Bomag BW 145 D-3, BW 145 DH-3, BW 145 PDH-3 Operator Manual

Operating instructions

Maintenance instructions

BW 145 D-3 / DH-3 / PDH-3

S/N 101 581 21.... 901 581 47 ....

S/N 101 581 22.... 901 581 48 ....

S/N 101 581 23 .... 901 581 49 ....

Catalogue number

008 157 08

Single drum roller

01/2004

Foreword

Foreword

BOMAG m achines are products from the wide range of BOMAG compaction equipment.

BOMAG's vast experience, together with th e
most up-to-date productio n and testi ng meth­ods, including servicelife tests of all important
components and highest quality demands,
guarantee maximum reliability of your ma­chine.

These instructions com prise:

l Safety regulations
l Operating instructions
l Maintenance instructions
l Trouble s hooting

Using these instructions will

l help yo u to get to know the machine.
l avoid malfunctions caus ed by unexpert opera-

tion.

Compliance with the maintenance instruc tions will

l increase th e reliability of your machine on the

site,

l increase the service life of the ma chine,
l reduce repair costs and down times.

BOMAG shall no t assume liability for safe func­tioning of the machine

Youshould only operate the machine if you are ful­ly familiar with the contents of these instructions.

You must also obs erve all applicable safety regu­lations.

Please observe also the guidelines of the Civil En­gineeringLiability Association "Safety Regulations
for the Operation of Road Rollers and Soil Com­pactors" and the applicable acc ident preven tio n in­structions.

For your own safety you should only use BOMAG-spare parts.

We reserv e the right for technical modifica­tions withoutprior notification.

Theseoperating and maintenance instructions are
also available in other languages.

A spare part catalogue can be obtained from your
BOMAG dealer when giving him the serial number
of your machine.

Information about t he c orrec t use of our machines
in earth work and for asphalt applications can be
obtained from your BOMAG dealer.

The above points do not constitute an extension of
thewarrantyand liabilityconditionsspecified i n t he
general terms of business of BOMAG.

We wish you much success with your BOMAG
machines.

BOMAG GmbH & Co. OHG

l if it is handled in a way which does not comply

with the usual modes of use,

l if it is used for purposes other than thos e men-

tioned in the instructions.

No warranty claims can be lodged f or damage re­sulting from

l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.

Please note!

This manual has been written for the operator and
the service personnel at the site.

Keep this manual always clo se at hand, e.g.in t he
tool compartment of the m achine or in the contain­er provide d.

PrintedinGermany
Copyright by BOMAG

BOMAG 3BW 145 D-3/DH-3/PDH-3

Foreword

Please fill in

............................

Machinetype(Fig.1)

............................

Serial-number (Fi g. 1 and 2)

............................

Engine type (Fig. 3)

............................

Engine nu mber (Fig. 3)

Note

i

Supplement the above data together with th e com ­missioning prot oc ol.

During commissioning our organisation will in­struct you in the operation and maintenance of the
machine.

Please obs erve strictly the safe ty regulations and
all notes on risks and dangers!

Fig. 1

Fig. 2

Fig. 3

BOMAG4 BW 145 D-3/DH-3/PDH-3

Table of Contents

Technical Data 7
Safety regulations 11
Indicators and Controls 19

3.1 General notes 22

Operation 29

4.1 General notes 30

4.2 Tests before taking into operation 30

4.3 Starting the engine 31

4.4 Starting with jump leads 33

4.5 Driving the machine 34

4.6 Emergency exit 35

4.7 Operating the parking brake, s top ping the machine 36

4.8 Shutting the engine down 36

4.9 Switching t he vibration on and off 37

4.10 Adjusting the seat 38

4.11 Operating the hood 39

4.12 Towing in case of a n engine failure 39

4.13 Transport 41

Maintenance 43

5.1 General notes on maintenance 44

5.2 Fuels and lubric ants 45

5.3 Table of fuels and lubricants 48

5.4 Running-in instructions 49

5.5 Maintenance chart 50

5.6 Checking t he engine oil level 52

5.7 Checking the fuel filter water separator 52

5.8 Checking the fuel level 53

5.9 Checking the hydraulic oil level 54

5.10 Checking the tire pressure 55

5.11 Cleaning the cooling fins on the radiator 55

5.12 Cleaning the cooling fins on the hydraulic oil cooler 56

5.13 Check the oil level in the drive axle 57

5.14 Checking the oil level in left/right wheel hubs 58

5.15 Checking the oil level in the v ibration bearings 58

5.16 Servicing the battery 59

5.17 Draining t he sludge from the fuel tank 60

5.18 Change engine oil and oil filter c art ridge 60

5.19 Checking the V-bel t tension, tightening 62

5.20 Checking, adjusting the valve clearance 63

5.21 Changing the oil in the vibration bearings 64

5.22 Change the oil in the drive ax le 65

BOMAG 5BW 145 D-3/DH-3/PDH-3

Table of Contents

5.23 Change the oil in t he wheel hubs 66

5.24 Changing the fuel pre-filter 67

5.25 Changing the fuel filter cartridge 68

5.26 Checking the fastenings on the diesel engine 68

5.27 Tightenin g the fastening o f the axle on the fram e 69

5.28 Tightenin g the wheel nuts 69

5.29 Checking the ROPS 70

5.30 Changing hydraulic oil and breather f ilter 71

5.31 Changing the hydraulic oil filter 72

5.32 Checking the injection valves 74

5.33 Replacing the toothed belt 75

5.34 Checking, cleaning, changing the combustion air filter 76

5.35 Adjusting the parking brake 79

5.36 Changing the tires 80

5.37 Adjusting the scrapers 81

5.38 Changing the fresh air filter in the cabin 82

5.39 Tightening torques 82

5.40 Engine conservation 83

Trouble shooting 85

6.1 General notes 86

6.2 Engine 87

BOMAG6 BW 145 D-3/DH-3/PDH-3

1 Technical Data

BOMAG 7BW 145 D-3/DH-3/PDH-3

Technical Data

Fig. 4

Dimensions inmmA B D H H2 K L O1 O2 S W

BW 14 5 D-3
BW 14 5 DH-3
BW 14 5 PDH-3

*

2222 1546 1058 1900 2750 313 4194 60 60 22 1426
2222 1546 1058 1900 2750 313 4194 60 60 22 1426
2222 1546 1044 1900 2750 313 4194 60 60 15 1426

BW 145 D-3 BW 145 DH-3 BW 145 PDH-3

Weights

Operating weight (CECE)

kg 4990 5050 5330
with ROPS-cabin
Front axle load (CECE) kg 2620 2680 2960
Rear axle load (CE CE) kg 2370 2370 2370
Static linear load kg/cm 18,4 18,8 -

Travel characteristics

Travel speed (1) km/h 0 ... 6 0 ... 5 0 ... 5
Travel speed (2) km/h 0 ... 10 0 ... 10 0 ... 10
Max. gradability with vi-

%475555

bration

BOMAG8 BW 145 D-3/DH-3/PDH-3

Technical Data

*

BW 14 5 D-3 BW 145 DH-3 BW 14 5 PDH-3

Drive

Engine manufacturer Deutz Deutz Deutz
Type BF4L 2011 BF4L 2011 BF4L 2011
Cooling Air/oil Air/oil Air/oil
Number of cylinders 4 4 4
Rated power ISO 3046 kW 56 56 56
Rated speed rpm 2650 2650 2650
Fuel Diesel Diesel Diesel
Electrical equipm ent V 12 12 12
Drive system hydrostatic hydrostatic hydrostatic
Driven axles 2 2 2

Brakes

Service brake hydrostatic hydrostatic hydrosta tic
Parking brake hydr.-mech. hydr.-mech. hydr.-mech.

Steering

Type of steering articulated articulated articulated
Steering operation hydrostatic hydrostatic hydrostatic

Vibration

Drive system hydrostatic hydrostatic hydrostatic
Frequency Hz 34 34 34
Amplitude mm 1,7/0,85 1,7/0,85 1,4/0,7

Tires

Tire size 335/ 80R20MPT81 335/80R20MPT81 340/80R18IT530
Air pressure bar 1,8 1,8 1,8

Tank contents

Hydraulic oil Litres 44 44 44
Fuel Litres 110 110 110
Engine oil Litres 10,5 10,5 10,5

* The right for technical modifications remains reserved

BOMAG 9BW 145 D-3/DH-3/PDH-3

Technical Data

The following noise and vibration values a ccording to the EC-directive for machines, edition (91/368/
EEC) were measured a t nominal engin e speed and with the vib rati on switched o n. The machine was
standing o n an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise value

The soun d level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is

sound pressure level at the work place of the operator (with cabin):

L

pA

=78,4dB(A)

sound capacity level:

L

wA

These soundvalues were de termined according to ISO 3744 for the sound capacity level (L
for sound pressure level (L

=101,8dB(A)

) at t he place of the operator.

pA

) and ISO 6081

wA

Vibration value

The vibration values according to enclosure 1, paragra ph 3. 6. 3. a of the EC -machine regulation are:

Vibration of the entire boy (driver’s seat)

The we ighted effective acceleration value determine d according to ISO 2631 part 1, is ≤0,5 m/sec

Hand-arm vibration values

The we ighted effective acceleration value determine d according to ISO 8662 part 1, is ≤2,5 m/sec

2

.

2

.

BOMAG10 BW 145 D-3/DH-3/PDH-3

2 Safety regulations

BOMAG 11BW 145 D-3/DH-3/PDH-3

Safety regulations

General

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:

l the machine is used for purpos es other than

those it is inten ded for

l the machine is operated by untrained pers on-

nel

l the m achine is modified or converted in an un -

professional way

l the applicable s afety regulations are not ob-

served.

Each p erson involved in operation, mainte­nance and repair of the machine must there­fore read and apply t hese 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

Unintended use

Dangers may, however, arise from the machine if
it is used by untrained personnel in an unprofes­sional w ay or if it is used for purp ose s other than
those mentioned in these instructions.

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

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

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 m us t be clearly specified and com­plied with.

Persons u nder 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 pe rsonnel.

l generallyacknowledgedsafety and road tr affic

regulations

l country specific safety regulations. It is the

duty of the operator to know and observe
these regu lations. This applies also for local
regulations and the regulations fo r various
types of manual work. If the recommendations
in this manual differ from the regulations valid
in your country, you m ust strictly observe the
regulations in your country.

Intended use

This machine must only be used for:

l compaction of bituminous m aterials, e.g. road

surface layers. (AC and AD machines only)

l medium and heavy compacti on tasks in earth

work (road sub-bases)

l This m ac hine must only be operated with fully

functional safety equipment.

l The machine should be checked b y an expert

once every year.

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 t his machine. We w ish to make ex­pressly clear that wehave not tested or a utho rized
any original parts or special equipment not sup­plied by us. The installation and/or use of such
products can impair the active and/or passive 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.

BOMAG12 BW 145 D-3/DH-3/PDH-3

Safety regulations

!

Caution

Sections marked like this point out possible
dangers for the machine or for parts of the ma­chine.

Note

i

Sections marked li ke this provide technical infor­mation concerning t he optimal economical use of
the machine.

Environment

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

Observe all environment protection regula­tions.

Informationand safety stickers/decals on the m achine

Keep st ick ers/decals complete (see s pare parts
catalogue) and fully legible and observe their
meaning.

