintenance instructions! Danger Paragraphs marked ike this highight possibe dangers for persons.! Caution Paragraphs marked ike this highight possibe dangers for machines or parts of the machine. i Note Paragraphs marked ike this contain technica information for the optima economica use of the machine. Environment Paragraphs marked ike this point out practices for safe and environmenta disposa of fues and ubricants as we as repacement parts. Observe the reguations for the protection of the environment. Loading/transporting the machine Make sure that persons are not endangered by the machine tipping or siding off. Use ony safe ifting gear of sufficient oad bearing capacity Minimum ifting capacity of ifting gear: see operating weight in chapter "Technica Data". Loads must ony be attached and hoisted by an expert (capabe person). Fasten the ifting gear ony at the specified ifting points. Check ifting eye for damage before use. Do not use a damaged or in any other way impaired ifting eye. Do not ift or ower the machine jerkiy. The tension must aways be effective in vertica direction. The machine must not swing about when being ifted. Do not step or stand under suspended oads. Aways use suitabe ashing gear on the ifting points to ash down the machine. Lash the machine down, so that it is secured against roing, siding and turning over. Starting the machine Before starting Become acquainted with the equipment, the contro eements, the working principe of the machine and the working area. BOMAG 13

14 Safety reguations Wear your persona protective outfit (hard hat, safety boots, etc.). Wear ear defenders. Before starting the machine check whether: the machine shows any obvious fauts a guards and safety eements are in pace the contros are fuy functiona the machine is free of oiy and combustibe materia a grips are free of grease, ois, fue, dirt, snow and ice. Use ony machines which are serviced at reguar intervas. For emergency starting take a correct position to the engine and hod the crank hande correcty. Do not use any starting aids ike start piot or ether. Starting and operation of the machine is cosed rooms and trenches Exhaust gases are highy dangerous! Aways ensure an adequate suppy of fresh air when starting and operating in cosed rooms and trenches! Operation Operate the machine ony with the steering rod foded down. Guide the machine ony by the steering rod. Guide the machine so hat your hands do not hit against soid objects, danger of injury. As a measure to avoid injury the machine must ony be guided from the side by the steering hande Aways keep an eye on a running machine. Watch out for unusua noises and deveopment of smoke. Perform troube shooting and have the faut corrected. Operate the machine ony with fu engine speed, as otherwise the centrifuga cutch wi be destroyed. Parking the machine Park the machine on eve and firm ground. Before eaving the machine: Park the machine so that it cannot tip over, shut the engine down and pu the ignition key out. Mark machines, which coud be in the way, with a ceary visibe sign. Refueing Do not inhae any fue fumes. Refue ony with the engine shut down. Do not refue in cosed rooms. No open fire, do not smoke. Do not spi any fue. Catch running out fue, do not et it seep into the ground. Keep dirt and water away from the fue. A eaking fue tank can cause an exposion. Ensure tight fit of the fue tank cover, if necessary repace immediatey. Maintenance work Compy with the maintenance work described in the operating and maintenance instructions, incuding the information concerning the repacement of parts. Maintenance work must ony be performed by quaified and authorized persons. Keep unauthorized persons away from the machine. Do not touch hot engine parts. Do not perform maintenance work whie the motor is running. Park the machine on eve, firm ground. Remove the key from the ignition switch. Work on hydrauic ines Reieve hydrauic pressures before working on hydrauic ines. Hydrauic oi escaping under pressure can penetrate the skin and cause severe injury. When being injured by hydrauic oi consut a medica doctor immediatey, as otherwise this may cause severe infections. Do not change the setting of pressure reief vaves. Drain the hydrauic oi at operating temperature danger of scading! Any hydrauic oi must be caught and disposed of in an environmentay friendy manner. Aways catch and dispose of hydrauic ois separatey. Do not start the engine after draining the hydrauic oi. 14 BOMAG

15 Safety reguations Once a work is competed (with the system sti depressurized!) check a connections and fittings for eaks. Changing hydrauic hoses Hydrauic hoses must be visuay inspected at reguar intervas. Hydrauic hoses must be immediatey repaced if: the outer ayer is damaged down to the inay (e.g. chafing, cuts, cracks). the outer ayer is britte (formation of cracks in the hose materia). the hose shows deformations in pressurized and depressurized condition, which do not compy with the genuine shape of the hydrauic hose. the hose shows deformations in bends, e.g. squeezing, bucking, ayer separation, formation of bisters, parts of the hose are eaking. hoses are not correcty instaed the hydrauic hose has separated from the fitting the fitting shows corrosion that impairs both function and strength. fittings are damaged or deformed, whereby the function and strength of the hose - hose connection is impaired. hoses are mixed up by mistake. Ony genuine BOMAG repacement hydrauic hoses ensure that the correct hose type (pressure range) is used at the right ocation. Working on the engine Drain the engine oi at operating temperature danger of scading! Wipe off spied oi, catch running out oi and dispose of environmentay. Store used fiters and other oi contaminated materias in a separate, speciay marked container and dispose of environmentay. Working on eectric parts of the machine Before starting to work on eectric parts of the machine disconnect the battery and cover it with insuating materia. Do not use fuses with higher ampere ratings and do not bridge fuses - fire hazard! Working on the battery When working on the battery do not smoke, do not use open fire! Do not et acid come in contact with hands or cothes! When injured by acid fush off with cear water and seek medica advice. Meta objects (e.g. toos, rings, watch straps) must not come in contact with the battery poes danger of short circuit and burning! For recharging remove the pugs from the battery to avoid the accumuation of highy exposive gases. Observe the appicabe instructions when starting with an auxiiary battery. Switch off the charging current before removing the charging camps. Ensure sufficient ventiation, especiay if the battery is to be charged in a cosed room. Dispose of od batteries according to reguations. Working on the fue system Do not inhae any fue fumes. Avoid open fire, do not smoke, do not spi any fue. Catch running out fue, do not et it seep into the ground and dispose off environmentay. Ceaning work Do not perform ceaning work whie the motor is running. Do not use gasoine or other easiy infammabe substances for ceaning. When using a steam ceaner for ceaning do not subject eectrica parts and insuation materia to the direct jet or cover these items beforehand. Do not guide the water jet directy into air fiter and air intake or exhaust muffer. After maintenance work After a maintenance work is competed reinsta a guards and safety instaations. Repair Repair work must ony be performed by quaified and authorized persons. Use our repair instructions for this work. BOMAG 15

