BOMAG - machines are products from the wide
F oreword
product range of BOMAG compaction equip-
ment.
The vast experience of BOMAG as well as most
modern production and testing methods, e.g.
lifetime tests of all important components and
most stringent quaolity demands ensure high-
est reliability of your machine.
This manual comprises:
l Safety regulations
l Operating instructions
l Maintenance instructions
l Trouble shooting
Using these instructions will
l help you become acquainted with the ma-
chine.
l avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
l increase the reliability of the machine on the
construction site,
l prolong the lifetime of the machine,
l avoid repair costs and downtime.
BOMAG will not assume liability for the correct
function of the machine
l if it is handled in a way which does not comply
with the usual mode of operation,
l if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of
l operating errors,
l insufficient maintenance and
l incorrect fuels and lubricants.
Please note!
These instructions were written for the operator
and the service man on the construction site.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in the contain-
er provided for this purpose. These operating and
maintenance instructions are part of the machine.
BW 124 DH-3/PDH-3
Only operate the machine after you have been
properly instructed and by observing these in-
structions.
Please observe strictly the safety regulations.
Please observe also the guidelines of the civil en-
gineering liability association "Safety Rules for the
Operation of Road Rollers and Soil Compactors"
and the applicable instructions for the prevention
of accidents.
For your own safety you should only use gen-
uine BOMAG spare parts.
In the course of technical development we re-
serve the right for modifications without prior
notification.
These operating and maintenance instructions are
also available in other languages.
You can obtain the spare parts catalogue fromyour
BOMAG dealer against the serial number of your
machine.
You can also obtain information about the correct
use of your machine in earth and asphalt construc-
tion from your BOMAG dealer.
The information in this manual does not extent or
replace the warranty and liability conditions in the
general terms of business of BOMAG.
We wish you much success with your BOMAG
machine.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
Please fill in
............................
Machine type (Fig. 1)
............................
Serial-number (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine number (Fig. 3)

i Note Fig. 1
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!

Fig. 2

Fig. 3

BW 124 DH-3/PDH-3
 Table of Contents

BW 124 DH-3/PDH-3
Table of Contents

BW 124 DH-3/PDH-3
 1 Technical Data

BW 124 DH-3/PDH-3
Fig. 4

Dimensions in A B D H H2 K L1 O1 O2 S W
mm
BW 124 DH-3 1805 1310 960 1805 2400 320 3350 55 55 15 1200
BW 124 PDH3 1805 1310 960 1805 2400 320 3350 55 55 15 1200
BW 124 PDB3 1805 1310 960 1805 2400 320 3900 55 55 15 1200

*
BW 124 DH-3 BW 124 PDH-3 BW 124 PDB-3

Weights without dozer

blade
Operating weight (CECE) kg 3300 3350 3650
with ROPS
Front axle load (CECE) kg 1600 1650 1950
Rear axle load (CECE) kg 1700 1700 1700
Static linear load kg/cm 13,3 - -

Travel characteristics
Travel speed (1) km/h 0 ... 9 0 ... 9 0 ... 9
Max. gradability with vi- % 55 55 55
bration

Drive
Engine manufacturer Deutz Deutz Deutz
Type F3L 2011 F3L 2011 F3L 2011
Cooling Air/oil Air/oil Air/oil
Number of cylinders 3 3 3
Rated power ISO 9249 kW 33 33 33
Rated speed rpm 2500 2500 2500
Fuel Diesel Diesel Diesel

BW 124 DH-3/PDH-3
* BW 124 DH-3 BW 124 PDH-3 BW 124 PDB-3
Electrical equipment V 12 12 12
Drive system hydrostatic hydrostatic hydrostatic
Driven axles 2 2 2

Brakes
Service brake hydrostatic hydrostatic hydrostatic
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 41 41 41
Amplitude mm 1,7/0,85 1,6/0,80 1,6/0,80

Tires
Tire size 9.5-24 4PR AWR TT 9.5-24 STR 9.5-24 STR
Air pressure bar 1,8 1,8 1,8

Tank contents
Hydraulic oil Litres 35 35 35
Fuel Litres 60 60 60
Engine oil Litres 5,5 5,5 5,5
* The right for technical modifications remains reserved

BW 124 DH-3/PDH-3
The following noise and vibration values according to the EC-directive for machines, edition (91/368/
EEC) were measured at nominal engine speed and with the vibration switched on. The machine was
standing on an elastic base.

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

Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is

sound pressure level at the work place of the operator (with protection canopy):
LpA = BW 124 DH-3 86,9 dB(A)
LpA = BW 124 PDH-3 86,8 dB(A)

sound capacity level:

LwA = BW 124 DH-3 103,3 dB(A)
LwA = BW 124 PDH-3 103,2 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 6081
for sound pressure level (LpA) at the place of the operator.

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

Vibration of the entire boy (driver’s seat)

The weighted effective acceleration value determined according to ISO 2631 part 1, is ≤0,5 m/sec2.

Hand-arm vibration values

The weighted effective acceleration value determined according to ISO 8662 part 1, is ≤2,5 m/sec2.