Replace damaged or illegible s tickers/decals im­mediately.

Loading the machine

Use onl y strong and stable loading ramps. The
ramp inclinationmust be lower than the gradability
of the machine.

Secure t he machine against t urning over or slip­ping off.

Secure t he machine on the transport vehicle
against rolling off, slipping and turning ov er.

Persons are highly endangered if

l they step or stand under loads being lifted
l they remain in the drive range of the machine

during a demonstration or during loading.

The machine m us t not swing about when lifted off
the ground.

Use only safe lifting gear of sufficient load bearing
capacity.

Attach the lifting gear only to the specified lifting
points.

Towing the machine

Sincethemachineisnotfittedwithatowinghitch,
the machine cannot be towed with a tow bar.

If the machine has to be towed urgently out of the
danger zone because of other risks, this must only
be done on level ground or uphillusing chains and
ropes. For this pu rp os e towing r opes of sufficient
tensile strength must be fastened on the lifting
eyes.

After releasing the brake the mac hine can only be
braked by the towing vehicle.

Before releasing the brake block the machine with
chocks to prevent unintended rolling.

Checking the roll-over protection structure (ROPS)

The machine fra me must not be distorted, bent or
cracked in the area of the ROPS structure.

The ROPS s tructure must no t show any rust, dam­age, hairline cracks or open fractures.

The ROPS must not rattle about when driving the
machine. This would mean that the fa stening
screws are insufficiently fastened . All screwed
connections must be tight and in accordance with
the specifications (observe the tightening tor­ques). Screws and nuts must not be damaged,
distorted or deformed.

No additional parts must be welded or bolted on
and no holes must be drilled without the permis­sion of the dealer, since t his may impair the
strength of the structure.

Starting the machine

Before starting

Operation of the machine is only permitted when
sitting in the operator's seat.

Use only machines which have been properly
serviced at regular intervals.

Become acquainted with the eq uipm ent, the con­trol elements, the working mode of the machine
and the area you will be working in.

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

Check before mounting the machine if:

l there are persons or obstruc tions beside or

under the machine

BOMAG 13BW 145 D-3/DH-3/PDH-3

Safety regulations

l themachine is freeofany oilyand com bustible

material

l all handrails, steps and platforms are free of

grease, oils, fuels, dirt, snow and ice

l the engine compartment hood is closed and

locked

To climb onto the machine use steps and hand­rails.

Check before starting, whet her:

l the machine shows any obvious defects
l all protective devi ce s are properly secured in

their place

l steering, brakes, control element s , lighting

and warning horn are in order

l the seat is correctly adjusted
l the mirrors (if available) are clean and correct-

ly adjusted.

Do not start the machine if any gauges, control
lights or controls are defective.

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

On machines with ROP S you should always wear
your seat belt!

Starting

Start and operate the machine only from the oper­ator's seat

For starting set al l control levers to "neutral posi­tion".

Do not use any starting aid s such as Start Pilot or
ether.

After starting check all gauges.

Starting with jump leads

Connect plus with plus and minus with minus
(ground cable) - always connect the ground cable
last and disconnect it first! Wrong c onnec tions
may cause severe d amage in the electric system.

Never start the engin e by bridging the electrical
connections on the starter, becaus e the machine
would probably start to move immediately.

Starting in closed rooms

Exhaust gases are toxic! Always ensure an a de­quate supply of fresh air when starting in closed
rooms!

Driving the machine

Persons in the danger area

If the machine should turn over and the cabin door
is closed, th e right hand side cabin window can be
used as an emergency ex it .

Check if there are pers ons o r obstacles in the dan­ger area before st arting or r es uming work, espe­cially when drivingin reverse.

If necessary give warning signals. Stop work im­mediately, if persons remain in the danger area
despite the warning.

Do not stand in the machine's articulation area
while the engine is running. Danger of injury!

Driving

In emergency s ituations and in case of danger op­erate the emergency stop switch im mediately. Do
not use the emergency stop switch as service
brake.

Resume operation only after eliminating the dan­ger that has led to the actuation of the emergency
stop.

If the machine comes in contact with high voltage
power lines:

l do not leave the operator's stand
l warn o thers from coming close to th e machine

or touching it

l ifpossible move the machine out of the danger

zone

l have the power s hut off

Operate the machine only from the operator's
stand.

Keep the cabin doors closed.
Do not adjust the operator's seat while driving.
Do not climb onto or off the machine whileit is driv-

ing.
Choose the trav el direction only whenthe machine

is standing.
Do not use the machine to transport persons.
If you recognize unusual noises and the develop-

ment of smoke, detect the cause and have the
fault corrected.

Always ke ep a s afe distance to e xcavat ions and
embankments and avoid all activities wh ich could
impair the stability of the machine.

BOMAG14 BW 145 D-3/DH-3/PDH-3

Safety regulations

Do notwork with vibration on hard concrete, cured
asphalt or hard frozen ground.

When driving under flyovers, bridges, tunnels,
power lines etc. ensure suf ficient distance.

Drivingongradientsandslopes

Do no t drive on gradients which exceed the maxi­mum gradability of the machine.

Always drive extremely carefully on slopes and al­ways direct ly up or down the slope, never diago­nally. Change to the lower speed range before
approaching the inclination.

Wetand loosesoils reduce theground adhesionof
the m achine on gradients and slopes considera­bly. Highe r risk o f accidents!

Behaviour in traffic

Match your speed to the working conditions.
Always give way to loade d vehicles.
Switch the lights on if the vis ibility is po or.
Keep away from edges and embank ments.

Check the effect of vibration

When compacting with vibration check the effect
on nearby buildings and underground supply lines
(gas, water, sewage, power li nes ) and s top vibra­tory compact ion if necessary.

Never use the vibration on hard (frozen, concrete)
ground. Risk of bearing damage!

Parking the machine

Park the machine on level and firm ground.
Before leaving the machine:

l move the travel control lever to neutral position
l apply the parking brake
l shut the engine down and pull the ignition key

out

l lock the cabin door
l secure the cabin against unauthorized use.

Do no t jump off the machine, but use access steps
and h and rails.

Mark parked machines, which could be an ob­struction, by attaching clearly visible signs.

Parkingongradientsorslopes

Secure t he machine against roll ing away, place
metal c hoc ks in front of and behind the drums.

Filling the fuel tank

Do not inhale fuel fumes.
Refuelonly after shutting the engine and the aux-

iliary heater down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not

let it seep into the ground.
Wipe off spil led fuel. Keep fuel free of dirt and wa-

ter.
Leaking fuel tanks can cause explosions. Ensure

tight fit of the fuel tank filling cover, replace it if nec­essary.

Fire protectio n measures

Makeyourselfacquainted withthelocation and t he
operation of fire extinguishers. Observe fire wa rn­ing and fire fighting installations.

Maintenance work

Strictly apply the specified maintenance tasks, in­cluding the changing of parts.

Maintenance work must only be carried out by
skilled and authorized personnel.

In case of maintenanc e and assembly work over­head make sure to use the prescribed or other
safe access steps, ladders and gangways. Do not
use parts of the machine as access steps.

Keep unauthorized persons away from the ma­chine.

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

Park the machine on ground as level and firm as
possible.

Pull the ignition key out.
Secure the articulated joint with the articulation

lock.

Working on hydraulic lines

Depressurize hydraulic lines bef ore working on
them. Hydraulic oil esca ping under pressure can
penetrate the skin and cause severe i njury. Con­sult a doctor if y ou are injured b y pressurized hy­draulic oil as otherwise serious infections may
result.

When adjusting the hydraulic system do not stand
behind the drums/wheels.

BOMAG 15BW 145 D-3/DH-3/PDH-3

Safety regulations

Do not change t he setting of high pressure relief
valves.

Drain the hydraulic oil at operating temperature ­danger of scalding!

Catch running out hydraulic oil and dispose of en­vironmentally.

Always collect and dispose of biodegradable hy­draulic oils separately.

Do not start the engine after draining the hydraulic
oil.

Check all connections and fittings for leakages
once all work is completed (with the lines still de­pressurized!).

Changing of hydraulic hoses

Hydraulic hoses must be examined visually at reg­ular intervals.

Hydraulic hoses must be changed immediately in
case of:

l damageto the outer su rface down to t he lining

(e.g. chafings, cuts, cracks)

l embrittlement of the outer surface (develop-

ment of cracks in the hose material)

l deformation under pressurized and depressu -

rized conditions, which are not in accordanc e
with the natural shape of the hydraulic hose

l deformationinbends s uchas squeezed spots,

extreme bends, layer separation, format ion of
blisters

l leakages
l non-observance of installation requirements.
l separation of t he hydraulic hose from the

crimped fitting

l corrosion of the crimped fitting, which impairs

the function and the strength

l do not m ix up hoses by mistake
l damage or deformation of the fitting which ef-

fects the function and the strength or impairs
the hose/hose connection.

Only the use of genui ne BOMAG hoses ensures
that the correct type of hose (pressure range) is
used at the right place.

Working on the engine

Shut the engine down before opening the engine
compartment hood.

Drain the hydraulic oil at operating temperature ­danger of scalding!

Wipe off spilled oil , catch running out oil and dis­pose of environmenta lly.

Store used filters and other oily materials in a spe­cially marked refuse container and dispose of en ­vironmentally.

Do not leave any tools or other parts, which could
lead to damage, in the engine c ompartment.

Working in the electric system

Disconnect the battery and cover it with insulating
material before starting t o work in the electric sys­tem.

Do not use f us es with higher Ampere ratings and
do not repair fuses with a piece of wire. Fire haz­ard!

Always disconnec t the battery before starting to
weld on the machine.

Workingonthebattery

When working on the bat terydo not smoke, do not
use open fire.

Do not let hands or clothes com e in contact with
acid. Treat acid injuries with clear water and con­sult a doctor.

Metal object s (e.g. t ools, rings, wrist watches)
must not touch the battery poles - danger of short
circuits and fire!

When recharging maintenance free batteries re­move all plugs to avo id the ac cumulation of highly
explosive gases.

Observe all relevant instruc tions when s t arting
with an auxiliary battery.

Dispose of used batteries environment ally.
Shut the charging current down before discon-

necting charging clamps.
Ensure an adequate s upply of fresh air, especially

if the battery is to be charged in a closed room.

Working on the fuel system

Do not inhale f uel fumes.
No open fire, do not s moke, do not spill any fuel.
Catch running out fuel, do not let it seep into the

ground an d dispose of environmentally.

BOMAG16 BW 145 D-3/DH-3/PDH-3

Workingonwheelsandtires

Explosion-like bursting of tires and parts of tires
and rims can cause most severe or even fatal inju­ries.

The assembly of tires must only be carried out by
experienced personnel and with the correct equip­ment. If necessary have the tires assembled in a
qualified work s hop.

Always ensure correct tire pressure and do not ex ­ceed the max. permissible pressure.

Examine the tires every day for too low pressure,
cuts, bulges, faulty rims, missing wheel studs or
nuts. Do not drive with faulty tires or w heels.

Non-stick emu lsion must only be mixed of water
and n on-s tick additives according to the instruc­tions of the non-stick agent manufacturer. Strictly
observe t he regulations for the protection of the
environment.

Cleaning

Do no t clean the machine while the engine is run­ning.