16 Safety reguations Exhaust gases are highy dangerous! Aways ensure an adequate suppy of fresh air when starting in cosed rooms! Mark defective machines by attaching a warning note to the steering hande. Weding Before starting weding work on the machine disconnect the battery and cover the fue tank with insuating materia. Safety stickers on the machine Keep safety stickers in good condition and egibe and foow their meaning. Repace damaged and iegibe safety stickers. 16 BOMAG

17 MAX Safety reguations L WA db START MIN MIN 1-2 MINUTEN START OPERATION STOP MIN STOP 1-2 MINUTEN STOP HYDRAULIK Fig Stickers and decas 1 Information sticker - Lashing point 2 Information sticker - Lifting point 3 Information sticker - Utra-ow suphur fue 4 Maintenance sticker 5 Operation sticker - Throtte ever 6 Information sticker - Guaranteed sound capacity eve 7 Operation sticker - Trave ever 8 Instruction sticker - Wear ear defenders 9 Brief operating instructions 10 Information sticker - Hydrauic oi BOMAG 17

18 Safety reguations 18 BOMAG

19 4 Indicators and Contros BOMAG 19

20 Indicators and Contros 4.1 Genera notes If you are not yet famiiar with the contro and dispay eements on this machine you shoud read this section thoroughy before starting any operation on the machine. Here a functions are described in detai. The section "Operation" contains ony brief descriptions of the individua contro steps. 4.2 Description of indicators and contro eements Fig. 6 No. 1 = No. 2 = Steering rod height adjustment Locking paw ever Fig. 7 No. 3 = No. 4 = No. 5 = No. 6 = Throtte ever Hande Trave ever (tip switch) Backup protection 20 BOMAG

21 Indicators and Contros Position "II" = Engine starts, warning buzzer off Fig. 8 No. 7 = Decompression ever Fig. 11 No. 10 = Fuse (25 A) i Note Ony machines with eectric starter.! Caution Aways cover the fuse with the protective cover. Machines with Economizer 2 are protected by an additiona fuse (5 A). Fig. 9 No. 8 = Safety crank hande 1! Danger Fire hazard! Do not use fuses with higher ampere ratings and do not bridge fuses. Fig. 10 No. 9 = Start switch Position "0" = Ignition off, warning buzzer off Position "I" = Ignition on, warning buzzer on 1 Optiona equipment 2 Optiona equipment BOMAG 21

22 Indicators and Contros 4.3 Function of the Economizer Surface covering compaction contro is used to determine the dynamic stiffness of the soi. A acceeration sensor measures the reaction of the soi to the vibrating base pate of the vibratory pate. An LED dispay shows the soi stiffness measuring vaue as a non-dimensiona vaue. This continuous measuring dispay enabes the detection and directed subsequent compaction of possiby arising weak spots. Fig. 12 No. 11 = Operating hour meter Fig. 13 No. 12 = Economizer dispay 1 Fig. 14 The Economizer consists of two components: the evauation and dispay modue is integrated in the maintenance fap (within the operator's view). It shows the measuring vaue measured by the compaction contro. The acceeration sensor is fastened to the base pate. It converts the acceerations occurring on the base pate into votage signas. For the output of the measuring vaue in the LED dispay the votage signa from the acceeration sensor is picked up and processed by the evauation unit. In order to achieve the required soi stiffness measured in MN/m 2, a reference measurement (e.g. dynamic oad pate) must be made before the materia is compacted. This is necessary to find out how many LEDs in the Economizer dispay correspond with the required vaue in MN/m 2 on the soi being compacted. 1 Optiona equipment 22 BOMAG

23 Indicators and Contros Evauation and dispay modue Fig. 15 The yeow LEDs represent the measuring vaue from the compaction contro in 10 stages. The brightness of the respective ast LED varies in order to show intermediate vaues (exampe: 4,5: four LEDs are fuy on, the fifth LED ights with reduced brightness). The red LED informs about the system status. Acceeration sensor The sensor consists of a sensor eement, which is encosed in a sensor housing, and a connecting cabe with pug-in connector. Actua sensor, housing, cabe and pug-in connector come as a unit, which cannot be repaired on its own. The unit is mounted to the base pate of the machine. i Note The Economizer is maintenance free. Do not cean the front screen with hard objects! The materia may be destroyed. Possiby disturbing scratches can be removed by poishing, e.g. with acquer poish. i Note Vibrating pates of the same type show identica measuring vaues when used on the same soi. The measuring vaues achieved with different vibratory pates with Economizer from BOMAG can be made comparabe by caibration to a reference vaue. BOMAG 23

24 Indicators and Contros 24 BOMAG

25 5 Operation BOMAG 25

26 Operation 5.1 Genera If you are not yet acquainted with the contros and indicating eements on this machine you shoud thoroughy read chapter "Indicators and contro eements" before starting work. A indicators and contro eements are described in detai in this chapter. 5.2 Tests before taking into operation The foowing inspections must be carried out before each working day or before a onger working period.! Danger Danger of accident! Pease observe stricty the safety reguations in the corresponding section of this instruction manua! Park the machine on ground as eve as possibe. Ceaning the machine. Check: condition of engine and machine. fue tank and fue ines for eaks. screw connections for tight fit. i Note For a description of the foowing tasks refer to the chapter "Daiy maintenance". Check the engine oi eve, top up if necessary. Check the fue eve, top up if necessary. Check the hydrauic oi eve, top up if necessary. Air fiter service indicator 26 BOMAG

27 Operation 5.3 Foding down the steering rod 5.4 Operating the ow oi eve safety device! Caution The ow oi eve safety device does not reease the operator from his duty to check the oi eve every day. The engine is equipped with a ow oi eve safety device, which interrupts the fue fow to the injection pump. The engine wi stop. If the ow oi eve safety device has responded or if the fue tank has been driven empty, the fue shut-off vave must be opened manuay. Fig. 16 Pu the ocking paw ever (2) (Fig. 16) and ower the steering rod, so that it can swing freey. Adjust the steering rod with the height adjustment (1) to the height of your body. Aways perform the foowing work if: after the ow oi eve safety device has responded and engine oi has been fied up. if the fue tank was driven empty. if the fue in the suppy ine has been used up when cranking the engine free during cod starting or by starting fauts Fig. 17 Fi in fue Press the hand ever (Fig. 17) for approx. five seconds against the spring. The engine is ready for starting. BOMAG 27