BW 124 DH-3/PDH-3
 2 Safety regulations

BW 124 DH-3/PDH-3
General
This BOMAG machine is built in accordance
with the latest technical standard and the valid
technical rules and regulations. There is, how-
ever, a risk of danger for persons and property
if:
l the machine is used for purposes other than
those it is intended for
l the machine is operated by untrained person-
nel
l the machine is modified or converted in an un-
professional way
l the applicable safety regulations are not ob-
served.
Each person involved in operation, mainte-
nance and repair of the machine must there-
fore read and apply these safety regulations.
This should be confirmed by obtaining the sig-
natures of the customer, if necessary.
Furthermore the following regulations and instruc-
tions are obviously also valid:
l applicable accident prevention instructions
l generally acknowledged safety and road traffic
regulations
l country specific safety regulations. It is the
duty of the operator to know and observe
these regulations. This applies also for local
regulations and the regulations for various
types of manual work. If the recommendations
in this manual differ from the regulations valid
in your country, you must strictly observe the
regulations in your country.
Intended use
This machine must only be used for:
l compaction of bituminous material, e.g. road
surface layers (only AC and AD machines)
l light and medium compaction work in earth
construction (road sub-bases)
l you should only operate the machine with fully
functional safety equipment
l have the machine inspected by an expert once
every year
Unintended use
Dangers may, however, arise from the machine if
it is used by untrained personnel in an unprofes-
sional way or if it is used for purposes other than
those mentioned in these instructions.
Do not work with vibration on hard concrete, on a
cured concrete layer or heavily frozen ground.
Starting and operation of the machine in an explo-
sive environment is prohibited.
Who is allowed to work with the ma-
chine?
The machine must only be operated by trained
and authorized persons which are at least 18
years of age. The responsibilities for the operation
of the machine must be clearly specified and com-
plied with.
Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
the machine.
Maintenance and repair tasks require specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Conversions and alterations to the ma-
chine
Unauthorized conversions to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
pressly clear that we have not tested or authorized
any original parts or special equipment not sup-
plied by us. The installation and/or use of such
products can impair the active and/or passive driv-
ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
Safety notes in the operating and main-
tenance instructions:
Danger
Sections marked like this point out possible
dangers for persons.
BW 124 DH-3/PDH-3
 Caution
Sections marked like this point out possible
dangers for the machine or for parts of the ma-
chine.
i Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
Observe all environment protection regula-
tions.
Information and safety stickers/decals
on the machine
Keep stickers/decals complete (see spare parts
catalogue) and fully legible and observe their
meaning.
Replace damaged or illegible stickers/decals im-
mediately.
Loading the machine
Use only strong and stable loading ramps. The
ramp inclination must be lower than the gradability
of the machine.
Secure the machine against turning over or slip-
ping off.
Secure the machine on the transport vehicle
against rolling off, slipping and turning over.
Persons are highly endangered if
l they step or stand under loads being lifted
l they remain in the drive range of the machine
during a demonstration or during loading.
The machine must not swing about when lifted off
the ground.
Use only safe lifting gear of sufficient load bearing
capacity.
Attach the lifting gear only to the specified lifting
points.
BW 124 DH-3/PDH-3
Towing the machine
Since the machine is not fitted with a towing hitch,
the machine cannot be towed with a tow bar.
If the machine has to be towed urgently out of the
danger zone because of other risks, this must only
be done on level ground or uphill using chains and
ropes. For this purpose towing ropes of sufficient
tensile strength must be fastened on the lifting
eyes.
After releasing the brake the machine can only be
braked by the towing vehicle.
Before releasing the brake block the machine with
chocks to prevent unintended rolling.
Checking the roll-over protection
structure (ROPS)
The machine frame must not be distorted, bent or
cracked in the area of the ROPS structure.
The ROPS structure must not show any rust, dam-
age, hairline cracks or open fractures.
The ROPS must not rattle about when driving the
machine. This would mean that the fastening
screws are insufficiently fastened. All screwed
connections must be tight and in accordance with
the specifications (observe the tightening tor-
ques). 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 permis-
sion of the dealer, since this 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 equipment, the con-
trol elements, the working mode of the machine
and the area you will be working in.
Use your personal protective outfit (hard hat, safe-
ty boots etc.).
Check before mounting the machine if:
l there are persons or obstructions beside or
under the machine
l the machine is free of any oily and combustible
material
l all handrails, steps and platforms are free of
grease, oils, fuels, dirt, snow and ice
l the engine compartment hood is closed and
locked
To climb onto the machine use steps and hand-
rails.
Check before starting, whether:
l the machine shows any obvious defects
l all protective devices are properly secured in
their place
l steering, brakes, control elements, lighting
and warning horn are in order
l the seat is correctly adjusted
l the mirrors (if available) are clean and correct-
ly adjusted.
Do not start the machine if any gauges, control
lights or controls are defective.
Do not take any loose objects with you or fasten
them to the machine.
On machines with ROPS you should always wear
your seat belt!
Starting
Start and operate the machine only from the oper-
ator's seat
For starting set all control levers to "neutral posi-
tion".
Do not use any starting aids such as Start Pilot or
ether.
After starting check all gauges.
Starting with jump leads
Connect plus with plus and minus with minus
(ground cable) - always connect the ground cable
last and disconnect it first! Wrong connections
may cause severe damage in the electric system.
Never start the engine by bridging the electrical
connections on the starter, because the machine
would probably start to move immediately.
Starting in closed rooms
Exhaust gases are toxic! Always ensure an ade-
quate supply of fresh air when starting in closed
rooms!
Driving the machine
Persons in the danger area
If a machine has turned over and the cabin door is
jammed, the right hand cabin window can be used
as an escape door.
Before taking up work, also after breaks, you
should always convince yourself that the danger
zone is free of persons or obstructions, especially
when driving in reverse.
Give warning signals, if necessary. Stop work im-
mediately if persons remain in the danger zone,
despite the warning.
