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SYMBOLS USED IN THIS MANUAL The following symbols have been used in THIS Manual to help communicate the intent of instructions. When one of the symbols appears, it conveys the meaning defined below: Serious personal injury, death, and/or Serious personal injury and/or extensive extensive property damage can result property damage can result if the if the DANGER instructions are not...
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BOMAG machines are products from the wide range Always keep this manual close at hand, e.g. in the of BOMAG compaction equipment. tool compartment of the machine or in a specially provided container. These operating and maintenance BOMAG’s vast experience in connection with state- instructions are part of the machine.
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Please fill in ......................Machinetype(Fig. 1) ......................Serial No. (Fig. 1 and 2) ......................Engine type (Fig. 3) Fig. 1 ......................Engine No. (Fig. 3) Note: Fill in the above listed data when receiving the machine. Upon receipt of the machine our organization will instruct you about correct operation and maintenance.
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Table of Contents Technical Data Section 1 Safety Regulations Section 2 Indicators and Controls Section 3 Operation Section 4 Maintenance Section 5 Trouble Shooting Section 6...
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Section 1 TECHNICAL DATA TABLE OF CONTENTS PAGE TEChNiCAL DATA �������������������������������������������������������������������������������������������������������������������������� 2 4-2012...
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Section 1 TECHNICAL DATA Fig. 4 Dimensions in mm (in) BW 177D-50 2500 1816 1228 2225 2860 4913 1686 (98.4) (71.5) (48.3) (87.6) (112.6) (14.7) (193.4) (2.6) (2.6) (1.0) (66.4) BW 177 D-50 Weights Operating weight (CECE) with kg(lbs) 6965 (15,355) ROPS with Cabin kg(lbs)
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Section 1 TECHNICAL DATA BW 177 D-50 Electrical equipment Drive system hydrostatic Driven axles Brakes Service brake hydrostatic Parking brake hydr.-mech. Steering Type of steering articulated Steering operation hydrostatic Vibration Vibrating drum Drive system hydrostatic Frequency Hz (VPM) 30/40 (1,800/2,400) Amplitude mm (in) 1,8/0,9 (.071/.035)
Section 2 SAFTEY REGULATIONS tABlE of contEntS PAGE GEnErAl ��������������������������������������������������������������������������������������������������������������������������������������� 3 loAdinG thE mAchinE �������������������������������������������������������������������������������������������������������������� 4 towinG thE mAchinE ��������������������������������������������������������������������������������������������������������������� 4 StArtinG thE mAchinE ������������������������������������������������������������������������������������������������������������� 4 BEforE StArtinG �������������������������������������������������������������������������������������������������������������������� 4 StArtinG �������������������������������������������������������������������������������������������������������������������������������� 5 StArtinG with jumP lEAdS ����������������������������������������������������������������������������������������������� 5 StArtinG in cloSEd roomS ���������������������������������������������������������������������������������������������� 5 drivinG thE mAchinE ���������������������������������������������������������������������������������������������������������������...
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Section 2 SAFTEY REGULATIONS workinG on whEElS And tirES ��������������������������������������������������������������������������������������������� 8 clEAninG ������������������������������������������������������������������������������������������������������������������������������������� 8 AftEr mAintEnAncE work ����������������������������������������������������������������������������������������������������� 8 rEPAir ������������������������������������������������������������������������������������������������������������������������������������������� 8 tESt ����������������������������������������������������������������������������������������������������������������������������������������������� 8 4-2012...
Section 2 SAFTEY REGULATIONS General unintended use this BomAG machine is built in accordance with Dangers may, however, arise from the machine if it is the latest technical standard and the valid technical used by untrained personnel in an unprofessional way rules and regulations�...
Section 2 SAFTEY REGULATIONS Sections marked like this point out towing the machine possible dangers for the machine or for Since the machine is notfitted with a towing hitch, the parts of the machine� machine cannot be towed with a tow bar. Note: Sections marked like this provide If the machine has to be towed urgently out of the danger technical information concerning the...
Section 2 SAFTEY REGULATIONS driving the machine the machine is free of any oily and combustible • material Persons in the endangered area all handrails, steps and platforms are free of • If the machine has turned over and the cabin door grease, oils, fuels, dirt, snow and ice is jammed, use the right hand cabin window as an the engine compartment hood is closed and...