Do no t use gasoline or other easily inflammable
substances for cleaning purposes.

When using high pres su r e c leaning equipment do
notsubject elect rical partsandinsulating materials
to the direct water jet or cover them beforehand.

l Do not guide the water jet into the exhaust or

into the air filter.

Safety regulations

After maintenance work

Reinstall all protections and guards once all main­tenance work is c ompleted.

Repair

Attach a warning tag to the st eering wheel if the
machine is defective.

Repairs must only be performed by qualified per­sons who have been inst ructed for this purpose.
Use our repair instructions.

Exhaust gases are highly dangerous! Always en­sure an a dequate 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.

BOMAG 17BW 145 D-3/DH-3/PDH-3

Safety regulations

BOMAG18 BW 145 D-3/DH-3/PDH-3

3 Indicators and Controls

BOMAG 19BW 145 D-3/DH-3/PDH-3

Indicators and Controls

Fig. 5

BOMAG20 BW 145 D-3/DH-3/PDH-3

Indicators and Controls

1 Multi-function display
2 Rotary switch for f lashing beacon

*

3 Rotary switch for lighting (StVZO)*
4 Rotary switch for hazard light system*
5 Rotary switch for direction indicators left/right*
6 Rotary switch for working head li ghts*
7 Rotary switch vibration high/low frequency

* Optionalequipment

8 Rotary switch for speed range selection
9 Push but to n for wa rning horn
10 Emergency stop push button
11 Ignition switch (at the side)
12 Push button for vibration
13 Travel lever
14 Throttle lever
15 Locking plate for throttle l ev er

BOMAG 21BW 145 D-3/DH-3/PDH-3

Indicators and Controls

3.1 General notes

Please read th is s ec tion thoroughly before operat­ing t his machine if you are not yet conversant with
the indicators and cont rol elements. All function s
are described in detail hereunder.

Paragraph 4 Operation contains only concise de­scriptions of the individual operating steps.

Fig. 6

No. 1 = Multi-function display

Note

i

After switching the ignition on all lamps light up for
approx. 3 seconds as a self-te st.

ment, check the hydraulic system if it

comes on too early.
h=notused
i = Brakeclosedor travelleverinsecond

notched pos it ion
j = Fuel level gauge
k = Operating hour meter

Fig. 7

No. 2 = R otary switch for flashing beacon

Position "lef t" = Flashing beacon switched off
Position "right " = Flashing b eacon switched on

The control and warning lamps light up while the engine is running:

a = Hazard light switched on
b = Direction indicator switched on
c = Engine oil temperature too hi gh,

warning buz z er sounds. Clean en­gine and radiator

d = E ngine oil press ure too low, warning

buzzer sound s. Check the engine oil
level, if necessary have the engine
repaired.

e = A ir filter c artrid ge soiled. Clean,

change the cartridge.

f = The battery i s not being charged,

check the V-belt, if necessary repair
the generator.

= Light with ignition on and engine off.

g = Hydraulic oil filter soiled, the warning

buzzer sounds. Replace the filter ele-

Fig. 8

No. 3 = Rotary switch, lighting (StVZO)

Position "lef t" = light off
Position "mid-

dle" = f ender lights on, with the igni-

tion switch in position "I" or "P"

Position "right" = travel lights on, with ignition

switch in position "I".

*Option

BOMAG22 BW 145 D-3/DH-3/PDH-3

*

Indicators and Controls

Fig.9

No. 4 = Rotary switch for hazard light sys-

*

tem

Position "left" = hazard light switched off, the

control lights go out.

Position "r ight" = hazard light switched on, co n-

trol light 7 on fault monit oring
board lights up.

Fig. 10

No. 5 = R otary switch for direction indicators

left / right

**

Position "mid­dle" = direction indicator off

Position "lef t or
right" = fron t and rear direction indica-

torsontherespective side light
up, the control light 6 in the
fault monitoring board f lashes

Fig.11

No. 6 = Rotary switch working lights

***

Position "left" = light off
Position "right" = working lights on, with ignition

switch in position "I".

Fig.12

No. 7 = Rotary switch, vibration

Position "mid­dle" = vibration off

Position "left" = low amplitude, high frequency
Position "right" = high amplitude, low frequency

*Option
** Option

*** Option

BOMAG 23BW 145 D-3/DH-3/PDH-3

Indicators and Controls

Fig. 13

No. 8 = R otary switch for speed range selec-

tion

Position "turtle" = Working speed
Position "rab -

bit" = Transport speed

The engine will b e shut down and the brake will
close.

!

Danger

Danger o f accident!
Operate only in emergency situations during

operation, do not use as a service brake.
The machine should only be started again after

the danger, that cau sed the actuation of the
emergency stop sw itch, has been removed.

operate = push the button completely

down, it will automatically lock
in end position.

unlock = t urn the button clockw ise and

release it.

to drive = move the travel lever first to

braking position, then start the
engine and choose the travel
direction.

For safety reasons the travel system of the ma­chine will only be enabled after the travel lever has
been shi fted back to braking position.

Fig. 14

No. 9 = Push button for warning horn

Fig. 15

No. 10 = Emergency stop switch

Fig. 16

No. 11 = Ignition switch

Position "P"/ " 0" = Ignition off, key can be pulled

out, engine off

Position "I" = Ignition on, all control and

warning lights in the multi­function display light up fo r a
moment

Note

i

The engine can only be sta rted if both travel levers
are in “neutral”.

BOMAG24 BW 145 D-3/DH-3/PDH-3

The ignition switch is designed with a lock to pre­vent repetitive starting. For a new starting attempt
the igni ti on key must first be turned back to posi­tion "0".

Position "II" = turn further against spring

pressure, he engine st arts,
turn the ignition key back to
position once the engine has
started

!

Caution

Run the engine warm for a short while before
startingwork.Do not allow the engine to run
longer th an 10 minutes wit h 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.

Indicators and Controls

Fig.18

No. 13 = Travel lever

Position "mid­dle" = B rak ing position service brake

Position "middle,
right" = Parking brake, to start the en-

gine
Position "I" = Forward travel
Position "II" = Backwards travel

Fig. 17

No. 12 = Push button for vibration

l Select or actuate the freq uencies with the vi-

bration selector switch.

l Switch the vibration on or off by pressing the

push button.

Note

i

If the engine speed drops und er load when driving
on steep gradients, take the travel lever slightly
back towards neutral. This relieves the hydraulic
system and the diesel engine.

Fig.19

No. 14 = Throttle lever

Position "I" = Idle speed position
Position "II" = Full load position, operat ing

position for driving and vibra-

tion

BOMAG 25BW 145 D-3/DH-3/PDH-3

Indicators and Controls

!

Caution

Always drive and vibrate with max. engine
speed! Control the travel speed only with the
travel lev er!

No. 15 = Locking pla te for th rottle lever

pull = The throttle lever can be

movedtoposition"II"

release = The throttle lever locks in posi-

tion "II".

Fig. 21

No. 17 = Main fuse for battery

125A = (F00)

Note

i

The main fuse is located in the battery b ox under
the driver’s seat

Fig. 20

No. 16 = Fuses in electric installation box

F03, 15A = Vibration
F05, 25A = Socket
F13, 30A = Starting
F19, 15A = Working head lights*
F22, 15A = Working head lights, rear*
F24, 15A = Monitoring, gauges
F25, 15A = Solenoid valve brake/travel

!

Danger

Fire hazard!
Do not use fuses with higher ampere ratings

and do not b ri dge fuses.

Fig. 22

No.18=Pedalfordozerblade

*

Position "0" = Stop position. Dozer blade at

rest
Position "I" = Dozer blade up
Position "II" = Dozer blade down
Position "II" = Float position to level loose

soil when driving in reverse

!

Danger

Danger o f squashing!
Do not work underthelifted, unsupporteddoz-

er blade, support the blade if necessary.

* Optionalequipment

BOMAG26 BW 145 D-3/DH-3/PDH-3

Fig. 23

No. 19 = Fuse box, cabin

*

(1) - = not used
(2) 7,5A = Inside light
(3) 7,5A = Windscreen wiper/washe r,

rear

(4) 7,5A = Windscreen wiper/washe r,

front
(5) 7,5A = Flashing beacon
(6) 7,5A = Heating blower, radio

Indicators and Controls

Switch on the auxiliary hot air blower

Fig.24

No. 26 = Shut-off valve for cabin heater

Note

i

The heat exchanger of the cabi n heater receives
the heat energy from the lubrication oil i n the en­gine.

Position "I" = Cabin heater switched off
Position "II" = Cabin heater full power

*****

!

Danger

Fire hazard!
Do not use fuses with higher ampere ratings

and do not bridge fuses.
No. 20 = Toggle switch, heating blower
No. 21 = Toggle switch, flashing beacon
No. 22 = Toggle switch, windscreen wiper/

washer, front

***

**

No. 23 = Toggle switch, windscreen wiper/

washer, rear

****

No. 24 = Cabin light

switch on = turn lamp glass clockwise
switch off = turn lam p glass counter-clock-

wise

No. 25 = Vent for fresh air intake

to operate the slide loosen the adjustment button.
slide to the left = air circulation pos ition
slide to the right = fresh air position

* Optionalequipment
** Option
*** Option
****Option

*****Optional equipment

BOMAG 27BW 145 D-3/DH-3/PDH-3

Indicators and Controls

BOMAG28 BW 145 D-3/DH-3/PDH-3

4Operation

BOMAG 29BW 145 D-3/DH-3/PDH-3

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 element s of t he machine.

All indicators and co ntrol elements are described
in detail in this chapter.

4.2 Tests before taking into op­eration

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

!

Danger

Danger o f accident!
Please observe strictly the safety regulations

in chapter 2 o f this instruction m anual!

l Park the machine on ground as level as possi-

ble.

Check:

l fuel tank and fuel lines for leaks
l screw joints for tight fit
l function of steering
l machine for cleanliness, damage
l presence of the appropriate operating and

maintenance instructions

l check w hether the machine has been properly

serviced.

Note

i

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

l Engine oi l level

Note

i

InhydraulicsystemsfilledwithPanolin HLPSynth.
46 alwa ys use the same oil to top up. With other
ester ba se d oils c onsult the lubrication oil serv ice
of the respective oil manufacturer.

l Check the hydraulic oil level, top up if nec es -

sary.

!

Danger

Fire hazard!
Do not refuel in closed rooms.

l Check the fuel level, top up if necessary.
l Check water separator in fuel system, drain if

necessary.

BOMAG30 BW 145 D-3/DH-3/PDH-3

Operation

l Check the scrapers, adjust if necessary
l Check the air pressure in the tires For values

refer to the tec hnical data.

!

Caution

Ensure equal pressure in both tires.

4.3 Starting the engine

! Danger

Danger of accident!
Always wear your seat belt.

Fig.25

l Fasten your seat belt (Fig . 25).

Fig.26

l Check, whether the t rav el l ev er ( Fi g. 26) is en-

gaged in brake position.

BOMAG 31BW 145 D-3/DH-3/PDH-3

Operation

Fig. 27

l Turn the rotary vibration selector switch (Fig.

27) to position "0" , vibration off.

Fig. 28

l Check, whether the emergency stop switch

(Fig. 28) is unlocke d.

Fig. 30

l Turn the ignition key (Fig. 30) t o position "I".