Do not step or stand in the articulation area of the
machine when the engine is running. Danger of
squashing!
Driving
In events of emergency and in case of danger ac-
tuate the emergency stop switch immediately. Do
not use the emergency stop switch as service
brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop switch
has been eliminated.
If the machine has contacted high-voltage power
lines:
l do not leave the operator’s stand
l warn others from coming close to or touching
the machine
l if possible drive the machine out of the danger
zone
l have the power switched off
Operate the machine only from the operator’s
stand.
The machine is fitted with a seat contact switch
which enables starting of the diesel engine and
driving of the machine only when the driver’s seat
is occupied. Bridging of the safety equipment or
making it ineffective is strictly prohibited.
Do not adjust the driver’s seat while driving.
Do not climb onto or off the machine while the ma-
chine is driving.
Change the travel direction only at standstill.
Do not use the machine to transport persons.
BW 124 DH-3/PDH-3
In case of unusual noises and development of
smoke perform trouble shooting and have the fault
corrected.
Always keep a sufficient distance to excavation
walls and embankments and do not use working
methods that could impair the stability of the ma-
chine.
Do not work with vibration on hard concrete, cured
bitumen layers or extremely frozen ground.
Always keep a sufficient distance when passing
through subways, under bridges, tunnels, electric
power lines etc.
Driving on inclinations and slopes
Do not drive on gradients exceeding the maximum
gradability of the machine.
On slopes drive extremely careful and always di-
rectly up or down the slope. Change to a lower
gear before starting to drive.
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations
and slopes. Higher risk of accident!
Behaviour in traffic
Match the speed to the working conditions.
Always give way to loaded transport vehicles.
Switch the lights on if the visibility is poor.
Keep away from edges and embankments.
Checking the effect of vibration
When compacting with vibration you must check
the effect on nearby buildings and underground
supply lines (gas, water, sewage, electric power),
if necessary stop compaction work with vibration.
Do not activate the vibration on hard (frozen, con-
crete) ground. Danger of bearing damage!
Parking the machine
Park the machine on horizontal, level, firm ground.
Before leaving the machine:
l return the control lever to neutral position
l shut the engine down, pull the ignition key off
l secure the machine against unauthorized use.
Do not jump off the machine, but use hand grips
and access steps.
Mark machines, which could be in the way, with a
clearly visible sign.
BW 124 DH-3/PDH-3
Parking on slopes and inclinations
Secure the machine against rolling, place metal
chocks in front of and behind the wheels.
Filling the fuel tank
Do not inhale fuel fumes.
Refuel only after shutting the engine and the aux-
iliary heater down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Wipe off spilled fuel. Keep fuel free of dirt and wa-
ter.
Leaking fuel tanks can cause explosions. Ensure
tight fit of the fuel tank filling cover, replace it if nec-
essary.
Fire protection measures
Make yourself acquainted with the location and the
operation of fire extinguishers. Observe fire warn-
ing and fire fighting installations.
Maintenance work
Strictly apply the specified maintenance tasks, in-
cluding the changing of parts.
Maintenance work must only be carried out by
skilled and authorized personnel.
In case of maintenance and assembly work over-
head 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 ma-
chine.
Do not perform maintenance work while the ma-
chine 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 before working on
them. Hydraulic oil escaping under pressure can
penetrate the skin and cause severe injury. Con-
sult a doctor if you are injured by pressurized hy-
draulic oil as otherwise serious infections may
result.
When adjusting the hydraulic system do not stand
behind the drums/wheels.
Do not change the setting of high pressure relief
valves.
Drain the hydraulic oil at operating temperature -
danger of scalding!
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always collect and dispose of biodegradable hy-
draulic 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 de-
pressurized!).
Changing of hydraulic hoses
Hydraulic hoses must be examined visually at reg-
ular intervals.
Hydraulic hoses must be changed immediately in
case of:
l damage to the outer surface down to the 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 accordance
with the natural shape of the hydraulic hose
l deformation in bends such as squeezed spots,
extreme bends, layer separation, formation of
blisters
l leakages
l non-observance of installation requirements.
l separation of the hydraulic hose from the
crimped fitting
l corrosion of the crimped fitting, which impairs
the function and the strength
l do not mix 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 genuine 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 dis-
pose of environmentally.
Store used filters and other oily materials in a spe-
cially marked refuse container and dispose of en-
vironmentally.
Do not leave any tools or other parts, which could
lead to damage, in the engine compartment.
Working in the electric system
Disconnect the battery and cover it with insulating
material before starting to work in the electric sys-
tem.
Do not use fuses with higher Ampere ratings and
do not repair fuses with a piece of wire. Fire haz-
ard!
Always disconnect the battery before starting to
weld on the machine.
Working on the battery
When working on the battery do not smoke, do not
use open fire.
Do not let hands or clothes come in contact with
acid. Treat acid injuries with clear water and con-
sult a doctor.
Metal objects (e.g. tools, rings, wrist watches)
must not touch the battery poles - danger of short
circuits and fire!
When recharging maintenance free batteries re-
move all plugs to avoid the accumulation of highly
explosive gases.
Observe all relevant instructions when starting
with an auxiliary battery.
Dispose of used batteries environmentally.
Shut the charging current down before discon-
necting charging clamps.
Ensure an adequate supply of fresh air, especially
if the battery is to be charged in a closed room.
Working on the fuel system
Do not inhale fuel fumes.
No open fire, do not smoke, do not spill any fuel.
BW 124 DH-3/PDH-3
Catch running out fuel, do not let it seep into the Test
ground and dispose of environmentally. Depending on the type of application and the op-
Working on wheels and tires erating conditions vibratory equipment has to be
examined by a specialist whenever required, but
Explosion-like bursting of tires and parts of tires at least once every year.
and rims can cause most severe or even fatal inju-
ries.
The assembly of tires must only be carried out by
experienced personnel and with the correct equip-
ment. If necessary have the tires assembled in a
qualified workshop.
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 wheels.
Non-stick emulsion must only be mixed of water
and non-stick additives according to the instruc-
tions of the non-stick agent manufacturer. Strictly
observe the regulations for the protection of the
environment.