Section 2 SAFTEY REGULATIONS Do not work with vibration on hard concrete, on a cured Always secure parked machines, which could be in the concrete layer or heavily frozen ground. way, with appropriate measures. When passing under flyovers, bridges, tunnels, electric Parking on slopes and gradients power lines etc.
Section 2 SAFTEY REGULATIONS working on hydraulic lines Do not mix up hoses by mistake. • Always relieve the pressure in the hydraulic circuit damage or deformation of the fitting, which • before working on hydraulic lines. Hydraulic oil escaping impairs the function and strength of the hose/ under pressure may penetrate through the skin and hose connection.
Section 2 SAFTEY REGULATIONS cleaning Do not let acid come in contact with skin and clothes. If being injured by acid flush off with clear water and Do not clean the machine while the engine is running. seek for medical advice. Do not use gasoline or other combustible substances Metal objects (e.g.
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Section 3 INDICATORS AND CONTROLS TABLE OF CONTENTS PAGE GENErAL NOTES ��������������������������������������������������������������������������������������������������������������������������� 4 DESCriPTiON OF iNDiCATOrS AND CONTrOL ELEmENTS������������������������������������������������������ 4 4-2012...
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Section 3 INDICATORS AND CONTROLS Fig. 6 4-2012...
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Section 3 INDICATORS AND CONTROLS Ignition switch 11 Warring light “ASC” Anti-Spin-Control Instrument cluster 12 Rotary switch for direction indicators left/right Vent for heating and ventilation, driver 13 Rotary switch for hazard light system Vent for heating and ventilation, footwell 14 Rotary switch for lighting (StVZO) Push button vibration 15 Rotary switch for working lights...
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Section 3 INDICATORS AND CONTROLS Description of indicators and control General notes elements Please read this section thoroughly before operating this machine if you are not yet conversant with the indicators and control elements. All functions are described in detail hereunder. Paragraph 4 Operation contains only concise descriptions of the individual operating steps.
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Section 3 INDICATORS AND CONTROLS i yellow = Water separator in fuel pre- cleaner. Lights when the water proportion in the fuel filter reaches the contacts. j red = N/A k yellow = Glow Plugs indicator lights when temperature is low (pre-heating for starting) l red = Hazard light*, flashes when the...
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Section 3 INDICATORS AND CONTROLS Fig. 9 Fig. 11 No� 5 = Push button for vibration No� 7 = rotary switch for vibration Select or actuate the frequencies with the • vibration selector switch. Position = Vibration off “middle” Switch the vibration on or off by pressing the •...
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Section 3 INDICATORS AND CONTROLS Fig. 14 Fig. 12 No� 9 = Emergency stop switch No� 8 = rotary Switch for speed range The engine will be shut down and the brake will close. selection BW177 D-50 Danger of accident! Position “turtle”...
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Section 3 INDICATORS AND CONTROLS Fig. 15 Fig. 17 No� 10 = Push button for warning horn No� 14 = rotary switch for light system (StVZO)* Position “Left” = Light off Position = Sidelights on, with ignition “Middle” switch in position “I” or “P” Position “Right”...
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Section 3 INDICATORS AND CONTROLS Always drive and vibrate with max� engine speed! Control the travel speed with the travel lever� Fig. 19 No� 16 = Lever, steering wheel adjustment * Danger of accident! Do not adjust the steering wheel while Fig.
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Section 3 INDICATORS AND CONTROLS Fire hazard! Do not use fuses with higher ampere ratings and do not bridge fuses� (1), 15A = (F43) wiper/washer, rear* (2), 15A = (F44) wiper/washer, front* (3), 10A = (F130) relay for rear windscreen heating, reading light* (4), 25A = (F31) cabin fan*...
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Section 3 INDICATORS AND CONTROLS Fig. 31 No� 25 = main fuse for battery and Grid Heater 125A = (F00) Main Fuse (Inner Fuse) 125A = (F48) Glow Plugs (Outer Fuse) Note: Battery with main fuse is located on the side of the BW177-50 Fig.