Fig. 31

All control and warning lights (Fig. 31) in the mu lti­function display light upfor a few seconds as a self
test.

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

Fig. 29

l Set the throt tle lever ( Fig. 29) to position "II",

full speed.

!

Caution

Perform th e 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.

BOMAG32 BW 145 D-3/DH-3/PDH-3

Fig. 32

l Turn t he ignition key to position "II", the starter

cranks the engine.

l As soon as the engine ignites return the igni-

tion key to position "I".

Charge control light (f) and engine oil pressure
warning light (d) go out.

Operation

4.4 Starting with jump leads

!

Caution

Wrong co nnection will cause severe damage
to the electrical system.

Fig.34

l When starting withan externalbattery connect

both plu s poles (Fig. 34) first and both minus
poles (earth cable) after.

Fig. 33

l Once the engine runs correctly reduce the en-

gine spee d (Fig. 33) to position “I”, idle speed.

!

Caution

Run the engine warm for a short while, but do
not run with idle spee d for more tha n 10 mi n­utes.

l Perform the work steps described in the previ-

ous paragrapf.

l After starting disconnec t the minus pole s

(earth cable) first and the plus pole s after.

BOMAG 33BW 145 D-3/DH-3/PDH-3

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 c onditions 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).

Do not drive without wearing your seat belt.
Always give way to loaded transport vehicles!
Before starting to drive make sure that the

drive range is absolutely safe.

Fig. 36

l Shift the throttle leve r to position "II" (Fig. 36)

full load and lock it.

!

Caution

Select the travel speed range on ly when the
machineisstanding.

Fig. 35

l Select the desired travel speed range (F ig.

35).

Fig. 37

l Push the travel lever (Fig. 37) to the left out of

braking position and move it slowly to the de­sired travel direction.

The brake warning light (i) goes out.

Note

i

Shift the travel lever out of "0"-position s lowl y to
forward or rev erse, the machine will drive forward
or reverse at a speed whic h corresponds with the
displacement of the travel lever.

Returning the travel lever to w ards neutral will
brake the machine a nd in " 0" -position of the travel
lever the machine will stop.

!

Danger

Danger o f accident!
On i nclinations and slopes pull th e travel lever

to the right and lock it in braking position.

BOMAG34 BW 145 D-3/DH-3/PDH-3

Operation

Important notes on travel operation

!

Caution

When changing the travel direction hold the
travel lever for a moment in "0"-position, until
the machine has stopped, before actuating to
the new travel direction.

Do not operate jerkily!
Do not use the throttle lever to control the trav-

el speed! Control the travel speed with the
travel lever. During operation the throttle lever
must remain in fu ll load position.

When driving up and down inclinations move
the travel lever slowly back to wards neutral to
brake the machine.

If the engine speed drops when driving up ex­treme incli nati onsmove the ravel lever sligh tly
back, if necessary change to the lower speed
range.

Always use the lowest speed range (turtle) to
drive up and down inclinations.

4.6 Emergency exit

If the machine should turn ov er an d the cabin door
is closed, the right hand side cabin window can be
used as an emergency exit.

BOMAG 35BW 145 D-3/DH-3/PDH-3

Operation

4.7 Operating the parking
brake, stopping the ma­chine

Fig. 38

l Return the travel lever (Fig. 38) slowly to "neu-

tral"-position and engage i t to the right parking
brake position.

The hydrostat ic drive brakes the machine aut o­matically, the parking brake closes after approx. 2
seconds.

4.8 Shutting the engine down

!

Caution

Straighten the articulated joint to provide easi­er access to the machine.

Fig. 39

l Return the travel lever (Fig. 39) slowly to "neu-

tral"-position and engage it to the right in brak­ing position.

Note

i

The park ing brake also closes automatically when
shutting the engine down.

Fig. 40

l Pull the locking plate (Fig. 40) up and set the

throttle lever to position "I" (idle speed).

Note

i

Donot shutthe enginedown all of the sudden from
full speed, but let it idle for a while for temperature
equalization.

BOMAG36 BW 145 D-3/DH-3/PDH-3

Fig. 41

l Turn t he ignition key (Fig. 41) to pos it ion "0" or

"P" an d pull the ignition key out .

Note

i

After shut ting the engine down with the throttle le­ver th e ”central warning li ght” lights and the warn­ing buzzer sounds, until the ignition swi tch is
turned t o position ”0”. The parking brake closes
automatically when shutting the engine down.

!

Danger

Danger of accident!
On particularly steep inclinations place w heel

chocks in front of or beh in d drum and wheels.
Secure the m achine against un authorized use,

pull the ignition key out, lock the cabin d oor.

Operation

4.9 Switching the vibration on and off

!

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.

Do not activate the vibration on hard (frozen,
concrete) ground. Danger of bearing damage!

!

Caution

When using the machine on asphalt
Vibration at standstill causes transverse

marks, 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.

Preselecting the vibration

Fig.42

l Preselect amplitude/frequency with the rotary

switch (Fig. 42).

BOMAG 37BW 145 D-3/DH-3/PDH-3

Operation

Switching the vibration on

Fig. 43

l Set the throt tle lever ( Fig. 43) to position "II",

full speed.

!

Caution

Switch the vibration on on ly at max. engine
speed.

4.10 Adjusting the seat

! Danger

Danger o f accident!
Do not adjust the driver’s seat while driving.

Fig. 45

l To adjust the seat in longitudinal direction dis-

engage lever 1 (Fig. 45) and push the seat for­ward or back.

Fig. 44

l Press the push button (Fig. 44) in the travel le-

ver while driving, the drum will vibrate.

Switching the vibration off

l Press the push button again and afte r work

switch the rotary vibration switch to position
"0".

l To adjust the inclination of the bac k r es t oper-

ate lever (2) and tilt the backrest forward or
back.

l To adjust the weight adjust lever (3) accord-

ingly.

Note

i

In its adjustment the lever (3) is locked in upwards
direction. This lock can be released by pressing
the lever completely down against the stop. Then
adjust to the weight of the operator by sliding the
lever down.

BOMAG38 BW 145 D-3/DH-3/PDH-3

Operation

4.11 Operating the hood

! Danger

Danger of accident!
If the hood needs to be opened further for

maintenance or repair work, support it safely.

Fig. 46

l Unlock the lock 1 (Fig. 46).
l To unlock the hood press the latch (2) down

and pu ll the handle (3) back.

4.12 Towing in case of an engine failure

!

Danger

Life hazard!
Since the machine is not fitted wi th a towing

hitch, the machine cannot be towed with a tow
bar.

If the machine has to be towed urgently out of
the danger zone because of other risks, this
must only be done on level ground or uphill us­ing chains and ropes.

For this purpose towing ropes of sufficient ten­sile strength must be fastened on the lifting
eyes.

After releasing the brake the machine can only
be braked by the towing vehicle.

Before releasing the brake block the machine
with chocks to prevent u ni ntended rolling.

!

Caution

The max. towing speed must not exceed 2 km/
h (developm ent of heat i n the drive secti on of
the hyd raulic motor).

Fig. 47

l Pull the support ( Fig. 47) out of the brac k et in

the hood and hook it at the bottom into the
frame or at t he top into the traverse.

The tow ing distance must not exceed 1 km, be­cause the hydraulic circuit would run dry with­out the charge circuit in function.

l Secure the machine with wheel chocks

against unintentional rolling.

l Attach the towing ropes safely to the front or

rear lifting eyes.

BOMAG 39BW 145 D-3/DH-3/PDH-3

Operation

Fig. 48

l Slacken the counter n uts on both high pres-

sure relief valves (Fig. 48) to create a by -pas s
around the travel pump.

l Turnthe threaded spindle in until it isflush wit h

the nut.

l Retighten the counter nut.

Fig. 49

l To release the brake turn counter nuts 1 ( Fig .

49) approx. 8 mm back.

Fig. 50

l Remove plug 1 (Fig. 50).
l Place an U-section (5) across the brake hous-

ing (2) and turn the sc rew (4) into the tapped
bore (3), until it bottoms.

l Turn the nut (6) down and tighte n it approx .

one revolution . The drum must rotate freely.

After towing

!

Caution

Before loosening ropes or chains block the
machine with chocks to prevent uni ntended
rolling.

l Turn the threaded spindle of the high pressure

relief valves completely out again and tighten
the counter nuts.

l Turn all brake rele as ing screws of the axle

evenly back out, until they are light moving
again.

l Turn t he brake releasing screws (2) complete-

ly in against the stop.

l Repeat this measure on the opposite side.

BOMAG40 BW 145 D-3/DH-3/PDH-3

Fig. 51

l Turnthe brake releasing s c r ews (Fig. 51) back

in again, until t hey abut against the brake pis­ton.

Operation

4.13 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 o n the lifting points fo r
loading, tying or lifting the machin e.

Fig. 52

l Unscrew the brake releasing screws (Fig. 52)

for two turns and tighten the count er nuts.

l Repeat this adjustment procedure on the op-

posite wheel side.

Note

i

If necess ary replace the seal ring under the coun­ter nut if it is leaking.

For this purpose com pletely unscrew the brake re­leasing screw, replace the seal rin g and lubricate
the screw with silicone grease.

Reinstall t he screw with a n ew seal ring and adjust
the prot r usion as described above.

Fig.53

l Attach the articulation lock (Fig. 53).

BOMAG 41BW 145 D-3/DH-3/PDH-3

Operation

Fig. 54

l Lash the machine on the t r ans port vehicle

(Fig. 54), use the four lashing eyes on front
and rear frame for this purpose.

l Support the front frame to avoid overstressing

of the rubber buffers.

Fig. 55

l Forliftinguse alsothe f our lifting eyes (Fig. 55)

and approp riate lifting gear.

Weights: See technical data

l After transport rel ease the articulation lock

again and store i t in th e receptacle.

BOMAG42 BW 145 D-3/DH-3/PDH-3

5 Maintenance

BOMAG 43BW 145 D-3/DH-3/PDH-3

Maintenance

5.1 General notes on mainte­nance

When pe rforming maintenance work always com­ply with the appropriate safety regulations.

Thorough maintenance of the machine guaran­tees far longer safe functioning of the machine and
prolongs the lifetime of important components.
The effort needed for this work is only little com­pared with the problems that may arise when not
observing this rule.

The terms right/left corresp ond with t rav el direc­tion forward.

l Always clean machine and engine thoroughly

before starting maintenance work.

l For maintenance work st and the machine on

level ground.

l Perform maintenance work only with the en-

gine shut down.

l Relievehydraulicpressures beforeworking on

hydraulic lines.

l Before working on electric parts of the ma-

chine disconne ct the battery and cover i t with
insulation material.

l When working in the area of the articulated

joint attach the articulation lock (transport
lock).

Environment

Duringmaintenanceworkcatchalloilsandfu­els and do not let them seep into the ground or
into the sewage system. Dispose of oils, cool­ant and fuels environmentally.

Notes on the fuel system

The lifetime of the diesel engine depends to a
great extent on the cleanliness of the fuel.

l Keep fuel free of contaminants and water,

since this will d amage the injection elements
of the engine.

l Drumswithinside zinc liningarenot s uitableto

store fuel.

l The fuel dru m must r es t for a longer period of

time before drawing off fuel.

l Do not let the hose stir up the slurry at the bot-

tom of the drum.

l Do not draw of f fuel from near the bot to m of

the drum.

l The rest in the drum is not suitable f or the en-

gine and should only be used for cleaning pur­poses.