Cleaning
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other easily inflammable
substances for cleaning purposes.
When using high pressure cleaning equipment do
not subject electrical parts and insulating 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.

After maintenance work

Reinstall all protections and guards once all main-
tenance work is completed.

Repair
Attach a warning tag to the steering wheel if the
machine is defective.
Repairs must only be performed by qualified per-
sons who have been instructed for this purpose.
Use our repair instructions.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!

BW 124 DH-3/PDH-3
BW 124 DH-3/PDH-3
 3 Indicators and Controls

BW 124 DH-3/PDH-3
1 Instrument cluster 10 Emergency stop push button
2 Rotary switch for flashing beacon* 11 Ignition switch
3 Rotary switch for lighting (StVZO)* 12 Dozer blade control pedals
4 Rotary switch for hazard light system* 13 Push button for vibration
5 Rotary switch for direction indicators left/right* 14 Drive lever
6 Rotary switch for working head lights* 15 Throttle lever
7 Rotary switch vibration high/low frequency 16 Locking plate for throttle lever
8 Rotary switch for speed range selection
9 Push button for warning horn
* Optional equipment

BW 124 DH-3/PDH-3

3.1 General notes
Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise de-
scriptions of the individual operating steps.
ment, check the hydraulic system if it
comes on too early.
h = not used
i = Brake closed or travel lever in second
notched position
j = Fuel level gauge
k = Operating hour meter

Fig. 7
Fig. 6 No. 2 = Rotary switch for flashing beacon
No. 1 = Multi-function display Position "left" = Flashing beacon switched off
Position "right" = Flashing beacon switched on
i Note
After switching the ignition on all lamps light up for
approx. 3 seconds as a self-test.
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 high,
warning buzzer sounds. Clean en-
gine and radiator
d = Engine oil pressure too low, warning
buzzer sounds. Check the engine oil
level, if necessary have the engine Fig. 8
repaired. No. 3 = Rotary switch, lighting (StVZO) *
e = Air filter cartridge soiled. Clean, Position "left" = light off
change the cartridge.
Position "mid-
f = The battery is not being charged, dle" = fender lights on, with the igni-
check the V-belt, if necessary repair tion switch in position "I" or "P"
the generator.
Position "right" = travel lights on, with ignition
= Light with ignition on and engine off. switch in position "I".
g = Hydraulic oil filter soiled, the warning
buzzer sounds. Replace the filter ele-
* Option

BW 124 DH-3/PDH-3
Fig. 9 Fig. 11
No. 4 = Rotary switch for hazard light sys- No. 6 = Rotary switch working lights ***
tem* Position "left" = light off
Position "left" = hazard light switched off, the Position "right" = working lights on, with ignition
control lights go out. switch in position "I".
Position "right" = hazard light switched on, con-
trol light 7 on fault monitoring
board lights up.

Fig. 12
No. 7 = Rotary switch, vibration
Position "mid-
Fig. 10
dle" = vibration off
No. 5 = Rotary switch for direction indicators
left / right ** Position "left" = low amplitude, high frequency

Position "mid- Position "right" = high amplitude, low frequency

dle" = direction indicator off No. 8 = not used
Position "left or
right" = front and rear direction indica-
tors on the respective side light
up, the control light 6 in the
fault monitoring board flashes

* Option
** Option *** Option

BW 124 DH-3/PDH-3
 The engine will be shut down and the brake will
close.

! Danger
Danger of accident!
Operate only in emergency situations during
operation, do not use as a service brake.
The machine should only be started again after
the danger, that caused the actuation of the
emergency stop switch, has been removed.
operate = push the button completely
Fig. 13
down, it will automatically lock
in end position.
No. 8 = Rotary switch for speed range selec-
tion unlock = turn the button clockwise and
release it.
Position "turtle" = Working speed
to drive = move the travel lever first to
Position "rab-
braking position, then start the
bit" = Transport speed
engine and choose the travel
direction.
For safety reasons the travel system of the ma-
chine will only be enabled after the travel lever has
been shifted back to braking position.

Fig. 14
No. 9 = Push button for warning horn

Fig. 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 multi-
function display light up for a
moment

i Note
Fig. 15 The engine can only be started if both travel levers
No. 10 = Emergency stop switch are in “neutral”.

BW 124 DH-3/PDH-3
The ignition switch is designed with a lock to pre-
vent repetitive starting. For a new starting attempt
the ignition key must first be turned back to posi-
tion "0".
Position "II" = turn further against spring
pressure, he engine starts,
turn the ignition key back to
position once the engine has
started

!Caution
Run the engine warm for a short while before
starting work. Do not allow the engine to run Fig. 18
longer than 10 minutes with idle speed. No. 13 = Travel lever
Do not shut the engine down all of the sudden Position "mid-
from full speed, but let it idle for a while for dle" = Braking position service brake
temperature equalization.
Position "middle,
right" = Parking brake, to start the en-
gine
Position "I" = Forward travel
Position "II" = Backwards travel

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

Fig. 17
No. 12 = Push button for vibration
l Select or actuate the frequencies with the vi-
bration selector switch.
l Switch the vibration on or off by pressing the
push button.

Fig. 19
No. 14 = Throttle lever
Position "I" = Idle speed position
Position "II" = Full load position, operating
position for driving and vibra-
tion

BW 124 DH-3/PDH-3
 Indicators and Controls

! Caution
Always drive and vibrate with max. engine
speed! Control the travel speed only with the
travel lever!
No. 15 = Locking plate for throttle lever
pull = The throttle lever can be
moved to position "II"
release = The throttle lever locks in posi-
tion "II".

Fig. 21
No. 17 = Main fuse for battery
125A = (F00)

i Note
The main fuse is located in the battery box under
the driver’s seat

Fig. 20
No. 19 = Fuses in electric installation box
F03, 10A = Vibration
F05, 15A = Socket
F13, 30A = Starting
F19, 15A = Working head lights*
F22, 15A = Working head lights, rear*
F24, 15A = Monitoring, gauges
F25, 10A = Solenoid valve brake/travel Fig. 22
F41, 15A = Flashing beacon * No. 18 = Pedal for dozer blade*
Position "0" = Stop position. Dozer blade at
Danger rest
Fire hazard! Position "I" = Dozer blade up

Do not use fuses with higher ampere ratings Position "II" = Dozer blade down
and do not bridge fuses. Position "II" = Float position to level loose
soil when driving in reverse

Danger
!

Danger of squashing!
Do not work under the lifted, unsupported doz-
er blade, support the blade if necessary.