28 Operation 5.5 Starting the engine! Danger Exhaust gases are extremey dangerous! Aways ensure an adequate suppy of fresh air when starting and operating in cosed rooms and trenches! Starting attempts shoud not exceed 30 seconds uninterrupted or max. 3 times 10 seconds. After this time aow the starter to coo down to ambient temperature. If the engine has not started after these attempts, determine the cause. i Note The starter switch is designed with a re-start ock. For a new starting attempt turn the ignition key first back to position "0".! Danger Danger of accident! Before starting make sure that there are no persons in the danger area of engine or machine and that a safety instaations are in pace. Aways hod on to the machine. Aways keep an eye on a running machine.! Danger Loss of hearing! Wear your persona noise protection means (ear defenders) before starting operation. Fig. 19 Turn the ignition key to position "I" (Fig. 19), the warning buzzer sounds. Then turn the ignition key further to position "II" to start the engine. As soon as the engine runs, return the ignition key to position "I". The warning buzzer stops. Fig. 18 Set the throtte ever (Fig. 18) to position "MAX".! Caution Fig. 20 After starting take the throtte ever back to position "MIN" (Fig. 20). Run the engine warm for approx. 1 to 2 minutes in ide speed. 28 BOMAG

29 Operation i Note Operation of the vibratory pate can be started as soon as the engine responds to short throtte commands.! Caution When the engine is running eave the ignition key in position "I". 5.6 Emergency starting with safety crank hande 1 i Note This starting procedure shoud ony be used in case of a defective, discharged or missing battery. Fig. 21 Turn the ignition key to position I (Fig. 21), the warning buzzer does not sound. i Note With the ignition switch in position I the battery is being charged when the engine is running, as ong as the battery voatge is at east 9 Vot. Fig. 22 Pu the decompression ever (Fig. 22) in direction of arrow to the end stop. The compression ever cicks noticeaby into pace. 1 Optiona equipment BOMAG 29

30 Operation Fig. 23 Set the throtte ever (Fig. 23) to vibration step 1. Fig. 25 Take a correct position to the machine (Fig. 25). Hod the crank hande propery. Turn the crank hande with both hands sowy in direction of arrow unti it engages. Then turn the crank hande with increasing speed, unti the engine starts. Fig. 24 Open the rubber cover. Take the safety crank hande (1) (Fig. 24) out of the bracket. Insert the safety crank hande. i Note The positive engagement between engine and crank hande must be ensured by powerfu turning and shoud by no means be interrupted during the starting process. When the decompression ever returns to initia position (after five revoutions) the highest speed must be reached. i Note If the engine does not start repeat the starting process. In case of incorrect operation and repeated starting the decompression ever must aways be returned to initia position. 30 BOMAG

31 Operation 5.7 Operation of Economizer Fig. 26 Hook the safety crank hande (1) (Fig. 26) back into the bracket. Cose the pastci cover. Meaning of dispay LEDs/sef test The dispay LEDs signaize the measuring vaue of the system. After the corresponding processing by the evauation modue, the dispay shows a measurement for the compaction of the soi. The number of ighting LEDs symboizes the increasing compaction of the soi. The measuring system is automaticay started when switching on the machine. The system first of a runs a sef test of the LED dispay. Fig. 28 Sef test: the LEDs come on in individua steps from one to ten. Once a LEDs are on, the dispay goes out again in singe steps. Fig. 27 After starting take the throtte ever back to position "MIN" (Fig. 27). i Note Run the engine warm in ide speed for a short whie before starting work. Operation of the vibratory pate can be started as soon as the engine responds to short throtte commands. Fig. 29 After competion of the sef test the system returns to measuring operation; the status LED (red) first of a ights permanenty; this enabes the detection of possiby existing system fauts. BOMAG 31

32 Operation Notes on operation Dispay vaues higher during the first pass than during the second pass: the front rounded shape increases the contact area on oose materia, a sighty higher measuring vaue may be dispayed. The Economizer does not reach the maximum dispay vaue, even after many passes: due to different soi stiffness vaues the maximum vaue cannot be reached in each case. The dispay varies during a pass by one point up/down: caused by sight fuctuations in materia composition and ift height, the mean vaue indicated during the ast pass is decisive. The dispayed vaue rises when changing the trave direction: the effective force appied to the soi by the vibratory pate rises when reversing the trave direction. Correct measuring vaues can ony be achieved in forward and reverse trave with maximum speed. The dispay rises to the red section, whie a yeow LEDs are on: this signaizes that the maximum possibe compaction with this vibratory pate has been reached. When the red status LED is permanenty on, but no other LED ights, the Economizer does not detect any vibration. The red status LED fashes, if the vibration frequency is too ow. In order to obtain comparabe Economized measuring vaues, the vibratory pate must work with a predetermined frequency. Measuring vaues obtained with ow frequency cannot be compared with vaues obtained with high frequency. The dispayed measuring vaues are not pausibe: weak spots may aso be ocated under the ayer to be compacted and thus adversey affect compaction of the ayers above. In unfavourabe cases an excessivey varying materia composition or moisture can infuence the measuring resuts. Infuence of the water content in the soi on the Economizer: Dispay of reduced measuring vaues in case of to dry or to moist materia. Infuence of extension bars on the measuring vaue: Assembing or removing extension bars changes the contact area and the vibration ampitude. A generay vaid statement about the infuence on the measuring resut cannot be made. The measuring vaues can at present not be saved and documented. i Note Check the sensor on the base pate for tight fit! Both screws must be tight. 32 BOMAG

33 Operation 5.8 Work/operation Drive forward! Danger Danger of accident! Operate the machine ony with the steering rod foded down. Guide the machine ony by the steering rod. Guide the machine so hat your hands do not hit against soid objects.! Caution Operate the vibratory pate ony in one of the three possibe engine speed positions, as otherwise the centrifuga cutch may burn. For short breaks you shoud aways return the throtte ever to ide speed position, this avoids premature wear of the centrifuga cutch. Fig. 31 Press the upper part of the trave ever (tip switch) (Fig. 31), unti the vibratory pate has reached the desired forward trave speed. The machines drives with a speed which corresponds with the trave ever position. i Note The trave ever (tip switch) returns to midde position. The chosen forward speed is maintained. Drive backwards Fig. 30 Set the throtte ever (Fig. 30) to one of the two possibe vibration positions.! Danger Danger of accident! As a measure to avoid injury the machine must ony be guided from the side by the steering hande BOMAG 33