Notes on the performance of the en­gine

On diesel engines bot h c ombustion air and fu el in­jection qua ntities are thoroughly adapt ed to each
other and determine power, temperature level and
exhaust gas quality of the engine.

If you r engine has to work pe rmanently in "thin air"
(athigher altitudes)and underfull load, you should
consult the customer service o f BOMAG or the
customer serv ice of the engine manufacturer.

Notes on the hydraulic system

During maintenance work on the hydraulic system
cleanliness is of major i mportance. Makesure that
no dirt or other contaminating substances can en­ter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clo g noz­zles and pilot bores, thereby making expensive re­pairs inevitable.

l If,during the daily inspection ofthe oil level the

hydraulic oil level is found to have dropped,
check all lines, hoses and componen ts for
leaks.

l Seal extern al leaks im mediately. If necessary

inform the responsible c us t omer service.

l Do not store drums with hydraulic oil outdoors,

or at least under a c ov er. Water can be drawn
in through the bunghole when the weather
changes.

l Always use the filling and filtering unit

(BOMAG part-no. 007 610 01) to fill the hy­draulic system. T his u nit is fitted with a fine fil­ter to clean the hydraulic oil, thereby
prolonging the lifetime of the filter.

l Cleanfittings, filler c ov ers and the area around

such parts before disassembly t o avoid enter­ing of dirt.

l Do not leave the tank opening unnec essarily

open, but cover it so that nothing can fall in.

BOMAG44 BW 145 D-3/DH-3/PDH-3

5.2 Fuels and lubricants

Engine oil

Quality

Lubrication oils are classified according to their
performance and qual ity class. Oils according to
other comparable specifications may be used.

Approved engine oils

Deutz DQC II DQC III
ACAE E3/96/E5-02 E 4-99
API CH-4/CG-4 ­DHD DHD-1 -

The exact assignment of the approved oilqualities
and oil change intervals c an be taken from the f ol­lowing section "Lubrication oil change intervals".

Consult your local service station if in doubt.

Maintenance

Oil viscosity

Multi-purpose oils shou ld be generally used.
Since lub rication oil changes its v isc os ity with the

temperature, the ambient temperature at the oper­ating loc atio n of the engine is o f utmost im por­tance when choosing the viscosity class (SAE­class) .

Optimal operating conditions can be achiev ed by
using the opposite oil viscosity chart (Fig. 56) as a
reference.

Occasionally falling short of the temperature limits
will impair the cold starting ability, but will not
cause any engine damage. In ord er to keep the
occurring wear as low as possible, occas s ional ex­ceeding of the limits should not happen ov er a
longer period of time.

Fig.56

With their better temperature and oxidation stabil­ity synthetic lubrication oils offer quite a few bene­fits.

Oil change intervals

The longest permissible time a lubrication oi l
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
atleastonce per year,irrespective of theoperating
hours reached.

ACEA

E3-96/E5-02
E4-99 = 500 operating hours

API

CG-4/CH-4 = 500 operating hours

!

Caution

These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight
and for ambient temperatures higher than

-10 °C.

BOMAG 45BW 145 D-3/DH-3/PDH-3

Maintenance

When using fuels with a sulphur content of
more than 0.5% to 1% or u nd er ambient tem­peratures below -10 °C the oil change intervals
specified in the table must be h alve d. For fuels
with a sulphur content of more than 1% you
should co nsult the responsible service ag en­cy.

Fuels

Quality

You should only use com mercially available brand
diesel fuel with a sulphur content below 0.5% and
ensure strict cleanliness when filling in. A higher
sulphur cont ent has a negative effect on the oil
changeintervals. Use onlywinter-grade diesel fuel
under low ambient temperatures. The fue l level
should alwaysbe topped up in duetime so that the
fuel tank is never run dry, as otherwise filter and in ­jection lines need to be bled.

When usi ng fuels with a Cetan num ber < 49 poor
starting and white smoke c an be ex pec ted, in pa r­ticular in connection with low ambient tempera­tures.

The following fuel specifications are permitted:
DIN/EN 590; DIN 51 601; Nato Codes: F -54, F-75;
BS 2869: A1 and A2; A ST M D 975-78: 1-D and 2­D.

l DIN/EN 590
l BS 2869
l ASTM D 975-78: 1-D and 2-D.

Operation with rape seed oilmethyl ester(RME „Bio Diesel“)

Due to the extrem e quality differences of RMEW­fuelsavailable on the market, whic h are caus ed by
the non-exist enc e of a standardization, BOMAG
does generally not approve any RME-fuels. If this
is neglected the warranty will become null and
void!

However, if you s till intend to operate the machine
with RME-fuels you sho uld observe t he following
information:

l Reduced engine power (approx. 7%), higher

fuel consumption.

l The quality of RME-fuel should be in compli-

ance with DIN draft 51606.

l Avoid longer periods of standstill (formation of

resin, corrosion in injection system)

l RME-fuel can damage the paint finish of the

machine.

l Fueldilution of engine oil,therefore shortening

of oil change intervals to half.

l Rubber parts, such as leak fuel return lines,

seats will be damaged in the long run and
need to be replaced on a regular basis or
should be replaced by parts made of fluo rinat ­ed rubber. However, fluorinated rubber is not
resistant agains t normal diesel fuel.

l If the fuel filter is c logged the filter change in-

tervals must be s horte ned accordingly.

l Nato Codes: F-54, F-34, F44 und XF63

Winter fuel

!

Danger

Diesel fuels must never be mixed with gaso­line.

For winter operation use only winter diesel fuel, to
avoid clogg ing because of paraff in separation. At
very low temperatures disturbing paraffin separa­tioncanalsobeexpectedwhenusingwinterdiesel
fuel.

In most cases a sufficientcold resistance can also
be achieved by adding flow enhancing fuel addi­tives. Consult the engine manufacturer.

Hydraulic oil

Thehydra ulic system is operated with hydraul ic oil
HV 46 (ISO) with a kinematic viscosity of

2

46 mm
es use only hi gh-quality hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils
type HV according to ISO 6743/3. The viscosity in­dex (VI) should be at least 150 (observe informa­tion of manufacturer).

Bio-degradable hydraulic oil

On request the hydraulic system can also be filled
with ester based biodegradable hydraulic oil (Pan­olin HLP Synth. 46). The biologically quickly de­gradable hy draulic oil meets all demands of a
mineral oil based hydraulic oil according to DIN

51524.

BOMAG46 BW 145 D-3/DH-3/PDH-3

/s at 40°C. For topping up or for oil chang-

Inhydraulic systemsfilled with PanolinHLP Synth.
46 alway s use the same oil to top up. When
changing from mineral oilbased hydraulic oil t o an
ester based biologicallydegradable oil,youshould
consult t he lubrication oil service of the oil manu­facturer for details.

Check t he filter more frequently after this change.

!

Caution

Oil change bio-degradable hydraulic oil:
Perform regular oil analyses for contentof wa-

ter and mineral oil.
Replace the hydrau lic oil filter element every

500 operating hours.

Oil for drive axle

For the drive axle use only multi-purpose transm is­sion oil of API-class GL5 w ith viscosity class SAE

90.
Theadditives in thisoil ens ure lowwear lu brication

under all operating conditions.

Maintenance

Lubrication grease

For lubrication use only EP-high pressure grease,
lithium saponified (penetration 2).

BOMAG 47BW 145 D-3/DH-3/PDH-3

Maintenance

5.3 Table of fuels and lubri­cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level m arks

Engine Engine oil ACEA: E3-96/E5-02 or approx. 10. 5 litres

API: CG-4/CH-4

SAE 10W/40

(-20°Cto+40°C)

Fuel

Diesel Winter diesel fuel approx. 110 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 44 litres

2

46 mm

Vibration be arings Engine oil S AE 15W/ 40 approx. 2, 1 litres

Drive axle Gear oil SAE 90, API GL5 approx. 6,7 litres
Planetary drive Gear oil SAE 90, API GL5 approx. 1 litre per side
Tires Water 68 litres

Calcium chloride (CaCl

/s at 40 °C

) or magnesium chloride

2

(MgCl

2)

29 kg

*

* Oil quantity with filter change

BOMAG48 BW 145 D-3/DH-3/PDH-3

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 e very day.

Dependingonthe loadthe engineis subjected
to,the oil consumption willdropto the normal
level after approx. 100 to 250 operating hours.

After 50 operating hours

l Retighten bolted connections on intake and

exhaust tubes, oil sump and engine mounts.

l Check t he engine for leaks.
l Retighten the bolted connections on the ma-

chine.

l Retighten all wheel fastening screws with t he

specified tightening torque.

l Check t he V-belt tension, tighten if necessary
l Oil change diesel engine
l Oil filter cartridge diesel engine
l Check the valve c learance, adjust if necess ary
l Oil change in drive axle
l Oil change in wheel hub of axle

After 500 operating ho urs

l Oil change vibration bearings

BOMAG 49BW 145 D-3/DH-3/PDH-3

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 Check the engine oil level Dipstick mark

5.7 Check the fuel filter water separa tor

5.8 Check the fuel level

5.9 Check the hy draulic oil level Inspection glass

Every 250 oper atin g hours

5.10 Check the tire pre ssure see technical data

5.11 Cleaning the cooling fins on the radiator

5.12 Cleaning the cooling fins on the hydraulic oil cooler

5.13 Check the oil le ve l in the drive axle

5.14 Check the oil level in the wheel hubs

5.15 Check the oil le ve l in the vibration bearings

Every 500 oper atin g hours

5.16 Service the battery distilled water, pole greas e

5.17 Drain the sludge from the fuel tan k

5.18 Change en gine oil and oil filter cartridge min. 1x per year

5.19 Checking the V-belt tension, tighteni ng

Every 1000 operating hours

5.20 Check, adjus t the valve clearance Intake = 0.3 mm, exha ust = 0.5 mm, on cold
engine

5.21 Change the oil in the v ibration bearings min. 1x per y ear

5.22 Change the oil in the drive axl e min. 1x per year

5.23 Change the oil in the wheel hubs min. 1x per year

5.24 Changing the fuel pre-filter

5.25 Change the fuel filter cartridge

5.26 Check the engine mounts

5.27 Check the fastening of the axle on the frame

5.28 Tighten the wheel nuts

5.29 Check the ROPS

BOMAG50 BW 145 D-3/DH-3/PDH-3

Maintenance

No. Designation Note

Every 2000 operating hours

5.30 Change hydraulic oil and breather filter* at lea st every 2 years

5.31 Change the hydrau lic oil filter* at least every 2 years

Every 3000 operating hours

5.32 Check the injection valves

Every 5000 operating hours

5.33 Replace the toot hed belt at least every 5 years

As required

5.34 Clean, change the combusti on air filter min. 1x every year, safety cartridge at least
every 2 years

5.35 Adjust the parking brake

5.36 Change the tires

5.37 Adjust the scrapers

5.38 Change the fresh air f ilter in the cabin

5.39 Tightening torques

5.40 Engine conservation

*Also in case of repairs in th e hydraulic system.