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Section 4 OPERATION TABLE OF CONTENTS PAGE GENErAL NOTES ��������������������������������������������������������������������������������������������������������������������������� 3 TESTS BEFOrE STArTiNG TO OPErATE �������������������������������������������������������������������������������������� 3 STArTiNG ThE ENGiNE ����������������������������������������������������������������������������������������������������������������� 5 STArTiNG wiTh jumP wirES ������������������������������������������������������������������������������������������������������ 7 DriviNG ThE mAChiNE ���������������������������������������������������������������������������������������������������������������� 7 SwiTChiNG ThE viBrATiON ON AND OFF ��������������������������������������������������������������������������������� 9 SwiTCh ThE viBrATiON ON ���������������������������������������������������������������������������������������������������...
Section 4 OPERATION General notes Tests before starting to operate Please read section 3 Indicators and Control Elements The following tests must be performed before each thoroughly before operating the machine if you are work day or before a longer work period. not yet fully familiar with the indicators and control Danger of accident! elements of the machine.
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Section 4 OPERATION Adjust the scrapers if necessary • Tire pressure. Pressure see technical data. • Ensure equal pressure in both tires� 4-2012...
Section 4 OPERATION Starting the engine Danger of accident! Always wear your seat belt� Fig. 35 Check, whether the emergency stop switch (Fig. • 35) is unlocked. Fig. 33 Check, whether the travel lever (Fig. 33) is • engaged to the right in brake position. Fig.
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Section 4 OPERATION Fig. 39 Fig. 38 Five [5] position switch is used to start engine and turn All control and warning lights (Fig. 38) in the fault electrical systems off. (Fig 39) monitoring board light up for a moment. Turn the ignition key to position “III”...
Section 4 OPERATION Starting with jump wires Driving the machine Danger of accident! wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes� Soil conditions and weather influences impair the gradability of the machine� Do not drive up and down inclinations exceeding the maximum gradability of the machine (see technical data)�...
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Section 4 OPERATION Fig. 41 Fig. 44 Close the cabin door (Fig. 41). Select the desired travel speed range (Fig. 44). • • BW177 DH/PDH-50 Fig. 42 Fig. 45 Fasten your seat belt (Fig. 42). • Turn the rotary switch (Fig. 45) to “Max” position •...
Section 4 OPERATION NOTE: Shift the travel lever out of “0”- position Switching the vibration on and off slowly to forward or reverse, the machine will drive forward or reverse at a speed risk of damage! which corresponds with the displacement when compacting with vibration of the travel lever�...
Section 4 OPERATION Pre-selecting the vibration Fig. 51 Press the push button (Fig. 51) in the travel lever • Fig. 49 while driving, the drum will vibrate. Pre-select amplitude/frequency with the rotary • Switching the vibration off switch (Fig. 49). Switch the vibration on Press the push button again and after work •...
Section 4 OPERATION The machine is automatically braked by the hydrostatic Operating the parking brake, stopping the drive and parking brake closes. machine NOTE: The parking brake also closes automatically when shutting the engine down� Fig. 52 Return the travel lever (Fig. 52) slowly to “neutral” •...
Section 4 OPERATION Shutting the engine down Straighten the articulated joint to provide easier access to the machine� Fig. 55 Turn the ignition switch (Fig. 55) to position “0” • or “P” and pull the ignition key out. NOTE: The parking brake closes automatically Fig.
Section 4 OPERATION Emergency exit Adjusting the steering wheel* If the machine should turn over and the cabin door is closed, the right hand side cabin window can be used as an emergency exit. Fig. 56 Adjustment of steering wheel in height, pull lever •...
Section 4 OPERATION Adjusting the seat Adjusting the optional seat * Danger of accident! Do not adjust the seat while driving� Fig. 58 To adjust the seat in longitudinal direction dis- • Fig. 57 engage lever e (Fig. 58) upwards and push the seat forward or back.
Section 4 OPERATION Operating the hood Danger of accident! if the hood needs to be opened further for maintenance or repair work, support it safely� Bottom position Fig. 62 Pull the spring pin (Fig. 62) out of the bracket. • Secure the hood in the protection tube with •...
Section 4 OPERATION Towing in case of an engine failure Bw177 D-50 Secure the machine with wheel chocks against unintentional rolling� Danger of accident! when using towing ropes tow the machine only uphill� when towing downhill you must use a rigid towing device�...