34 Operation 5.9 Backup protection! Danger Danger of accident! As a measure to avoid injury during backwards trave, the machine must ony be guided from the side by the steering hande. Fig. 32 Press the upper part of the trave ever (tip switch) (Fig. 32), unti the vibratory pate has reached the desired reverse trave speed. The machines vibrates backwards with a speed which corresponds to the trave ever position. i Note The trave ever (tip switch) returns to midde position. The chosen backwards speed is maintained. If the vibratory pate got stuck Fig. 34 When actuating the reversing protection (Fig. 34), the trave ever (tip switch) switches over from backwards to forward trave. Fig. 33 Set the throtte ever (Fig. 33) to position "MIN". Guide the vibratory pate by the steering rod in accordance the trave ever position, unti it is free again. 34 BOMAG

35 Operation 5.10 Stopping the vibratory pate, shutting down the engine Fig. 37 Set the throtte ever to position "STOP" (Fig. 37), the warning buzzer sounds. Fig. 35 Operate the trave ever (tip switch) (Fig. 35), unti the vibratory pate vibrates on the spot.! Caution Do not shut the engine down a of the sudden from fu speed, but et it ide for a whie for temperature equaization. Fig. 38 Turn the ignition key (Fig. 38) to position "0" and pu it out. The warning buzzer stops. Fig. 36 Shift the throtte ever to position "MIN" (Fig. 36) and et the engine run with ide speed for a short whie. BOMAG 35

36 Operation 5.11 Loading/transport! Danger Danger of accident! Life hazard! Make sure that persons are not endangered by the machine tipping or siding off. Use ony safe ifting gear of sufficient oad bearing capacity Minimum ifting capacity of ifting gear: see operating weight in chapter "Technica Data". Loads must ony be attached and hoisted by an expert (capabe person). For ifting the machine attach the ifting gear ony to the ifting eye provided for this purpose. Check ifting eye for damage before use. Do not use a damaged or in any other way impaired ifting eye. Do not ift or ower the machine jerkiy. The tension must aways be effective in vertica direction. The machine must not swing about when being ifted. Do not step or stand under suspended oads. Aways use suitabe ashing gear on the ifting points to ash down the machine. Lash the machine down, so that it is secured against roing, siding and turning over. Fig. 40 Fod the ifting hook (Fig. 40) up. Fig. 41 Aways attach the ifting tacke to the ifting eye to oad the vibratory pate (Fig. 41) on a transport vehice. Lash the vibratory pate down to the transport vehice, so that it is secured against roing, siding and turning over. Fasten the ashing tacke at the marked ashing points. Fig. 39 Adjust the steering rod upright and engage the ocking ever (Fig. 39). 36 BOMAG

37 6 Maintenance BOMAG 37

38 Maintenance 6.1 Genera notes on maintenance When performing maintenance work ensure strict compiance with the respective safety instructions and particuary the safety reguations mentioned in the corresponding section of these operating and maintenance instructions. Thorough maintenance of the machine guarantees far onger safe functioning of the machine and proongs the ifetime of important components. The effort needed for this work is ony itte compared with the probems that may arise when not observing this rue. Aways cean machine and engine thoroughy before starting maintenance work. For maintenance work stand the machine on eve ground. Do not touch hot engine parts. Perform maintenance work ony with the engine shut down. Environment During maintenance work catch a ois and fues and do not et them seep into the ground or into the sewage system. Dispose of ois and fues environmentay. Keep used fiters in a separate waste container and dispose of environmentay. Open the hood to perform maintenance work. Fig. 42 Loosen the hood fasteners (1) on both sides and remove the fasteners (2) from both sides (Fig. 42). Fod the hood back. Notes on the fue system The ifetime of the diese engine depends to a great extent on the ceaniness of the fue. Keep fue free of contaminants and water, since this wi damage the injection eements of the engine. Drums with inside zinc ining are not suitabe to store fue. The fue drum must rest for a onger period of time before drawing off fue. Under no circumstances must the drum be roed to the tapping point just before drawing out fue. When choosing the storage pace for fue make sure that spied fue wi not harm the environment. Do not et the hose stir up the surry at the bottom of the drum. Do not draw off fue from near the bottom of the drum. The rest in the drum is not suitabe for the engine and shoud ony be used for ceaning purposes. Notes on the performance of the engine On diese engines both combustion air and fue injection quantities are thoroughy adapted to each 38 BOMAG

39 Maintenance other and determine power, temperature eve and exhaust gas quaity of the engine. If your engine has to work permanenty in "thin air" (at higher atitudes) and under fu oad, you shoud consut our customer service or the customer service of the engine manufacturer. 6.2 Fues and ubricants Engine oi Oi viscosity Frequent causes of fauts Operating errors Incorrect, inadequate maintenance If you cannot ocate the cause of a faut or rectify it yoursef by foowing the troube shooting chart, you shoud contact our customer service department. Fig. 43 Choose the oi viscosity in dependence on the ambient temperature at the operating ocation of the engine (see diagram). Occasionay faing short of the temperature imit wi impair the cod starting abiity, but wi not cause any engine damage. Temperature reated ubrication oi changes can be avoided by using muti-purpose ois. The foowing oi change intervas appy aso when using muti-purpose ois. Oi quaity You shoud preferaby use ois of API quaity cass CD/CE/CF/CF-4/CG-4 or higher, or ACEA B2/E2. Lubrication oi change intervas API: CD/CE/CF/ CF-4/CG-4 = 250 operating hours ACEA B2/E2 = 250 operating hours i Note When changing to a higher aoyed oi quaity after a onger period of operation, it is recommended to perform the first oi change of the higher quaity oi aready after 25 operating hours. BOMAG 39

40 Maintenance! Caution The ongest permissibe time ubrication oi shoud remain in an engine is 1 year. Fues Quaity You shoud ony use commerciay avaiabe brand diese fue and ensure strict ceaniness when fiing in. Since this engine compies with the exhaust gas standard acc. to EPA 1 Stage TIER 4, the use of utra-ow suphur diese fue is mandatory, if the engine is operated within an area where compiance with EPA is required. The fue provision shoud aways be topped up in due time, so that the tank wi not run dry. The foowing fue specifications are permitted: EN 590 BS 2869: A1 and A2 ASTM D D and 2-D Winter fue For winter operation use ony winter diese fue, to avoid cogging because of paraffin separation. At very ow temperatures disturbing paraffin separation can aso be expected when using winter diese fue. Minera oi based hydrauic oi The hydrauic system is operated with hydrauic oi HV 32 (ISO) with a kinematic viscosity of 32 mm 2 / s at 40 C (104 F). For topping up or for oi changes use ony high-quaity hydrauic oi, type HVLP according to DIN 51524, part 3, or hydrauic ois type HV according to ISO 6743/3. The viscosity index (VI) shoud be at east 150. (Observe the information of the manufacturer). 1 United States Environmenta Protection Agency 40 BOMAG