* Optional equipment

BOMAG
BW 124 DH-3/PDH-3
Fig. 23
No. 20 = Main fuse for battery
125A = (F00)

i Note
The main fuse is located in the battery box under
the driver’s seat

BW 124 DH-3/PDH-3
BW 124 DH-3/PDH-3
 4 Operation

BW 124 DH-3/PDH-3
4.1 General notes 4.2 Tests before taking into op-
eration
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
The following inspections must be carried out be-
you are not yet fully familiar with the indicators and
fore each working day or before a longer working
control elements of the machine.
period.
All indicators and control elements are described
in detail in this chapter.
Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
l Park the machine on ground as level as possi-
ble.

Check:
l fuel tank and fuel lines for leaks
l screw joints for tight fit
l function of steering
l machine for cleanliness, damage
l presence of the appropriate operating and
maintenance instructions
l check whether the machine has been properly
serviced.

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

i Note
In hydraulic systems filled with Panolin HLP Synth.
46 always use the same oil to top up. With other
ester based oils consult the lubrication oil service
of the respective oil manufacturer.
l Check the hydraulic oil level, top up if neces-
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.

BW 124 DH-3/PDH-3
 Operation

l Check the scrapers, adjust if necessary

4.3 Starting the engine
l Check the air pressure in the tires For values
refer to the technical data.

! Danger
Caution
!
Danger of accident!
Ensure equal pressure in both tires.
Always wear your seat belt.

Fig. 25

l Fasten your seat belt (Fig. 25).

Fig. 26

l Check, whether the travel lever (Fig. 26) is en-

gaged in brake position.

BOMAG
BW 124 DH-3/PDH-3
Operation

Fig. 27 Fig. 30

l Turn the rotary vibration selector switch (Fig. l Turn the ignition key (Fig. 30) to position "I".
27) to position "0", vibration off.

Fig. 31
Fig. 28 All control and warning lights (Fig. 31) in the multi-
l Check, whether the emergency stop switch function display light up for a few seconds as a self
(Fig. 28) is unlocked. test.
Charge control light (f), engine oil pressure warn-
ing light (d) and brake warning light (i) stay on.

! Caution
Perform the starting process for maximum 20
seconds without interruption and pause for a
minute between starting attempts.
If the engine has not started after two attempts
perform trouble shooting.

Fig. 29

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

full speed.

BOMAG
BW 124 DH-3/PDH-3
 Operation

4.4 Starting with jump leads

! Caution
Wrong connection will cause severe damage
to the electrical system.

Fig. 32

l Turn the 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.
Fig. 34

l When starting with an external battery connect

both plus poles (Fig. 34) first and both minus
poles (earth cable) after.
l Perform the work steps described in the previ-
ous paragrapf.
l After starting disconnect the minus poles
(earth cable) first and the plus poles after.

Fig. 33

l Once the engine runs correctly reduce the en-

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

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

BOMAG
BW 124 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 inclina-
tions and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive up and down inclinations exceed-
ing the maximum gradability of the machine
Fig. 36
(see technical data).
Do not drive without wearing your seat belt. l Shift the throttle lever to position "II" (Fig. 36)
full load and lock it.
Always give way to loaded transport vehicles!
Before starting to drive make sure that the
drive range is absolutely safe.
The machine must only be operated with fully
functional safety equipment.
Bridging of the seat contact switch is strictly
prohibited.

i Note
The machine is fitted with a seat contact switch
which enables starting of the diesel engine and
driving of the machine only when the driver’s seat
is occupied.
Fig. 37

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

Caution
Adjust the seat to the weight of the operator,
as otherwise there is a risk that the seat con-
tact switch may not be actuated.
braking position and move it slowly to the de-
sired travel direction.
The brake warning light (i) goes out.

i Note
Shift the travel lever out of "0"-position slowly to
forward or reverse, the machine will drive forward
or reverse at a speed which corresponds with the
displacement of the travel lever.
Returning the travel lever towards neutral will
brake the machine and in "0"-position of the travel
lever the machine will stop.

! Danger
Danger of accident!
Fig. 35 On inclinations and slopes pull the travel lever
l Select the desired travel speed range (Fig. to the right and lock it in braking position.
35).

BOMAG BW 124 DH-3/PDH-3

 Operation

Important notes on travel operation

4.6 Emergency exit
! Caution If the machine should turn over and the cabin door
When changing the travel direction hold the is closed, the right hand side cabin window can be
travel lever for a moment in "0"-position, until used as an emergency exit.
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 full load position.
When driving up and down inclinations move
the travel lever slowly back towards neutral to
brake the machine.
If the engine speed drops when driving up ex-
treme inclinations move the ravel lever slightly
back, if necessary change to the lower speed
range.
Always use the lowest speed range (turtle) to
drive up and down inclinations.

BW 124 DH-3/PDH-3 BOMAG

Operation

4.7 Operating the parking 4.8 Shutting the engine down

brake, stopping the ma-
chine ! Caution
Straighten the articulated joint to provide easi-
er access to the machine.

Fig. 38

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

Fig. 39
tral"-position and engage it to the right parking
brake position. l Return the travel lever (Fig. 39) slowly to "neu-
tral"-position and engage it to the right in brak-
The hydrostatic drive brakes the machine auto-
ing position.
matically, the parking brake closes after approx. 2
seconds.

i Note
The parking 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).

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

BOMAG BW 124 DH-3/PDH-3

 Operation

4.9 Switching the vibration on

and off

Fig. 41
l Turn the ignition key (Fig. 41) to position "0" or
"P" and pull the ignition key out.
i Note
After shutting the engine down with the throttle le-
ver the ”central warning light” lights and the warn-
ing buzzer sounds, until the ignition switch is
turned to position ”0”. The parking brake closes
automatically when shutting the engine down.
Danger
! machine.
Danger of accident!
On particularly steep inclinations place wheel
chocks in front of or behind drum and wheels.
Secure the machine against unauthorized use,
pull the ignition key out, lock the cabin door.
! Danger
Risk of damage!
When compacting with vibration you must
check the effect of nearby buildings and un-
derground supply lines (gas, water, sewage,
electric power), if necessary stop compaction
with vibration.
Do not activate the vibration on hard (frozen,
concrete) ground. Danger of bearing damage!
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
Preselecting the vibration

Fig. 42

l Preselect amplitude/frequency with the rotary

switch (Fig. 42).