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Section 4 OPERATION Fig. 66 Remove plug 1 (Fig. 66). • Place an U-section (4) across the brake housing • (2) and turn the screw (5) into the tapped bore (3), untilit bottoms. Turn the nut (6) down and tightenit approx. one •...
Section 4 OPERATION Towing in case of an engine failure Bw177 Dh/PDh-50 Secure the machine with wheel chocks against unintentional rolling� Danger of accident! when using towing ropes tow the machine only uphill� when towing downhill you must use a rigid towing device�...
Section 4 OPERATION Fig. 74 Fig. 72 Unscrew the brake releasing screws (Fig. 74) for • Press the emergency operation button (Fig. 72) • two turns and tighten the counter nuts. completely down. Repeat this adjustment procedure on the • NOTE: use a suitable pipe�...
Section 4 OPERATION Transport 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�...
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Section 4 OPERATION Operating the optional Dozer Blade * Do not use the dozer blade to transport per-sons� Danger to life! moving other vehicles with the dozer blade is prohibited! NOTE: Always lower the dozer blade to the ground before shutting the engine down� Dozer Blade inoperable at low idle�...
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Section 5 MAINTENANCE TABLE OF CONTENTS PAGE GENErAL NOTES ON mAiNTENANCE ����������������������������������������������������������������������������������������� 5 NOTES ON ThE FuEL SySTEm �������������������������������������������������������������������������������������������������� 5 NOTES ON ThE ENGiNE PErFOrmANCE ��������������������������������������������������������������������������������� 5 NOTES ON ThE hydrAuLiC SySTEm �������������������������������������������������������������������������������������� 5 NOTES ON ThE COOLiNG SySTEm ������������������������������������������������������������������������������������������� 6 FuELS ANd LuBriCANTS �������������������������������������������������������������������������������������������������������������...
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Section 5 MAINTENANCE ChECkiNG ThE COOLANT LEvEL ���������������������������������������������������������������������������������������������� 16 ChECkiNG ThE hydrAuLiC OiL LEvEL ������������������������������������������������������������������������������������ 16 ChECkINg ThE V-bElT ������������������������������������������������������������������������������������������������������ 17 ChECkiNG ThE TirE PrESSurE ������������������������������������������������������������������������������������������������� 17 AdjuSTiNG ThE SCrAPErS ������������������������������������������������������������������������������������������������������� 18 ChANGiNG ENGiNE OiL ANd OiL FiLTEr CArTridGES ���������������������������������������������������������� 19 CLEAN ThE COOLiNG FiNS ON ENGiNE ANd hydrAuLiC OiL COOLEr �������������������������������...
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Section 5 MAINTENANCE rETiGhTEN ThE FASTENiNG OF ThE AxLE ON ThE FrAmE ��������������������������������������������������� 34 TiGhTENiNG ThE WhEEL NuTS ������������������������������������������������������������������������������������������������� 35 ChECkiNG ThE rOPS ������������������������������������������������������������������������������������������������������������������ 35 ChECkiNG, AdjuSTiNG ThE vALvE CLEArANCE �������������������������������������������������������������������� 36 ChANGiNG ThE hydrAuLiC OiL ANd ThE BrEAThEr FiLTEr ���������������������������������������������� 39 ChANGiNG ThE hydrAuLiC OiL FiLTEr ����������������������������������������������������������������������������������...
Section 5 MAINTENANCE General notes on maintenance When servicing the machine pay careful attention to Do not draw off fuel from near the bottom of the • all applicable safety instructions. fuel drum. Fuel left in the fuel drum is not suitable for the •...
Section 5 MAINTENANCE Notes on the cooling system Fuels and lubricants On water cooled engines the preparation and Engine oil monitoring of the coolant is of utmost importance, as otherwise engine failures caused by corrosion, caviation Oil quality and freezing may occur. Lubrication oils are classified according to their The coolant is a mixture of water and a cooling system performance and quality class.
Section 5 MAINTENANCE Fuels Fuel quality You should only use commercially available brand diesel fuel with a sulphur content below 0.5% (5000 ppm) and ensure strict cleanliness when filling in. Use only winter-grade diesel fuel under low ambient temperatures. The fuel level should always be topped up in due time so that the fuel tank is never run dry, as otherwise filter and injection lines need to be bled.