41 Maintenance 6.3 Tabe of fues and ubricants Assemby Fue or ubricant Quantity Motor Summer Winter Attention! Observe the eve marks - Engine oi API CD/CE/CF/CF-4/CG-4 approx. 1.9 (0.5 ga us) SAE 5W/30 (-5 C to +35 C) (+23 F to +95 F) SAE 5W/40 (-5 C bis +45 C) (+23 F bis +113 F) SAE 10W/30 (-5 C to +35 C) (+23 F to +95 F) SAE 10W/40 (-5 C to +45 C) (+23 F to +113 F) SAE 10W/40 (0 C to +40 C) (+32 F to +104 F) SAE 30 (+15 C to +30 C) (+59 F to 86 F) SAE 10W (-5 C to +5 C) (+23 F to +41 F) SAE 40 (+20 C to +35 C) (+68 F to +95 F) - Fue Diese Winter diese fue (-12 C) (+10.4 F) approx (2.6 ga us) Vibrator shaft housing as engine oi approx. 0.6 (0.16 ga us) Hydrauic system Hydrauic oi (ISO), HV32 kinem. viscosity of 32 mm 2 /s at 40 C (104 F). approx. 2.3 (0.6 ga us) BOMAG 41

42 Maintenance 6.4 Running-in instructions The foowing maintenance work must be performed when running in new machines or overhaued engines:! Caution During the running-in period, up to approx. 200 operating hours, check the engine oi eve twice every day. Depending on the oad the engine is subjected to, the oi consumption wi drop to the norma eve after approx. 100 to 200 operating hours. After 25 operating hours Change the engine oi. Check engine and machine for eaks. Check the vave cearance, adjust if necessary Retighten the fastening screws on air fiter exhaust, fue tank and other attachments. Retighten the boted connections on the machine. Check the vibration drive V-bets. Check the oi eve in the vibrator housing. 42 BOMAG

43 Maintenance 6.5 Maintenance tabe No. Maintenance work Comment daiy monthy haf-annuay annuay every 2 years as required 6.6 Cean the machine X 6.7 Check the engine oi eve Dipstick mark X 6.8 Check the fue eve X 6.9 Check the hydrauic oi eve Inspection gass X 6.10 Check the air fiter service indicator Rubber spout X 6.11 Cean the cooing fins and the cooing air intake openings X 6.12 Drain the sudge from the fue tank X 6.13 Check condition of battery, grease poes X 6.14 Check, adjust the vave cearance X 6.15 Check the oi eve in the exciter housing X 6.16 Change engine oi and oi fiter at east every 250 operating hours X 6.17 Repace the fue fiter X 6.18 Change the oi in the exciter housing at east every 500 operating hours X 6.19 Check the rubber buffers X 6.20 Check the V-bet tension, if necessary repace the V-bet X 6.21 Change hydrauic oi and fiter at east every 500 operating hours X 6.22 Check, cean the air fiter, repace if necessary renew min. 1 x year X 6.23 Tighten a boted connections X 6.24 Engine conservation X BOMAG 43

44 Maintenance 44 BOMAG

45 Maintenance every day Maintenance every day 6.6 Cean the machine 6.7 Check the engine oi eve! Caution Perform ceaning work ony after the engine has cooed down and with the engine stopped.! Caution Park the machine on eve ground so that the engine is in horizonta position. For quaity of oi refer to the "tabe of fues and ubricants". Fig. 44! Caution Do not guide the water jet directy into the dry air fiter intake opening (Fig. 44) and into the opening for the crank hande. Cover the eectric equipment against the direct water jet. After wet ceaning run the engine warm to evaporate a water residues and to avoid corrosion. Fig. 45 Shut down the engine. Open the rear rubber cover. Pu the dipstick (Fig. 45) out, wipe it off with a int-free, cean coth and reinsert it unti it bottoms. Pu out the oi dipstick again and read the oi eve. The oi eve shoud reach the upper mark on the dipstick. If the oi eve is too ow top up oi immediatey. After a running time of approx. one minute shut the engine down, wait unti a oi has run back into the oi sump, check the oi eve. BOMAG 45

46 Maintenance every day 6.8 Check the fue eve! Danger Fire hazard! When working on the fue system do not use open fire, do not smoke, do not spi any fue. Do not refue in cosed rooms. Shut down the engine. i Note After the tank has been driven empty the mechanica oi pressure monitoring system must be activated (see chapter "Actuating the oi pressure monitoring system").! Danger Heath hazard! Do not inhae any fue fumes. Environment Catch running out fue, do not et it seep into the ground. Fig. 46 Cean the area around the fier opening. Open the fier cap on the fue tank and check the fue eve visuay.! Caution Contaminated fue can cause mafunction or even damage of the engine. For quaity and quantity of fue refer to the "tabe of fues and ubricants". If necessary, fi in fue through a funne with screen fiter (Fig. 46). Cose the fue tank tighty. 46 BOMAG

47 Maintenance every day 6.9 Check the hydrauic oi eve 6.10 Check the air fiter service indicator! Caution If, during the daiy inspection of the oi eve the hydrauic oi eve is found to have dropped, check a ines, hoses and components for eaks. Acceerate the engine for a short whie to fu speed. Fig. 47 Check the oi eve in the inspection gass (Fig. 47). i Note At room temperature of approx. 20 C (68 F) the hydrauic oi eve shoud reach approx. the midde of the inspection gass. Minimum eve 1/3 of inspection gass. Fig. 48 If the rubber beows (Fig. 48) contracts and covers the green fied, the air fiter must be ceaned or, if necessary, repaced (see chapter "Checking, ceaning or repacing the air fiter"). i Note Under very dusty conditions check the rubber beows severa times every day. For quaity of oi refer to the "tabe of fues and ubricants". Top up hydrauioc oi, if necessary. BOMAG 47