BW 124 DH-3/PDH-3 BOMAG

Operation

Switching the vibration on

4.10 Adjusting the seat

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

Fig. 43

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

full speed.

! Caution
Switch the vibration on only at max. engine
Fig. 45
speed.
l To adjust the seat in longitudinal direction dis-
engage lever 1 (Fig. 45) and push the seat for-
ward or back.
l To adjust the inclination of the backrest oper-
ate lever (2) and tilt the backrest forward or
back.
l To adjust the weight adjust lever (3) accord-
ingly.

Fig. 44
l Press the push button (Fig. 44) in the travel le-
ver while driving, the drum will vibrate.
i Note
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.

Switching the vibration off

l Press the push button again and after work
switch the rotary vibration switch to position
"0".

BOMAG BW 124 DH-3/PDH-3

4.12 Operating the hood 4.13 Towing in case of an engine
failure
Danger
Danger of accident! Danger
If the hood needs to be opened further for Mortal danger!
maintenance or repair work, support it safely.
Since the machine is not fitted with a towing
hitch, the machine cannot be towed with a tow
bar.
If the machine has to be towed urgently out of
the danger zone because of other risks, this
must only be done on level ground or uphill us-
ing chains and ropes.
For this purpose towing ropes of sufficient ten-
sile 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
Fig. 56
with chocks to prevent unintended rolling.

l Unlock the lock 1 (Fig. 56).

l To unlock the hood press the latch (2) down
and pull the handle (3) back.
Caution
The max. towing speed must not exceed 2 km/
h (development of heat in the drive section of
the hydraulic motor).
The towing distance must not exceed 1 km, be-
cause the hydraulic circuit would run dry with-
out 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.

Fig. 57

l Pull the hood rest (Fig. 57) out of the bracket

in the hood and hook it into the frame at the
bottom.

BW 124 DH-3/PDH-3
Fig. 58 Fig. 60

l Slacken the counter nuts on both high pres- l Turn the screw for venting the drum brake
sure relief valves (Fig. 58) to create a by-pass (Fig. 60) evenly in clockwise direction, until the
around the travel pump. drum can turn freely.
l Turn the threaded spindle in until it is flush with
the nut. After towing
l Retighten the counter nut.
l Remove the floor plate. Caution
Before loosening ropes or chains block the
machine with chocks to prevent unintended
rolling.
l Turn the threaded spindle of the high pressure
relief valves completely out again and tighten
the counter nuts.
l Turn the threaded spindles on the axle back
out to the end stop and tighten the counter
nuts.
l Reinstall the floor plate.
l Turn the screw for venting the drum brake anti-
clockwise against the stop.
Fig. 59

l In order to release the brake on the axle slack-

en the counter nut (Fig. 59), turn the threaded
spindles (3 pieces) on each side of the axle
evenly in, until the brake is released.
l Repeat this measure on the opposite side.

BW 124 DH-3/PDH-3
4.14 Transport

Danger
Danger of accident!
Use only stable loading ramps of sufficient
load bearing capacity. Make sure that persons
are not endangered by the machine tipping or
sliding off.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
Do not stand or step under loads being lifted. Fig. 62
Always use shackles on the lifting points for l Lash the machine on the transport vehicle
loading, tying or lifting the machine. (Fig. 62), 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. 61

l Attach the articulation lock (Fig. 61).

Fig. 63

l For lifting use also the four lifting eyes (Fig. 63)
and appropriate lifting gear.

Weights: See technical data.

l After transport release the articulation lock
again and store it in the receptacle.

BW 124 DH-3/PDH-3
BW 124 DH-3/PDH-3
 5 Maintenance

BW 124 DH-3/PDH-3

5.1 General notes on mainte-
nance
When performing maintenance work always com-
ply with the appropriate safety regulations.
Thorough maintenance of the machine guaran-
tees far longer safe functioning of the machine and
prolongs the lifetime of important components.
The effort needed for this work is only little com-
pared with the problems that may arise when not
observing this rule.
The terms right/left correspond with travel direc-
tion forward.
l Always clean machine and engine thoroughly
before starting maintenance work.
l For maintenance work stand the machine on
level ground.
l Perform maintenance work only with the en-
gine shut down.
l Relieve hydraulic pressures before working on
hydraulic lines.
l Before working on electric parts of the ma-
chine disconnect the battery and cover it with
insulation material.
l When working in the area of the articulated
joint attach the articulation lock (transport
lock).
Environment
During maintenance work catch all oils and fu-
els and do not let them seep into the ground or
into the sewage system. Dispose of oils, cool-
ant and fuels environmentally.
Notes on the fuel system
The lifetime of the diesel engine depends to a
great extent on the cleanliness of the fuel.
l Keep fuel free of contaminants and water,
since this will damage the injection elements
of the engine.
l Drums with inside zinc lining are not suitable to
store fuel.
l The fuel drum must rest for a longer period of
time before drawing off fuel.
l Do not let the hose stir up the slurry at the bot-
tom of the drum.
l Do not draw off fuel from near the bottom of
the drum.
l The rest in the drum is not suitable for the en-
gine and should only be used for cleaning pur-
poses.
Notes on the performance of the en-
gine
On diesel engines both combustion air and fuel in-
jection quantities are thoroughly adapted to each
other and determine power, temperature level and
exhaust gas quality of the engine.
If your engine has to work permanently in "thin air"
(at higher altitudes) and under full load, you should
consult the customer service of BOMAG or the
customer service of the engine manufacturer.
Notes on the hydraulic system
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that
no dirt or other contaminating substances can en-
ter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clog noz-
zles and pilot bores, thereby making expensive re-
pairs inevitable.
l If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped,
check all lines, hoses and components for
leaks.
l Seal external leaks immediately. If necessary
inform the responsible customer service.
l Do not store drums with hydraulic oil outdoors,
or at least under a cover. Water can be drawn
in through the bunghole when the weather
changes.
l Always use the filling and filtering unit
(BOMAG part-no. 007 610 01) to fill the hy-
draulic system. This unit is fitted with a fine fil-
ter to clean the hydraulic oil, thereby
prolonging the lifetime of the filter.
l Clean fittings, filler covers and the area around
such parts before disassembly to avoid enter-
ing of dirt.
l Do not leave the tank opening unnecessarily
open, but cover it so that nothing can fall in.
BW 124 DH-3/PDH-3