Section 5 MAINTENANCE hydraulic oil In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel additives. The hydraulic system is operated with hydraulic oil HV Consult the engine manufacturer. 46 (ISO) with a kinematic viscosity of 46 mm2/s (cSt) Biodiesel at 40°C.
Section 5 MAINTENANCE Coolant, anti-freeze agent The concentration of cooling system protection agent must be checked with Use only soft tap water (drinking water) to prepare the a refractometer (Fleetguard part-no� coolant mix. C2800)� Other measuring equipment is not suitable for high-performance As a protection against frost, corrosion and boiling diesel engines�...
Section 5 MAINTENANCE Table of fuels and lubricants Assembly Fuel or lubricant quantity approx� Summer Winter Attention: Observe the level marks Engine Engine oil approx. 8.5 litres, (9.0 qt) without oil filter API CH-4/SJ, CI-4/SK ACEA: E5,E7 SAE 10W/40 -4°F to +104°F (-20 °C to +40 °C) SAE 15W/40 +5°F to +104°F...
Section 5 MAINTENANCE running-in instructions The following maintenance work must be performed when running in new machines or overhauled engines: up to approx� 250 operating hours check the engine oil level twice every day� depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx�...
Section 5 MAINTENANCE maintenance chart With all maintenance intervals perform also the work for shorter preceding service intervals. designation Note Every 10 operating hours Check the engine oil level Dipstick mark Checking, cleaning the water separator Check the fuel level Check the coolant level Check the hydraulic oil level Inspection glass...
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Section 5 MAINTENANCE Designation Note Every 1000 operating hours Change the oil in the drive axle min. 1x per year Change the oil in the planetary gears min. 1x per year Changing the oil in the drum drive gear DH and PDH machines, at least 1x per year min.
Section 5 MAINTENANCE Check the engine oil level Check, clean the water separator NOTE: The machine must stand on level ground� danger of injury! Shut the engine down and wait for Support the engine hood for all approx� 15 minutes until all oil has run maintenance and repair work�...
Section 5 MAINTENANCE Co n t a m i n a t e d f u e l c a n c a u s e Checking the fuel level malfunction or even damage of the engine� Fire hazard! if necessary fill in fuel through a screen When working on the fuel system do not use open fire, do not smoke, do not filter�...
Section 5 MAINTENANCE Checking the coolant level Checking the hydraulic oil level danger of scalding! in hydraulic systems filled with hv68 (TdhType) always use the same oil to Never remove the cap from the top up� compensation tank when the engine is hot�...
Section 5 MAINTENANCE Checking the v-belt Checking the tire pressure Since the tires are filled with water, you should always turn the inflation valve to top position to check the tire pressure! Always close the valves with the dust cap� Fig.
Section 5 MAINTENANCE Adjusting the scrapers smooth drum only padfoot drum only (.984in) Fig. 102 Fig. 103 Check the condition and adjustment of the front Check condition and adjustment of scrapers 2 • • and rear scrapers, adjust or replace the scraper (Fig.
Section 5 MAINTENANCE Changing engine oil and oil filter cartridges The oil change at 500 operating hours refers to the use of fuels with a sulphur content of less than 0�5%� When using fuels with a sulphur content higher than 0�5 % the oil change intervals must be halved (see section fuels and lubricants)�...
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Section 5 MAINTENANCE Fig. 107 Fig. 109 Turn the new filter cartridge (Fig. 107) on by Check the oil level again (Fig. 109), if necessary fill • • hand, until the seal contacts. up to the Max.-mark. Tighten the filter element for another half turn. •...
Section 5 MAINTENANCE Cleaning with cold cleansing agent Clean the cooling fins on engine and hydraulic oil cooler Protect electrical equipment such as generator, regulator and starter against danger of injury! the direct water jet� Perform cleaning work only after the engine has cooled down and with the Spray the engine with a suitable cleansing agent, •...
Section 5 MAINTENANCE Check the oil level in the drive axle Checking the oil level in the left/right hand planetary drives Fig. 111 Fig. 112 Unscrew the oil level inspection plug (Fig. 111) • and check the oil level. Drive the machine, until both plugs 1 (Fig. 112) •...