48 Maintenance every day 48 BOMAG

49 Maintenance every month Maintenance every month 6.11 Cean the cooing fins and the cooing air intake openings! Danger Danger of injury! Aways wear protective cothes (gogges, goves) when working with compressed air.! Caution Dirty operating conditions, particuary ubrication oi and fue deposits on the cooing fins of the engine and the cooing air intake opening have an adverse effect on the cooing of the engine. You shoud therefore immediatey sea any oi or fue eaks near fue tank, cyinder or cooing air intake. On a oi contaminated engine use a cod ceansing agent for ceaning. After a sufficient soaking time cean off with a water or steam jet and bow out with compressed air. Run the engine warm for a whie to avoid corrosion.! Caution Look for the cause of oiy contamination and have any eaks seaed by our customer service. Fig. 49 Loosen dried on dirt with a suitabe brush (Fig. 49) from a cooing fins and cooing air intake openings and bow it off with compressed air.! Danger Fire hazard! Do not use any infammabe sovents.! Caution Do not guide the water jet directy into the cooing air openings of the recoi starter, into the air fiter and on eectrica equipment. BOMAG 49

50 Maintenance every month 6.12 Drain the sudge from the fue tank! Danger Fire hazard! When working on the fue system do not use open fire, do not smoke, do not spi any fue.! Danger Heath hazard! Do not inhae any fue fumes. Environment Any fue must be caught and disposed of in an environmentay friendy manner. i Note For this work the fue tank shoud contain ony a itte quantity of fue. Fig. 50 Unscrew the drain pug (Fig. 50) underneath the fue tank, drain off fue and catch it. Once a fue has run out screw the oi drain pug back in with a new sea ring. i Note After the tank has been driven empty the mechanica oi pressure monitoring system must be activated (see chapter "Actuating the oi pressure monitoring system"). 50 BOMAG

51 Maintenance every 6 months Maintenance every 6 months 6.13 Check the battery condition, grease the poes! Danger Danger of burning! When working on the battery do not use open fire, do not smoke! Do not et acid come in contact with skin or cothes! Wear safety gogges! Do not ay any toos on the battery! Fig. 52 Unscrew the battery hoder (Fig. 52). Remove the vibration damper mat. Non-maintenance free batteries: Cean battery and battery compartment. Open pugs and check the acid eve. With contro inserts: Check whether the acid eve reaches the bottom end of the contro inserts. Fig. 51 Loosen the hood fastening screws (1) on both sides and remove the hood fastening screws (2) on both sides (Fig. 51). Fod the hood back to open. With transparent battery housing: Check whether the acid eve reaches the eve mark on the housing. Maintenance free batteries: Cean the battery Grease the poes Tighten the termina camps Environment Dispose of the od batteries environmentay.! Danger Deveopment of gas! For recharging remove the pugs from the battery to avoid the accumuation of highy exposive gases. BOMAG 51

52 Maintenance every 6 months 6.14 Check, adjust the vave cearance! Caution Check and adjust ony when the engine is cod. The gasket for the cyinder head cover must be generay renewed. Checking the vave cearance Fig. 53 Cean the condition of the vibration insuation mats, repace if ncessary (Fig. 53). Retighten the battery hoder.! Caution Reinsta the battery compartment cover. Fig. 54 Decompression ever 1 (Fig. 54) must be initia position. Fig. 55 Turn the engine in correct direction, unti compression resistance can be fet. Disassembe the vave cover (Fig. 55). 52 BOMAG

53 Maintenance every 6 months 6.15 Check the oi eve in the exciter housing! Caution Park the machine on eve ground. Cean the area around breather and drain pug. Fig. 56 Check the vave cearance with a feeer gauge on both vaves (Fig. 56). Nomina vaue: Intake vave (I) 0.10 mm (0.004 inch) Exhaust vave (E) 0.20 mm (0,008 inch) 1 2 Adjusting the vave cearance Fig. 58 Unscrew the beeding screw (1) (Fig. 58). Unscrew the oi eve inspection pug (2) and check the oi eve. The oi eve must reach the bottom edge of the inspection opening, if necessary fi in oi. Fig. 57 Sighty sacken the counter nut 2 (Fig. 57). Adjust setscrew (1) with a screwdriver, unti the feeer gauge can be inserted and pued out with itte resistance after retightening the counter nut. Assembe the cyinder head cover with a new gasket. After a short test run check the vave cover for eaks. For quaity of oi refer to the "tabe of fues and ubricants". Cean the oi eve inspection pug and screw in with seaing agent (e.g. BOMAG ). Screw the beeding screw back in. BOMAG 53

54 Maintenance every 6 months 54 BOMAG

55 Maintenance every year Maintenance every year 6.16 Change engine oi and oi fiter! Danger Danger of scading! When draining off hot oi. By hot oi when unscrewing the engine oi fiter.! Caution Drain the oi ony when the engine is warm. For quaity and quantity of oi refer to the "tabe of fues and ubricants". Environment Catch running out oi and dispose of environmentay together with the oi fiter. Park the machine on eve ground so that the engine is in horizonta position. Fig. 60 Cean the drain hose from dust and dirt. OIL Unscrew the oi drain pug (Fig. 60) and catch any oi running out. Cean the drain pug and screw it back in (tightening torque: 20 Nm (14.8 ft.bs)). Fig. 59 Pu out the oi dipstick (Fig. 59). Fig. 61 Unscrew the cap (Fig. 61). Wipe the seaing face on the engine cean. Insert the new fiter cartridge with the recess facing downwards. Check the sea in the cover, repace if necessary. Screw the cover in oi tight. BOMAG 55

56 Maintenance every year 6.17 Repacing the fue fiter! Danger Fire hazard! When working on the fue system do not use open fire, do not smoke, do not spi any fue. Fig. 62 Fi in fresh engine oi through the fier opening (Fig. 62). Push the dipstick back in.! Danger Heath hazard! Do not inhae any fue fumes.! Caution Ensure strict ceaniness! Thoroughy cean the area around the fue fiter. Environment Catch running out fue and dispose of environmentay together with the fue fiter. Fig. 63 After a short test run check for eaks. Check the oi eve on the dipstick (Fig. 63), correct if necessary. Fig. 64 Pu the fue fiter (Fig. 64) out of the top and bottom hoses. i Note In case of contamination drain off and catch the sudge from the fue tank, fush out with cean diese fue. Insta the new fue fiter by observing the fow direction. Fi the fue tank again. 56 BOMAG