BOMAG 51BW 145 D-3/DH-3/PDH-3

Every 10 operating hours

Every1 0oper ating hours

5.6 Checking the engine oil lev-

5.7 Checking the fuel filter wa-

el

Note

i

With the machine on level ground shut the engine
down and wait for about 15 minutes, so that all oil
can flow back into the oil sump.

l Open the engine hood

Fig. 57

l Pull th e dipstick (Fig. 57) out, wipe it off with a

lint-free, clean cloth and reinsert it until it bot­toms.

ter separator

!

Danger

Danger of injury!
Support the engine hood for all maintenance

and repair work.

Note

i

The service intervals for the water separator de­pend on the water content in the fuel a nd can
therefore notbe determined precisely. After taking
the engine into operation you s hould therefore
check the water separator every day for signs of
water.

If a to high quantity is drained off, th e filter must be
refilled with fuel. See chapter "maintenance a s re­quired", bleeding the fuel system.

Environment

Catch running out fuel and dispose of environ­mentally.

l Pull the di ps ti ck back out again .
l The oil level must be between both marks

"Min" and "Max".

l If the oil level is too low top up oil immediately.
l If the oil level is too high, determine the cause

and drain the oil off.

!

Caution

Before lo nger wo rk periods you should always
toptheoiluptothe"MAX"-mark.

For quality and quantity of oil r efer to the table of fuels and lubricants

Fig. 58

l Slacken the drain plug (Fig. 58) for a few turns

and catch running out fuel / water.

l Tighten the drain plug again and check for

leaks, if necessary replace the seal ring.

BOMAG52 BW 145 D-3/DH-3/PDH-3

5.8 Checking the fuel level

Every 10 operating hours

!

Caution

Contaminated fuel can cause malfunction or
even damage of the engine.

! Danger

Fire hazard!
When working on the fuel system do not use

open fire, do not smoke, do not refuelin closed
rooms, do not inhale any fuel fumes.

Fig. 59

l Check the fuel level on the fuel gauge “j” (Fig.

59).

If necessary, fill in fuel through a funnel with
screen.

l If necessary top up with fuel (diesel or winter

diesel).

For quality of fuel refer to the table of fuels and lubricants.

Note

i

Do not drive t he fuel t ank dry, as otherwise the fuel
system need s to be bled.

l Clean the area around the filler openin g.

Fig. 60

l Open the fuel tank cover (Fig. 60).

BOMAG 53BW 145 D-3/DH-3/PDH-3

Every 10 operating hours

5.9 Checking 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 o f the respective oil manufac­turer.

Fig. 62

l If necessary fill in hydraulic oil throughthe filler

neck (Fig. 62).

Forquality and quantity of oil referto the table of fuels and lub ricants.

Fig. 61

l Check the hydraulic oil level in the inspection

glass (Fig. 61).

Normal level

approx. 3 cm below the top edge of the inspection
glass.

Minimum level

Middle of inspection glass.

!

Caution

If, during the daily inspection of t he oil level
the hydraulic oil level is found t o have
dropped, check all lines, hoses and compo­nents for leaks.

BOMAG54 BW 145 D-3/DH-3/PDH-3

Every2 50 operatinghours

5.10 Checking the tire pressure

!

Caution

Since the tires are filled with water, you should
always turn the inflation valve to top position
to check the tire pressu re!

Always close the valves with the dust cap.

Every 250 operating hours

5.11 Cleaning the cooling fins on the radiator

!

Danger

Danger of injury!
Perform cleaning work only after the engine

has cooled down and with the engine stopped.

Note

i

Dirton fan blades and oil coolerreduce the cooling
effect. Dirt deposits in these areas are substantial­ly supported by oil and fuel on these surfaces. For
this reason you should always se al any oil or fuel
leaks in the vicinity of the cooling fan or the oil
cooler and clean the cooling surfaces after.

Cleaning with compressed air

Fig. 63

l Check the tire pressure with a pressure gauge

and the tire inflation valve 1 (F ig. 63) in top po­sition.

Nominal value see "technical d ata" .

Note

i

Ensure ev en pressure in all tires.

l Screw the valve caps ba ck on.

Note

i

Start to blow out from the exhaust side.

Fig.64

l Take the cooling air d uc t cover off and blow

the radiator (Fig. 64) out, starting from the air
discharge side.

l Remove all dirtthat has been blown into the air

duct.

BOMAG 55BW 145 D-3/DH-3/PDH-3

Every 250 operating hours

Cleaning with cold cleansing agent

!

Caution

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

Protect el ectrical equipment such as genera­tor, regulator and starter against the direct wa­ter jet.

l Spray the engine with a suitable cleansing

agent, e.g. cold cleanser, let it soak in for a
while and spray it off with a strong water jet.

l Reassemble the coolingair ductcover, runthe

engine warm for a while to avoid corrosion.

5.12 Cleaning the coolingfins on the hydraulic oil cooler

!

Danger

Danger of injury!
Perform cleaning work only after the engine

has cooled down and with the enginestopped.

!

Caution

Do not damage any coo ling fins on the cooler
core when cleaning.

Note

i

Dirton fanblades andoil cooler reduce the cool ing
effect. Dirt deposits in thes e areas are substantial­ly supported by oil and fuel on these surfaces. For
this reaso n you should always seal any oil or fuel
leaks in the vicinity of the cooling fan or the oil
cooler and clean the cooling surf aces after.

Cleaning with compressed air

Note

i

Start to blow out from the exhaust side.

Fig. 65

l Blow the cooler (Fig. 65) out with compress ed

air.

BOMAG56 BW 145 D-3/DH-3/PDH-3

Every 250 operating hours

Cleaning with cold cleansing agent

!

Caution

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

Protect electrical equipment such as genera­tor, regulator and starter a gainst the direct wa­ter jet.

l Spray the radiator with a suitable cle ans ing

agent, e.g. cold cleanser, le t it soak in for a
while and spray it off with a strong water jet.

l Run the engine warm for a while to avoi d cor-

rosion.

5.13 Check the oil level in the drive axle

l Park the machine on level ground.

Fig.66

l Unscrew the oil level ins pec tion plug (Fig. 66)

andchecktheoillevel.

Note

i

The second level inspection plug as at the back.
After filling in oil wait until the oil has evenly distrib-

uted inside the axle.

The oil level must reach the bo ttom edge of the
level bore.

l Topupoil,ifnecessary.

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

l Turn the level inspection plug tightly back in.

BOMAG 57BW 145 D-3/DH-3/PDH-3

Every 250 operating hours

5.14 Checking the oil level in left/ right wheel hubs

Fig. 67

l Move the m ac hine until the oil level inspection

plug 1 (Fig. 67) is in horizontal position.

l Clean and unscrew the plug.

The oil level must reach the bottom edge of the
bore.

l Topupoil,ifnecessary.

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

l Screw the plug back in tightly.
l Repeat this inspection on the other side.

5.15 Checkingthe oil level in the vibration bearings

Fig. 68

l Drive the machine, until t he oil level inspection

plug 1 (Fig. 68) is v ert ically below the hub.

l Clean and unscrew the oil level inspection

plug.

The oil level must reach the bottom edge of the
bore.

l Ifnecessary fill inoil through the filler an d drain

bore (2).

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

BOMAG58 BW 145 D-3/DH-3/PDH-3

Every5 00 operatinghours

5.16 Servicing the battery

! Danger

Danger of causticization !
When working on the battery do not use open

fire, do not smoke!
Do not let acid come in contact with skin or

clothes!

Wear protective clothing!
Do not lay any tools on the battery!
For rech arging remove the plugs from the bat-

tery to avoid the accumula tion of highly exp lo ­sive gases.

Every 500 operating hours

Fig.70

l Remove t he battery (F ig. 70) and clean the

battery compartment.

l Clean th e outside of the battery.

Environment

Dispose of the old battery environmentally.

Fig. 69

l Unscrew both fastening screws ( Fig. 69) from

the seat console and fold the seat forward.

l Clean bat tery poles and pole clamps and

grease them with pole grease (Vaseli ne).

l Check t he fastening of the battery.
l On serviceable batteries check the acid level,

if necessary top up to the filling mark with dis­tilled water.

BOMAG 59BW 145 D-3/DH-3/PDH-3

Every 500 operating hours

5.17 Draining the sludge from the fuel tank

!

Danger

Fire hazard!
When working on the fuel system do not use

open fire, do not smoke!
Do not spill any fuel.
Catch running out fuel, do not let it seep into

the ground.
Do not inhale any fuel fumes.

5.18 Changeengineoiland oil fil­ter cartridge

!

Caution

The oil change at 500 operating hours refers to
theuse of oilsof oil qualityclassAPI CG-4/CH­4 or ACAE E3 -96/E5-02 respectively.

See secti on 5.2 "Fuels and Lubricants".
Drain the engine oil only when the engine is

warm.

!

Danger

Danger o f scalding!
When draining off hot oil.

By hot oil when unscrewing the engine oil fil­ter.

Environment

Catch running out oil and dispose of environ­mentally together with the eng ine oil filter car­tridge.

Fig. 71

l Unscrew the cap (Fig. 71) and drain off ap-

prox. 5 litres of fuel.

l Turn the cap tightly back in.

Fig. 72

l Unscrew the drain plug (Fig. 72) and catch

running out oil.

l Turn the drain plug tightly back in.

BOMAG60 BW 145 D-3/DH-3/PDH-3

Every 500 operating hours

Fig. 73

l Unscrew th e filter cartridge (Fig. 73) using an

appropriate filter wrench.

l Clean t he sealing face on the f ilter carrier from

any dirt.

l Slightly oil the rubber seal on t he new filter car-

tridge.

l Turn the new filter cartridge on by hand, until

the seal contacts.

l Tighten the filter element for another half turn.

Fig.75

l On machines with cabin set the lever for oil

heat exc hanger hea ting to position II.

l Run the engine for approx. 3 minutes at idle

speed.

l Shut the engine down and s et the lever for oil

heat exc hanger hea ting to position I.

l Wait for about 15 minut es , so that all oil can

flow back into the oil sump.

Fig. 74

l Fill in new engine oil (Fig. 74).

Forquality and quantity of oil referto the table of fuels and lubricants.

l Tighten the oil f il ler cap properly.

Fig.76

l Check the oil level again(Fig. 76), if necessary

fill up to the Max.-mark.

l Check filter cartridge and drain plug for leaks.

BOMAG 61BW 145 D-3/DH-3/PDH-3

Every 500 operating hours

5.19 Checking theV-belttension, tightening

Checking the V-belt

Fig. 77

l Inspect the entire circumference of the V-belt

visually for damage and cracks.

l Replace damaged or c rac ke d V-belts.
l Checkwith thumbpressure whether theV-belt

can be depressed more than 10 . .. 15 m m be­tweentheV-belt pulleys(Fig.77), reti ght en the
V-belt if necessary.

Retightening the V-belt

Fig. 78

l Slightly slacken the fasteni ng screw 1 (Fig.

78).

l Press the idling pulley (2) in direction "I", until

the correct V-belt tension is achieved.

l Tighten the fastening screws (1).

BOMAG62 BW 145 D-3/DH-3/PDH-3

Every1 000ope rating hours

5.20 Checking, adjusting the valve clearance

!

Caution

Before checking the valve clearance let the en­gine cool dow n for at least 30 m inutes. The en­gine oil temperature must be less than 60 °C.