Section 5 MAINTENANCE Checking the oil level in the Checking the oil level in the vibration bearing drum drive gear Only dh and Pdh machines Fig. 113 Drive the machine until the oil level control plug • Fig. 114 1 (Fig. 113) is vertically below the hub. Move the machine until one plug 1 (Fig.
Section 5 MAINTENANCE Exhausted batteries (batteries with Service the battery formation of suphate on the plates are danger of cauterisation! danger of not covered under warranty! explosion! When working on the battery do not use Remove the four screws holding the cover to •...
Section 5 MAINTENANCE draining the fuel tank sludge 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�...
Section 5 MAINTENANCE Change the fuel filter cartridge Fire hazard! When working 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�...
Section 5 MAINTENANCE Change the fuel pre-filter cartridge Fire hazard! When working 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�...
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Section 5 MAINTENANCE Cooling Fan V-belt, Removal and Installation Fig. 125 Install the drive belt • Using a breaker bar, raise the alternator on Fig. 123 the adjustment bar (1), and adjust the fan belt tension to specifications. Remove the drive bet by loosening the alternator •...
Section 5 MAINTENANCE Tensioning the v-belt Check condition and tension of refrigerant (optional) compressor v-belt, replace the v-belt danger of injury! Work on the v-belt must only be performed with the engine shut down� Checking the v-belt Fig. 128 Slightly slacken the fastening screws 1, 2 and 3 •...
Section 5 MAINTENANCE Change the oil in the drive axle NOTE: On other axle versions drain and filler plugs are of slightly different design� Perform the oil change accordingly� drain oil only at operating temperature� Environment Fig. 130 Catch old oil and dispose of environmentally� Fill in oil through the oil level inspection bores •...
Section 5 MAINTENANCE Change the oil in the planetary drive drain the oil only at operating temperature� Change the oil on both sides of the axle� Environment Catch the old oil and dispose of environmetally� Fig. 132 Move the drive wheel until the plug (Fig. 132) in •...
Section 5 MAINTENANCE For quality and quantity of oil refer to the table of Change the oil in the drum drive gear fuels and lubricants� Only dh and Pdh machines Turn filler plug (2) and drain and level inspection • plug (1) tightly back in.
Section 5 MAINTENANCE For quality and quantity of oil refer to the table of Changing the oil in the vibration bearings fuels and lubricants� Fit oil level control plug (1) and drain and filler • plug (2) with new sealing rings and screw them back in.
Section 5 MAINTENANCE Checking the fastening elements retighten the fastening of the axle on the on the engine frame Fig. 138 Fig. 137 Check all fastening nuts on axle mounting bolts • Check the fastening of air intake and exhaust (Fig.
Section 5 MAINTENANCE Tightening the wheel nuts Checking the rOPS NOTE: On machines with a fitted cabin the rOPS (roll Over Protection Structure) is integrated in the cabin� Please observe also the respective section in the safety regulations in this manual� Fig.
Section 5 MAINTENANCE Checking, adjusting the valve clearance Before checking the valve clearance let the engine cool down for at least 30 minutes� The engine temperature should be lower than 60 °C� Remove the air filter. • Fig. 143 Removing the Rocker Lever Cover Remove the •...
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Section 5 MAINTENANCE Fig. 145 Fig. 147 Overhead Set Adjustment Adjust intake and exhaust clearances in the • • Rotate the crankshaft in the normal direction following firing order by rotating the crankshaft (Clockwise)� 180 degrees clockwise (1-2-4-3 firing order) or Check the movement of the intake valve number use the following procedure to adjust in two 4 cylinder.
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Section 5 MAINTENANCE Fig. 149 Fig. 151 Tighten the locknut to secure the adjustment Tighten the locknut to secure the adjustment • • screw. screw. Locknut Torque value Locknut Torque value N•m ft-lb N•m ft-lb Fig. 150 Fig. 152 Rotate the crankshaft in the normal direction one Reinstalling the rocker lever cover.
Section 5 MAINTENANCE Changing the hydraulic oil and the breather filter NOTE: See also section “Notes on the hydraulic System”� Apart from the normal oil change intervals the hydraulic oil must also be changed after major repairs in the hydraulic system� Change the hydraulic oil only at operating temperature�...