57 Maintenance every year i Note After the tank has been driven empty the mechanica oi pressure monitoring system must be activated (see chapter "Actuating the oi pressure monitoring system") Changing the oi in the exciter housing! Caution Park the machine on eve ground. For quaity and quantity of oi refer to the tabe of fues and ubricants. Environment Catch running out oi, do not et it seep into the ground and dispose off environmentay. Cean the area around breather and drain pug. 1 2 OIL Fig. 65 Unscrew ventiation (1) (Fig. 65) and eve inspection pugs (2). Drain the oi through the inspection pug bore. For this purpose tit the machine to the side with the oi drain opening and support it safey. BOMAG 57

58 Maintenance every year 6.19 Check the rubber buffers Fig. 66 Tit the machine to the opposite side and secure it propery. Fi in fresh oi through the eve inspection opening (Fig. 66). Fig. 68 Check a rubber buffers (Fig. 68) for tight fit, cracks and damage and repace immediatey if damaged. 1 2 Fig. 67 Stand the machine on eve ground and check the oi eve (Fig. 67). The oi eve must reach the bottom edge of the oi eve inspection bore. Cean eve pug (2) and screw in with seaing agent (e.g. BOMAG ). Screw vent pug (1) tighty back in BOMAG

59 Maintenance every year 6.20 Check the V-bet tension, if necessary repace the V- bet Repacing the V-bet Checking the V-bet Fig. 69 Unscrew fastening screws (1) (Fig. 69) and take off the cover (2). Fig. 71 Remove the safety cover (1) (Fig. 71). Loosen the screws (2) and take off the V-bet puey (3). Insta the new V-bet. Fasten the V-bet puey. Assembe the protection cover (1), tighten the screws with 15 Nm (11.1 ft.bs). Insta the cover (2) (Fig. 69). Fig. 70 Check condition and tightness of V-bet (Fig. 70).! Caution Compression measurement: approx mm ( in) Repace a damaged V-bet. The V-bet cannot be tightened manuay. Aways repace the V-bet, if the compression measurement is exceeded. BOMAG 59

60 Maintenance every year 60 BOMAG

61 Maintenance every 2 years Maintenance every 2 years 6.21 Change hydrauic oi and fiter Changing the breather fiter! Danger Danger of scading! Danger of scading by hot oi.! Caution Park the machine on eve ground. Drain off hydrauic oi at operating temperature. Repace the hydrauic oi fiter with every hydrauic oi change. Change the hydrauic oi at east every 2 years. For quaity and quantity of oi refer to the "tabe of fues and ubricants". Environment Catch running out oi and dispose of environmentay together with the fiter. Fig. 73 Cean hydrauic tank and surrounding area. Unscrew the pug and take out the breather fiter pug (Fig. 73). Cean the through bore in the pug. Insert a new breather fiter pug and screw the pug tighty back in. Change hydrauic oi and fiter Fig. 72 Loosen the engine hood fastening (1) (Fig. 72) on both sides and remove the hood fastenings on both sides. Fod the engine hood open Fig. 74 Disconnect the connecting hoses (Fig. 74). BOMAG 61

62 Maintenance every 2 years Fig. 75 Disconnect the connecting fange (Fig. 75). Fig. 77 Fasten the connecting fange (Fig. 77) with a new gasket to the hydrauic oi tank (tightening torque: 13 Nm (9.6 ft.bs)). Fig. 76 Unscrew and empty the hydrauic tank (Fig. 76). Reinsta the hydrauic tank after it has been emptied. Fig. 78 Fi in new hydrauic oi (Fig. 78). Check the oi eve in the inspection gass, top up if necessary. Nomina vaue: Midde of inspection gass Screw in the fier pug. Reconnect the connecting hoses. 62 BOMAG

63 As required As required 6.22 Check, cean the air fiter, repace if necessary! Caution Do not use gasoine or hot fuids to cean the air fiter. Do not continue to use a damaged air fiter eement. If in doubt use a new air fiter. The air fiter must be changed after severa times ceaning, but at the atest after one year. Each ceaning interva must be marked with a cross on the cover of the air fiter. Ceaning does not make sense if the air fiter eement is covered with a sooty deposit. Use a new air fiter. Incorrecty handed air fiters may become ineffective because of damage (e.g. cracks) and cause damage to the engine. In case of wet or oiy dirt repace the fiter eement. Fig. 80 Bow the air fiter out from inside to outside with dry compressed air (max. 5 bar (72 psi)) (Fig. 80).! Hod the air fiter under an ange to the ight or examine it with a amp for cracks or other signs of damage. Caution The air fiter must be repaced if the sightest damage on fiter paper or sea ips is found. Fig. 79 Unscrew the wing nut for cover (1) (Fig. 79) and take off the cover. Pu out the air fiter.! Danger Danger of injury! Aways wear protective cothes (gogges, goves) when working with compressed air. Fig. 81 Insert the air fiter (2) (Fig. 81).! Check the seaing face (3) on the housing. Caution When tightening the cover do not damage the sea on the fiter housing. Attach the cover (1) (Fig. 81) and tighten it with the wing screws. BOMAG 63

64 As required 6.23 Tightening the screws i Note Sef ocking nuts must aways be repaced by new ones after they have been unscrewed. Fig. 82 Check the air fiter service indicator (Fig. 82). Fig. 83 *Strength casses for screws with untreated, nonubricated surfaces. The quaity designations are stamped on the screw heads. 8.8 = 8 G 10.9 = 10 K 12.9 = 12 K The vaues resut in a 90% utiization of the screw's yieding point at a coefficient of friction of μ tota = The compiance with the tightening torques is to be checked with torque wrenches. The tightening torques are not appicabe when using MoS 2 ubricants. 64 BOMAG