5.2 Fuels and lubricants
Engine oil
The use of high-quality HD brand oils in connec-
tion with the specified filter and oil change intervals
results in a longer lifetime and a higher perform-
ance of the engine.
Do not use and running-in oil for new or over-
hauled engines.
Oil viscosity
Multi-purpose oils should be generally used. Sin-
gle purpose engine oils may only be used with the
consent of the engine manufacturer.
In order to assure perfect cold starting it is import
to chose the viscosity (SAE-class) of the engine oil
according to the ambient temperature.
Fig. 64
Lubrication oil with a too high viscosity index caus-
es starting difficulties. The temperature when
starting the engine is therefore of highest impor-
tance when choosing the viscosity of engine oil for
winter operation.
BW 124 DH-3/PDH-3
Occasionally falling short of the temperature limit
will impair the cold starting ability, but will not
cause any engine damage.
Temperature related lubrication oil changes can
be avoided by using multi-purpose oils. The follow-
ing oil change intervals apply also when using mul-
ti-purpose oils.
Oil quality
Lubrication oil are classified according to their per-
formance and quality class. Specifications accord-
ing to API* and ACAE** (formerly CCMC) are
commonly used.
Permitted API-oils aspirating engines
API = CF, CF-4, CG-4, CH-4
Permitted ACAE-oils aspirating engines
ACAE = E1-96, E2-96, E3-96, E4-98
In regions where such qualities are not available
you should consult the engine manufacturer.
Lubrication oil change intervals
The lubrication oil change intervals depend on the
lubrication oil quality, the sulphur content in the
fuel and the operating conditions.
The first lubrication oil change after commission-
ing or when taking into service after major repairs
must be performed in accordance with the run-
ning-in instructions in this manual.
The longest permissible time a lubrication oil
should remain in an engine is one year. If the fol-
lowing oil change intervals are not reached over a
period of one year, the oil change should be per-
formed at least once per year, irrespective of the
operating hours reached.
E1-96 / E2-96 /
E3-98 / E4-98 = 500 operating hours
CF / CF-4 / CG-4
/ CH-4 = 500 operating hours
The change intervals apply for a sulphur content of
max. 0.5 % by weight in the diesel fuel and a per-
manent ambient temperature higher than 10 °C.
The lubrication oil change interval must be halved
in case of
* American Petroleum Institute
** Association des Constructeurs European d’Automobiles
l permanent ambient temperatures below
-10 °C and oil temperatures below 60 °C,
l or sulphur contents in the fuel of 0.5% to max.
1%
In case of a sulphur content in the fuel of more
than 1% by weight and permanent oil tempera-
tures below 60 °C you should consult the engine
manufacturer.
Fuels
Quality
Use only commercially available brand diesel fuels
with a low sulphur content.
Ensure strict cleanliness when filling in fuel.
Use only winter-grade diesel fuel under low ambi-
ent temperatures.
The fuel level should always be topped up in due
time so that the fuel tank is never run dry, as oth-
erwise filter and injection lines need to be bled.
The following fuel specifications are permitted:
DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75;
BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-
D.
Winter fuel
Bio-degradable hydraulic oil
On request the hydraulic system can also be filled
with synthetic ester based biodegradable hydrau-
lic oil (Panolin HLP Synth. 46). The biologically
quickly degradable hydraulic oil meets all de-
mands of a mineral oil based hydraulic oil accord-
ing to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.
46 always use the same oil to top up. When
changing from mineral oil based hydraulic oil to a
synthetic ester based biologically degradable oil,
you should consult the lubrication oil service of the
oil manufacturer for details.
Check the filter more frequently after this change.
Oil for drive axle
For the drive axle use only multi-purpose transmis-
sion oil of API-class GL5 with viscosity class SAE
90.
The additives in this oil ensure low wear lubrication
under all operating conditions.
Lubrication grease
For lubrication use only EP-high pressure grease,
lithium saponified (penetration 2).

Danger
Danger of explosion!
Do not mix diesel fuel with gasoline or alcohol.
For winter operation use only winter diesel fu-
el, to avoid clogging because of paraffin sepa-
ration. At very low temperatures disturbing
paraffin separation can also be expected when
using winter diesel fuel.

Hydraulic oil
The hydraulic system is operated with hydraulic oil
HV 46 (ISO) with a kinematic viscosity of 46 mm2/
s at 40 °C. For topping up or for oil changes use
only high-quality hydraulic oil, type HVLP accord-
ing 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).

BW 124 DH-3/PDH-3
5.3 Table of fuels and lubri-
cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil ACEA: E1-96 / E2-96 / E3-96 / E4-98 or approx. 5.5 litres*

API: CF / CF-4 / CG-4 / CH-4

SAE 15W/40

(-15 °C to +40 °C)

Fuel

Diesel Winter diesel fuel approx. 60 litres

Hydraulic system Hydraulic oil (ISO), HV68, kinem. viscosity approx. 35 litres
2
46 mm /s at 40 °C

Drum drive gear Gear oil SAE 90, API GL5 approx. 0.8 litres

Drive axle Gear oil SAE 90, API GL5 approx. 3.25 litres

Planetary drive Gear oil SAE 90, API GL5 approx. 0.75 litre per side

Pinion Housing Gear oil SAE 90, API GL5 approx. 0.45 litre

Tires Water 23 litres

Calcium chloride (CaCl2) or magnesium chloride 20 kg

(MgCl2)

* Oil filling quantity without filter change

BW 124 DH-3/PDH-3
5.4 Running-in instructions

The following maintenance work must be per-

formed when running in new machines or
overhauled engines:

Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.