Section 5 MAINTENANCE For quality and quantity of oil refer to the table of Changing the hydraulic oil filter fuels and lubricants� danger of scalding! NOTE: The breather filter for the hydraulic tank is There is a danger of scalding by hot oil located in the filler cap and must therefore when unscrewing the filter�...
Section 5 MAINTENANCE Take the old filter element (3) out and clean the • Changing the coolant filter bowl and the thread. danger of scalding! Reinstall the filter bowl with the new filter • Change the coolant only when the element, check the condition of the O-rings (1) engine is cold�...
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Section 5 MAINTENANCE Fig. 158 Unscrew the cap and fill in coolant up to the • MAX-mark. (Fig. 158) For quality of coolant refer to the chapter, fuels and lubricants� Start the diesel engine and run it warm to • operating temperature.
Section 5 MAINTENANCE Maintenance of the dry air filter is due when indicated Cleaning, changing the by the Air filter restriction indicator located on the side dry air filter cartridge of the engine. (Fig. 159) Maintenance of the Air filter must minimally occur after one year.
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Section 5 MAINTENANCE Fig. 162 Fig. 163 Pull out the main filter element (Fig. 162) with Blow the filter cartridge out from inside to • • light turning movements. outside with dry compressed air (max. 5 bar) (Fig. 163), until all dust has been removed. Cleaning the main filter element if necessary, the main filter element may be cleaned up to five times�...
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Section 5 MAINTENANCE Cleaning the dust bowl Remove the housing cover and pull the main • filter element off. Fig. 165 Fig. 166 Pull the internal part (Fig. 165) out and remove • the dust from the cover. Pull the safety element (Fig. 166) out by slight •...
Section 5 MAINTENANCE Adjusting the parking brake have adjustment work on the brake performed by a specialist! Always adjust both sides� Secure the machine with chocks against • unintentional rolling. Start the diesel engine to release the brake. • Fig. 169 To adjust the clearance turn the square 1 •...
Section 5 MAINTENANCE Changing the tires Changing the fresh air filter in the cabin danger of accident! Observe all safety notes for the lifting of loads� Place a jack (min. 5 t bearing capacity) under the • rear frame and jack the machine up so that the wheel can turn freely.
Section 5 MAINTENANCE Tightening torques Engine conservation If the engine is to be shut down for a longer period of BOLT TIGHTENING TORQUE time (e.g. over winter), we recommend to apply the DIMENSIONS FT. LBS. / N•m following conserving measures to avoid corrosion: 10.9 12.9 Clean the engine, including the cooling system:...
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Section 6 TROUBLE SHOOTING TABLE OF CONTENTS PAGE GENErAL NOTES ��������������������������������������������������������������������������������������������������������������������������� 2 ENGiNE ������������������������������������������������������������������������������������������������������������������������������������������� 3 OPTiONAL PAd FOOT/SmOOTh ShELL KiT mAiNTENANCE ��������������������������������������������������� 5 4-2012...
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Section 6 TROUBLE SHOOTING General notes The following work must only be carried out by qualified and trained personnel or by the sales service� Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions� Faults occur frequently due to the fact, that the machine has not been properly operated or serviced.
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Section 6 TROUBLE SHOOTING Engine Faults Possible cause Remedy The engine does Starter defective or pinion not engaging Have examined by a specialist not start Fuel tank empty Fill and bleed the tank Temperature below starting limit Use winter fuel and engine oil acc. to the ambient temperature.
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Section 6 TROUBLE SHOOTING Faults Possible cause Remedy Excessive Engine oil level too high Drain the oil to the upper dipstick mark exhaust smoke Dry air filter dirty Clean, replace if necessary Exhaust gas turbocharger defective Have examined by a specialist Poor compression due to burned or broken Have compression rings and pistons compression rings or incorrect valve...
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Section 6 TROUBLE SHOOTING Smooth shell kit Optional Pad foot/Smooth Shell Kit maintenance Units equipped with the optional Pad foot or Smooth shell kit requires maintenance� Failure to perform required maintenance will result in a shorten equipment life cycle and the voiding of the warranty�...