Valve clearance

Intake valve = 0.3 mm
Exhaust valve = 0.5 mm

l Open the engine hood c ompletelyand support

it safely.

Every 1000 operating hours

Fig.81

l Crank the engine with the starter until both

valves on cylinder 1 (Fig. 81) are “overlap­ping”.

Note

i

Overlapping means that the exhaust valve is not
yet complete ly closed and t he intake valve starts
to open.

Fig. 79

l Remove the valve cover (Fig. 79).

Fig. 80

l Press the engine shut-down lever 1 (Fig. 80)

against the stop (2) and fasten i t with a wire.

Thevalves marked black(Fig. 81) can be check ed
and adjusted.

Fig.82

l Crank the engine with the starter until both

valves on cylinder 4 (Fig. 82) are “ove rlapping”
(360° rot ation of the crankshaft).

Thevalves marked black(Fig. 82) can be check ed
and adjusted.

l Assemble the cylinder head cover with a new

gasket.

BOMAG 63BW 145 D-3/DH-3/PDH-3

Every 1000 operating hours

Adjusting the valve clearance

Fig. 83

l Loosen the c ounter 2 (Fig. 83) and regulate

the setscrew (1), until the feeler gauge can be
inserted and pulled out with little resistance af­ter retightening the counter nut.

!

Caution

After a short test run check the engine for
leaks.

5.21 Changing the oil in the vi­bration bearings

!

Caution

Drain o il only at operating temperature.

Fig. 84

l Move the drum, until the drain and filler plug 2

(Fig. 84) is in bottom pos ition.

l Clean and unscrew the oil level inspection

plug (1) as well as the drain and fi ller plug.

Environment

Catchrunningoutoil.

Fig. 85

l Once all oil has been drained off mo ve the

drum, until the oil level inspection plug 1 (Fig.

85) is positioned vertically under the hub.

l Fill in oil, until it starts to run out through the

level inspection bore.

BOMAG64 BW 145 D-3/DH-3/PDH-3

Every 1000 operating hours

Forquality and quantity of oil referto the table of fuels and lubricants.

l Screw oil level inspection plug (1) and drain

and filler plug (2) back in with new seal rings.

5.22 Change the oil in the drive axle

Note

i

On other axle versions drain and filler plugs are of
slightly different design. Perform theoil change ac­cordingly.

!

Caution

Drain oil only at operating temperature.

Environment

Catch old oil and dispose of environmentally.

l Park the machine on level ground.

Fig.86

l Clean and unscrew all level inspection and

drain plugs (Fig. 86).

l Drain and catch all oil.
l Clean the drain pl ug and turn it back in with a

new seal ring.

BOMAG 65BW 145 D-3/DH-3/PDH-3

Every 1000 operating hours

Fig. 87

l Fill in oil through the oil level inspection bores

(Fig. 87), until it has reached the bottom edge
of the bore.

Note

i

The second leve l inspection plug as at the back.

5.23 Change the oil in the wheel hubs

!

Caution

Drain o il only at operating temperature.
Change the oil on both sides of the axl e.

Environment

Catch old oil and dispose of environmentally.

After filling in oil wait until the oil has evenly distrib­uted inside the axle.

For quality and quantity of oil r efer to the table of fuels and lub ricants.

l Retighten the filler and level inspection plug.

Fig. 88

l Move the drive wheel,until the plug (Fig. 88) is

in bottom position.

l Clean and unscrew the plug.
l Drain and catch al l oil.

Fig. 89

l Move the drive wheel,until the plug (Fig. 89) is

in horizontal position on the housing.

l Fillin oil, until it reachesthe bottom edge ofthe

bore.

BOMAG66 BW 145 D-3/DH-3/PDH-3

Every 1000 operating hours

Forquality and quantity of oil referto the table of fuels and lubricants.

l Turn the plug tightly back in.
l Change the oil also on the oppos ite side.

5.24 Changing the fuel pre-filter

! Danger

Fire hazard!
When workin g on the fuel system do not use

open fire, do not smoke and do not spill any fu­el.

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

Do not inhale any fuel fumes.

Fig.90

l Remove the hose clamps and pull the fuel pre-

filter (Fig. 90) out of the fuel hoses.

!

Caution

Observe the flow direction of the filter.
The arrow must point towards the fuel pump.

l Install the new f uel pre-filter.

BOMAG 67BW 145 D-3/DH-3/PDH-3

Every 1000 operating hours

5.25 Changing the fuel filter car­tridge

!

Danger

Fire hazard!
When working on the fuel system do not use

openfire,donotsmokeanddo not spillanyfu­el.

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

Do not inhale any fuel fumes.

5.26 Checking the fastenings on the diesel engine

Fig. 92

l Check the fastening of intake and exhaust

tubes (Fig. 92) on the cylinder h eads for tight
fit.

l Check sockets and c lamps between air filter,

exhaust turbocharger and charge air line as
well as the lubricat ion air line for tight fit and
leaks.

Fig. 91

l Unscrew the fuel filter cartridge (Fig. 91) using

an appropriate filter wrench.

l Cleanthe sealing face on the filter carrier from

any dirt.

l Cover the rubber seal on the new filter car-

tridge slightly with oil and fill in clean fuel.

l Turn the new fuel filter cartridge on by hand,

until the seal cont ac ts.

l Tighten t he fuel filter cartridge for anothe r half

turn.

l Afterthe test drive check the filter cartridge for

leaks.

Note

i

Bleeding of the fuel system is not necessary.

l Check fastening and tightness of the lubrica-

tion oil sump.

Fig. 93

l Check the condition and tight fit of the engine

pillow blocks (Fig. 93).

BOMAG68 BW 145 D-3/DH-3/PDH-3

Every 1000 operating hours

5.27 Tightening the fastening of the axle on the frame

Fig. 94

l Check all fastening nuts for the axle studs for

tight fit (Fig. 94).

5.28 Tightening the wheel nuts

Fig.95

l Tighten the wheel nuts (Fig. 95) in acrosswise

pattern.

Tightening torques 550 Nm (405 ft-lb) (M22x1,5)

BOMAG 69BW 145 D-3/DH-3/PDH-3

Every 1000 operating hours

5.29 Checking the ROPS

Note

i

With the cabin assembled the ROPS (Roll Over
Protection S tructure) is integrated in the cabin.

Please obs erve also the respective section in the
safety regulations in this m anual.

Fig. 96

l Check the cabin, especially the ROPS (Fig.

96) for cracks, corrosion, damage and missing
fastening elements.

Note

i

Unusual m ov ements and noises (vibrations) dur­ing ope ra tion indicate damage or loose fastening
elements.

l Check the fastening screws for the cabin

(ROPS) to the operat or's platform for tight fit.

l Check the suspension buff ers for the opera-

tor's stand for tight fit.

l Check the condition and the fastening of the

seat belt.

BOMAG70 BW 145 D-3/DH-3/PDH-3

Every2 000ope rating hours

5.30 Changing hydraulic oil and breather filter

Note

i

See also chapter 5.1 "Notes on the hydraulic sys­tem".

!

Caution

Apart f rom t he normal oil change intervals, the
hydraulic oil must also be changed after m aj or
repairs in the hydraulic system.

Perform the oil change when the hydraulic oil
is warm.

Clean the area round h ydraulic oil tank, filler
opening and breather filter.

Do not use any detergents to clean the system.
Do not start the engine after draining th e hy-

draulic oil.
Replace the hydraulic oi l filter element with

every hydraulic oil change.

Every 2000 operating hours

Fig.97

l Unscrew the plug (Fig. 97) and drain of f all hy-

draulic oil.

l Check the seal ring, replace if neces sary and

turn the plug tigh tly back in.

! Danger

Dangerof scalding!
Dangerof scalding by hot oil.

Environment

Catch running out oil and dispose of environ­mentally.

Note

i

Generally replace the hydraulic oil f ilter element
after the test run.

Fig.98

l Remove the filler cap (Fig. 98).
l Fill in new hydraulic oil through the screen.

Note

i

We recomm end to use the filling and filtering unit
(BOMAG part-no. 079 930 35) with fine filter to fill
the hydraulic system. This en sure s finest filtration
of the hydraulic oil, prolongs the lifetime of the hy­draulic oil filter an d protects the hydraulic system.

l Check t he oil level in the inspection glass.

Nominal value:

approx. 3 cm below the upper edge of the inspec ­tion glass

BOMAG 71BW 145 D-3/DH-3/PDH-3

Every 2000 operating hours

For quality and quantity of oil r efer to the table of fuels and lub ricants.

Note

i

The brea ther filter 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.

5.31 Changing the hydraulic oil filter

!

Danger

Danger o f scalding!
There is a danger of scaldi ng by hot oil when

unscrewing the filter.

!

Caution

If the filter has to be ch anged t og ether with the
hydraulic oil, the filter should in any case be
changed after the oil change and the test run.

Do not use the oil in the filter bowl.

Environment

Catch running out oil, dispose of oil and filter
element environmentally.

Note

i

The filter el ement must be changed with every hy ­draulic oil change and after major repairs in the hy ­draulic system.

Fig. 99

l Unscrew the cap nut 4 (Fig. 99) and take th e

filter bowl (5) with the filter element (3) off.

l Examine the sealing face on the filter element

thoroughly for any visible dirt.

!

Caution

Visible impurities may be an early indicator for
afailure of system components and predict the

BOMAG72 BW 145 D-3/DH-3/PDH-3

possible malfunction of important parts. In
such a case you should perform trouble shoot­ing a nd replace or repair the defective compo­nents. Nonobservance may lead to total
damage of the hydraulic system.

Do not clean or reuse the filter element.

l Take the old filter element (3) out and clean

the filter bowl an d the thread.

l Reinstall the filter bo wl with the new filter ele-

ment, chec k the condition of the O-rings (1)
and (2), replace if necessary.

l After a test run check the filter for leaks.

Every 2000 operating hours

BOMAG 73BW 145 D-3/DH-3/PDH-3

Every 3000 operating hours

Every3 000ope ratinghour s

5.32 Checking the injection valves

Note

i

This work must only be performed by authorized
service personnel.

The inject ion valves must be repla ce d every
12000 operating hours.

BOMAG74 BW 145 D-3/DH-3/PDH-3

Every5 000ope rating hours

5.33 Replacing the toothed belt

!

Caution

The toothed belt must only be changed by a
specialist workshop or by the After Sal es Serv­ice of BOMAG.

Do not retension toothed belts, replace them
together with the i dler pulley.

Replace a toothed belt at the latest after 5
years, even if the number o f operating hours
has not yet been reached.

Every 5000 operating hours

Fig. 100

l Have the toothed belt (Fig. 100) replaced by a

specialist works hop.

BOMAG 75BW 145 D-3/DH-3/PDH-3

As required

Asrequir ed

5.34 Checking, cleaning, chang­ing the combustion air filter

!

Caution

Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter ele­ment.

Do not use gasoline or hot fluids to clean the
filter element.

After cleaning the filter element must b e in­spected for damage using a torch.

Air filter elements withdamaged paper bellows
or seal lips m ust be replaced in any case.

The main filter element must be repla ced after
3 times cleaning, but at the l atest after one
year, irrespective of the operating hours.

Each cleaning interval must be marked w ith a
cross on the cover of the filter element.

Cleaning does not make sense if the air filter
element is covered with a sooty deposit. Use a
new filterelement.