65 As required 6.24 Engine conservation If the engine is to be shut down for a onger period of time (e.g. over winter), we recommend the foowing measures to avoid corrosion: Cean engine and cooing system: With cod ceansing agent and water jet or, even better, with steam ceaning equipment. Run the engine warm and shut it down. Drain the sti warm engine oi and fi in anticorrosion engine oi. Drain and catch the fue from the fue tank, mix it we with 10% anti-corrosion oi and fi it back in. Instead of mixing the fue with anti-corrosion oi you may aso fi the tank with injection pump testing oi with anti-corrosive properties (e.g. Caibration fuid B). Then run the engine for 10 minutes, so that ines, fiter, pump and nozzes are fied with the conserving mixture and the new engine oi is distributed to a parts. Take the cyinder head cover off, spray the rocker chamber with a mixture of diese fue and 10% anti-corrosion oi. Then fasten the cover again. Crank the engine severa times to spray the combustion chamber (throtte ever in stop position). Take the V-bet off and spray the grooves of the V-bet pueys with anti-corrosion oi. Remove the anti-corrosion oi before taking the machine back into service. Cose air intake on air fiter and exhaust opening tighty.! Caution A machine with conserved engine must be ceary marked by attaching a cear warning abe. i Note Depending on weather conditions these conservation measures wi protect the machine for approx. 6 to 12 months. Before taking the machine back into service you must drain off the conservation oi and repace it with engine oi (see tabe of fues and ubricants) according to API-(MIL-) cassification. Anti-corrosion ois are a ois which compy with the specification MIL-L B or TL /2 o Nato Code C640/642. BOMAG 65

66 As required 66 BOMAG

67 7 Troube shooting BOMAG 67

68 Troube shooting 7.1 Genera notes Pease observe stricty the safety reguations in the corresponding section of these operating and maintenance instructions. Mafunctions are frequenty caused by incorrect operation of the machine or insufficient maintenance. Whenever a faut occurs you shoud therefore thoroughy read these instruction on correct operation and maintenance. If you cannot ocate the cause of a faut or rectify it yoursef by foowing the troube shooting chart, you shoud contact our customer service department. 7.2 Starting with jump wires i Note Choose this type of starting if the starter battery is exhausted and the machine cannot be started manuay with the safety crank hande.! Caution A wrong connection wi cause severe damage in the eectric system. The auxiiary battery must have the same votage as the starter battery. Fig. 84 Loosen the hood fastening screws (1) on both sides and remove the hood fastening screws (2) on both sides (Fig. 84). Fod the hood back to open. Remove the battery hoder and take off the vibration damping mat. Check insuation mats, brackets and screw connections, repace if necessary. 68 BOMAG

69 Troube shooting Fig. 85 Join the pus poes on externa battery and starter battery with the jump wire (Fig. 85). Use the second jump start cabe to connect the negative poes on externa battery and starter battery. Perform the starting process as described before. When the engine is running remove the jump start cabe from the two negative poes first and from the positive poes after. i Note This work sequence is necessary to avoid short circuit caused by contact between positive and negative cabes. Cose the hood again and fasten it with bots. BOMAG 69

70 Troube shooting 7.3 Engine probems Faut Possibe cause Remedy Engine does not start or does not start immediatey, but can be cranked with the starter motor Throtte ever in stop or ide speed position. No fue at the injection pump. Set the ever to Start position. Fi in fue Check the entire fue system systematicay. Insufficient compression - incorrect vave cearance Check, adjust the vave cearance. - Wear on cyinder or piston rings Have examined by a speciaist. Additionay on engines with mechanica oi pressure monitoring With ow temperatures Injection nozze out of order No oi pressure Temperature beow starting imit. Fue geed because of insufficient cod compatibiity. Have examined by a speciaist. Check the oi eve. Activate mechanica oi pressure monitoring Observe cod start instructions. Pu the fue hose off the fue ift pump and check whether fue runs out of the fue pump cear and without ge. In case of geed fue you shoud either warm the engine up or drain the compete fue suppy system. Fi with a temperature resistant fue mixture. Starter speed too ow: - Oi with too high viscosity Repace engine oi with oi of correct viscosity - Insufficienty charged battery Check the battery, if necessary consut a speciaist workshop The starter is not switched on or the engine does not crank Faut in the eectric system: - Fuse defective - Battery or other cabe connections not correcty connected. - Cabe terminas oose or oxidised - Battery defective or not charged - Starter defective - Insufficienty charged battery Check eectric equipment and reated components or consut the our customer service. 70 BOMAG

71 Troube shooting Faut Possibe cause Remedy Engine ignites, but does not continue to run when switching the starter motor off. Fue fiter cogged. Fue suppy interrupted. Repace the fue fiter. Stop signa from monitoring eements connected with the oi pressure monitoring faciity: - no oi pressure Check the oi eve. Check the entire fue system systematicay. Engine shuts down by itsef during operation Tank empty. Fue fiter cogged. The mechanica oi pressure monitoring shuts the engine down because of a ack off oi Mechanica defects. Fi in fue. Repace the fue fiter. Check the oi eve, activate the oi pressure monitoring system. Engine ooses power and speed Fue suppy restricted: - Tank empty Fi in fue, activate the mechanica oi pressure monitoring system. - Fue fiter cogged Repace the fue fiter. - Insufficient tank ventiation Ensure sufficient ventiation of the tank. - Line connections eaking Check ine connections for eaks. Engine ooses power and speed, back exhaust smoke Engine overheating Throtte ever does not stay in seected position. Too much oi in crankcase. Air fiter dirty. Incorrect vave cearance. Injection nozze out of order Too much oi in engine. Insufficient cooing: - Dirt in the entire area of the cooing air fow Bock the throtte contro. Drain off oi. Cean or repace the air fiter. Adjust the vave cearance. Have examined by a speciaist. Drain the engine oi down to the top mark on the dipstick. Cean the cooing air area. - Air guide pates not competey cosed. Check air guide pates for competeness and good seaing BOMAG 71

72 Troube shooting 7.4 Troube shooting Economizer Faut Description Possibe cause Status-LED off Operation Status-LED on no frequency detected Engine not running Pug-in connector defective Sensor/cabe defective Status-LED fashing Frequency detected, but outside permissibe range Engine speed too ow Vibration frequency too ow Sensor defective atypica soi V-bet sipping incorrect V-bet instaed 72 BOMAG

73 8 Disposa BOMAG 73

74 Disposa 8.1 Fina shut-down of machine If the machine can no onger be used and needs to be finay shut down you must carry out the foowing work and have the machine disassembed by an officiay recognized speciaist workshop.! Danger Danger of cauterisation! Danger of exposion! When working on the battery do not use open fire, do not smoke! The battery contains acid. Do not et acid come in contact with skin or cothes! Wear protective cothing! Remove the batteries and dispose of in compiance with ega reguations. Environment Catch a fues and ubricants, do not et them seep into the ground and dispose of in compiance with ega reguations. Empty the fue tank. Drain ubrication oi from engine and exciter housing. Drain off hydrauic oi.! Danger Danger of exposion! Parts that previousy contained combustibe fuids must not be cut with a cutting torch. 74 BOMAG

75