Incorrectly handled f ilter elements may be­come ineffective because of damage (e. g.:
cracks) and cause engine damage.

Note

i

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

Fig. 102

l Remove the maintenan ce cover (Fig. 102).

Fig. 101

Maintenance of the dry air filter is due when con­trol light “e” (Fi g. 101) in the multi-function display
lights permanent ly when the engine is running, but
at the latest af ter one year.

Fig. 103

l Release the locking hook (Fig. 103) and take

the filter hood off.

l Clean filter hood and dust discharge valve.

BOMAG76 BW 145 D-3/DH-3/PDH-3

As required

Fig. 104

l Carefully loosen the main filter element ( Fig.

104).

The main filterelement 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 orderto reducethe rele as ed amount of
dust. T o release the seal pull t he main filter ele­ment carefully up, down and sideways or turn it
(Fig. 104) .

!

Caution

Avoid contact between main filter element and
housing.

Fig. 105

l Pull the main filter element (Fig. 105) carefully

out of the housing.

Fig.106

l Clean the se aling face on the outlet tube (Fig.

106).

Dust on the outer diameter of the outlet t ube can
impair effective sealing.

l Check t he old main filter element.

The old main fi lter element can b e of help to dis­cover foreign particles o n the sealing face, which
could lead to leaks. A l ine of dus t 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 If the main filter element is damaged, the safe-

ty elem ent must be replaced as well.

l Clean or replace the main filter ele ment.

Note

i

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

l Examine the main f ilter elemen t thoroughly for

damage.

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

l If necessary use safety element s.

BOMAG 77BW 145 D-3/DH-3/PDH-3

As required

Fig. 107

l Insert the main filter el ement (Fig. 107).

The radial sealing area is located at the inside of
the open filter edge. Thiscritical sealing area mus t
be under slight tension after the filter has been in­stalled. In order to achieve a t ight seal apply pres­sure to the ou ter edge of the filter and not to the
moveable c ent re.

l Reinstallthe filter hood withthe dus t discharge

valve.

!

Caution

The dust discharge valve must point vertical ly
downwards.

Dry cleaning of the main filter element

!

Danger

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

Fig. 108

Note

i

Forcleaning purposesfit a tube to t he compressed
air gun (Fig. 108),the end of which should be bent
for approx . 90°.

The length should reach down to the bottom of the
element.

l Blow the main filter element out with com-

pressed air (max. 5 bar) from inside to outside
by moving the tube up and down inside the el­ement, unt il it if free of dust.

l Examine the main filter element with a torch

for cracks and holes in the paper bellows.

!

Caution

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

Changing the safety filter element

!

Caution

The safety filter e lement must not be cleaned
and should not be used again after it has been
removed.

The safety filter element must be replaced:
if the main filter element is defective,
after three times cleaning of the main filter ele-

ment,
at the latest after 2 years,

BOMAG78 BW 145 D-3/DH-3/PDH-3

As required

if the warning light com es on again after serv­icing the main filter cartridge.

l Remove the housing cover and pull the main

filter element off.

Fig. 109

l Pull the safety element (Fig. 109) out by turn-

ing it lightly.

l Push in a new safety filter element.
l Reassemble main filter element and cover.

5.35 Adjusting the parking brake

!

Caution

Have adjustment work on the brake performed
by a specialist! Always adjust both sides.

l Secure the machine with chocks against unin-

tentional rolling.

l Start the diesel engine to release the brake.

Fig.110

l Unlock the travel lever (Fig. 110) by pushing it

to the left, but do not actuate it to posit ion "I" or
"II".

The parking brake is released

Fig.111

l Unscrew t he locking plate 2 (Fig. 111).
l Turn the square ( 1) in anti-clockwise direction

against the end stop.

BOMAG 79BW 145 D-3/DH-3/PDH-3

As required

Fig. 112

l Toadjust the clearance turn the square 1 (Fig.

112) three revolutions back in clockwise direc ­tion.

l Screw the locking plate back on.
l Pull the plug off the brake valve and try to

drive.

5.36 Changing the tires

! Danger

Danger o f accident!
Observe all safety notes for the lifting of load s.

l Place a jack (m in. 5 t bearing c apacity) under

the rear frame and jack the machine up so that
the wheel can turn freely.

l Unscrew the wheel nuts and take the wheel

off.

The machine must be brak ed.

Fig. 113

l Attach the wheel ( Fig. 113) and tighten the

wheel nuts crosswise with 550 Nm (405 ft. lb.).

l Check the tire pressure, see technical data.

BOMAG80 BW 145 D-3/DH-3/PDH-3

As required

5.37 Adjusting the scrapers

smooth drum only

Fig. 114

l Check th e condition and adjustment of the

front an d rear scrapers, adjust or r eplace the
scraper rubber if necessary.

l To adjust the scrapers 1 (Fig. 114) loosen the

fastening screws (2) in the slots and push the
scraper brac ket towards the drum until the
scraper touches.

er towards t he drum, leaving a gap of approx.
25 mm.

l Retighten the fastening sc rews .

l Retighten the fastening screws.

padfoot drum only

Fig. 115

l Check condition and adjustment of scrapers 2

(Fig. 115), adjust or replace the t eeth if neces­sary.

l To adjust the scrapers (2) slacken the fasten-

ing screws (1) in the s lots and move t he s c r ap-

BOMAG 81BW 145 D-3/DH-3/PDH-3

As required

5.38 Changing the fresh air filter in the cabin

Fig. 116

l Remove the filter screen (Fig. 116) and take

the filter out.

l Insert a new filter and re as semble the filter

screen.

5.39 Tightening torques

Fig. 117

* Strength classes for screws with un treated, non­lubricated surfac e. The s c r ew quality is stamp ed
on the screw heads.

8.8 = 8G

10.9 = 10K

12.9 = 12K

l Axle - frame

M24 = 880Nm

l Wheel nuts

M 22x 1,5 = 550 Nm
The values result in a 90% utilization of the screws

yielding poin t at a coefficient of friction of µ tot. =
0,14. The tightening torques are not valid when us­ing MOS

i

Note

lubricants.

2

Self locking nuts must always be replaced after
they h av e been unscrewed.

BOMAG82 BW 145 D-3/DH-3/PDH-3

5.40 Engine conservation

If t he engine is to be shut d own for a longer period
of time (e.g. over winter), we recommend to apply
the following conserving measures to avoid corro­sion:

l Clean the engine, including the cooling sys-

tem: With cold cle ans ing agent and a water jet
or, even better, with a steam cleaner.

l Run the engine warm and shut it down.
l Drain off the s till hot engine oil and fill in anti-

corrosion engine oil.

l Drain off the coolant and fill in system protec-

tion agent.

l Drain the fuel from the tank, mix it w ell with

10% anti-corrosion oil and fill it back in.

l Run the engine for 10 m inutes until all lines, fil-

ters, pumps and nozzles with this conserv ing
mixture a nd the new engi ne oil has been dis­tributed to all parts.

As required

l Now crank the engine seve ral times (without

ignition) to spray the combus tion chambers.

l Take the V-belts off and spray the grooves of

the V-belts with anti-corrosion oil. Remove the
anti-corrosion oil before resuming operation.

l Close intake and exhaust openings tightly.

Note

i

Depending on the weather conditions these con­serving m eas ures will provide protec tion for ap­prox. 6 to 12 m onths.

Before taking the engine back into operation all
conserving oil must be drained offand replaced by
regular engine oil, see chapter "Fuels and Lubri­cants" according to the API-(MIL)-classification.

Anti-corrosion o ils are those that comp ly with
the specific ation MIL-L-21260 B or TL 9150­037/2 or Nato Code C 640/642.

A machine with a conserved engine must be marked by attaching a clearly visible warning tag.

BOMAG 83BW 145 D-3/DH-3/PDH-3

As required

BOMAG84 BW 145 D-3/DH-3/PDH-3

6 Trouble shooting

BOMAG 85BW 145 D-3/DH-3/PDH-3

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 o f 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 c annot locate the cause
of the fault or eliminate it yourself by following the
trouble shoot ing charts, y ou should contact our
customer service departments at our branch o ffice
or dealers.

!

Danger

Danger of injury!
Keep away from rotating parts of the engine.

BOMAG86 BW 145 D-3/DH-3/PDH-3

6.2 Engine

Faults Possible cause Remedy

Trouble shooting

The engine
does not start

The engine
startspoorlyand
worksirregularly
with poo r power

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.

Fuel lines leaking Check all line c onnections for leakages

Battery discharg ed or not connected Tighten the pole clamps, check the cable

Injection valves or injection pump defec­tive

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

Especially during winter: the use of too
viscous eng ine oil

Fuel supply restricted, in winter fuel sys­tem clogged due to paraffin separation

Change the filter. us e winter fu el

and tighten the fittings.

connections
Have exami ned by a specialist

Have the battery chec k ed, clean the ter­minal clamps , tighten them and cover
them with acid free grease

Use engine oil suitable for the ambient
temperature

Change the fuel filter. Check the line con­nections for leaks and t ighten the fittings.

Use winter fuel in the cold season.
Incorrect valve clearance Adjust the valve clearance
Injection valve defective Have examined by a specialist
Injection lines leaking Check the lines for leakages
Turbo charger defective Have examined by a specialist
Dry air filter dirty clean, replace if necessary
Excessive play in the throttle cable Adjust the throttle cable, change it if nec -

essary

BOMAG 87BW 145 D-3/DH-3/PDH-3

Trouble shooting

Faults Possible cause Remedy

Excessive ex­haust smok e

Engine over­heats, shut
down imm edi­ately!

Engine oil level too high Drain the oil to the upper dipstick mark
Dry air filter dirty clean, replace if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Poor compression due to burned or bro-

ken compression rings or incorrect valve
clearance

Incorrect valve clearance Adjust the valve clearance
Cooling fins on radiator extremely soiled

(thewarning light "engine oil temperature"
lights)

Injection valve defective Have examined by a specialist
Engine oil level too low Top up engine oil to the upper dipstick

Filling capacity of the injection pump not
correctly adjusted

Cooling air flow restricted Clean the cooling air duct
V-belt loos or broken Tension or replace th e V-belt

Have com pres s ion rings and pistons ex­amined by a specialist, adjust the valve
clearance

Clean th e cooling fins

mark
Have adjusted by a specialist

Poor engine
power

Engine oi l pres­sure too low

The charge con­trol light lights
during opera­tion,thewarning
buzzer sounds

Engine oil level too high Drain the engine oil down to the upperdip-

stick mark
Dry air filter dirty clean, change i f necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Charge a ir 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 lig ht "en-

gine oil pressure" li ghts, the warning
buzzer sounds)

Leakages in the lubri cation system Shuttheengine down im mediately,check

Generator speed too low Check the V-belt tension, replac e the V-

The generator does not charge the bat­tery, be ca us e generator or regulator is de­fective

Topupoil

fittings on oil lines, lubricat ion oil filter and

oil cooler for leaks, if necessary tight en

the fittings.

belt if necessary

Have exam ined by a spec ialis

BOMAG88 BW 145 D-3/DH-3/PDH-3

Trouble shooting

BOMAG 89BW 145 D-3/DH-3/PDH-3

Trouble shooting

BOMAG90 BW 145 D-3/DH-3/PDH-3