After 50 operating hours

l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Check the engine for leaks.
l Retighten the bolted connections on the ma-
chine.
l Retighten all wheel fastening screws with the
specified tightening torque.
l Check the V-belt tension, tighten if necessary
l Oil change diesel engine
l Oil filter cartridge diesel engine
l Check the valve clearance, adjust if necessary
l Oil change in drive axle
l Oil change in planetary gear
l 1. Oil change in drum drive gear

After 500 operating hours

l 2. Oil change in drum drive gear

BW 124 DH-3/PDH-3
5.5 Maintenance chart

With all maintenance intervals perform also

the work for shorter preceding service inter-
vals.

No. Designation Note

Every 10 operating hours

5.6 Check the engine oil level Dipstick mark
5.7 Checking the fuel filter water separator
5.8 Check the fuel level
5.9 Check the hydraulic oil level Inspection glass
Every 50 operating hours
5.10 Checking the tire pressure see technical data
5.11 Adjusting the scrapers
Every 250 operating hours
5.12 Cleaning the cooling fins on the radiator
5.13 Cleaning the cooling fins on the hydraulic oil cooler
5.14 Checking the oil level in the drive axle
5.15 Checking the oil level in the planetary gears
5.16 Check the oil level in the drum drive gear
Every 500 operating hours
5.17 Servicing the battery distilled water, pole grease
5.18 Draining the sludge from the fuel tank
5.19 Changing engine oil and oil filter cartridge min. 1x per year
5.20 Checking the V-belt tension, tightening
Every 1000 operating hours
5.21 Check, adjust the valve clearance Intake = 0.3 mm, exhaust = 0.5 mm, on cold
engine
5.22 Changing the oil in the drum drive gear min. 1x per year
5.23 Changing the oil in the drive axle min. 1x per year
5.24 Change the oil in the planetary gears min. 1x per year
5.25 Changing the fuel pre-filter
5.26 Changing the fuel filter cartridge
5.27 Checking the fastenings on the diesel engine
5.28 Checking the fastening of the axle on the frame
5.29 Tightening the wheel nuts
5.30 Checking the ROPS

BW 124 DH-3/PDH-3
No. Designation Note

Every 2000 operating hours

5.31 Changing hydraulic oil and breather filter* at least every 2 years
5.32 Changing the hydraulic oil filter* at least every 2 years
Every 3000 operating hours
5.33 Replacing the toothed belt at least every 5 years
As required
5.34 Cleaning, changing the combustion air filter min. 1x every year, safety cartridge at least
every 2 years
5.35 Adjusting the parking brake
5.36 Changing the tires
5.37 Changing the fresh air filter in the cabin
5.38 Tightening torques
5.39 Engine conservation

* Also in case of repairs in the hydraulic system.

BW 124 DH-3/PDH-3
Every 10 operating hou rs

5.6 Check the engine oil level 5.7 Checking the fuel filter wa-
ter separator
i Note
With the machine on level ground shut the engine Danger
down and wait for about 15 minutes, so that all oil
Danger of injury!
can flow back into the oil sump.
Support the engine hood for all maintenance
l Open the engine hood
and repair work.

i Note
The service intervals for the water separator de-
pend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should therefore
check the water separator every day for signs of
water.
If a to high quantity is drained off, the filter must be
refilled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.

Fig. 65 Environment
l Pull the dipstick (Fig. 65) out, wipe it off with a Catch running out fuel and dispose of environ-
lint-free, clean cloth and reinsert it until it bot- mentally.
toms.
l Pull the dipstick 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 longer work periods you should always
top the oil up to the "MAX"-mark.

For quality and quantity of oil refer to the table Fig. 66

of fuels and lubricants l Slacken the drain plug (Fig. 66) 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.

BW 124 DH-3/PDH-3
 Caution
5.8 Check the fuel level
Contaminated fuel can cause malfunction or
even damage of the engine.
Danger If necessary, fill in fuel through a funnel with
Fire hazard! screen.

When working on the fuel system do not use l If necessary top up with fuel (diesel or winter
open fire, do not smoke, do not refuel in closed diesel).
rooms, do not inhale any fuel fumes. For quality of fuel refer to the table of fuels and
lubricants.

Fig. 67

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

67).

i Note
Do not drive the fuel tank dry, as otherwise the fuel
system needs to be bled.
l Clean the area around the filler opening.

Fig. 68

l Open the fuel tank cover (Fig. 68).

BW 124 DH-3/PDH-3
5.9 Check the hydraulic oil level

Danger
Danger of squashing!
Do not enter the articulation area while the en-
gine is running.

Caution
In hydraulic systems filled with Panolin HLP
Synth. 46 always use the same oil to top up.
Fig. 70
With other ester based oils consult the lubrica-
tion oil service of the respective oil manufac- l If necessary fill in hydraulic oil through the filler
turer. neck (Fig. 70) under the driver’s seat.

For quality and quantity of oil refer to the table

of fuels and lubricants.

Fig. 69

l Check the hydraulic oil level in the inspection

glass (Fig. 69).

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

Minimum level
Middle of inspection glass.

Caution
If, during the daily inspection of the oil level
the hydraulic oil level is found to have
dropped, check all lines, hoses and compo-
nents for leaks.

BW 124 DH-3/PDH-3
Every 50 oper ating hours

5.10 Checking the tire pressure 5.11 Adjusting the scrapers

Caution only smoot drum

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. 72

l Check adjustment and condition of front and

rear scrapers, if necessary adjust or replace
the scraper rubber.
Fig. 71 l In order to adjust the scrapers 1 (Fig. 72),
slacken the fastening screws (2) in the slots
l Check the tire pressure with a pressure gauge
and push the scraper bracket towards the
and the tire inflation valve 1 (Fig. 71) in top po-
drum.
sition.
l Retighten the fastening screws.
Nominal value see "technical data".
only padfoot drum
i Note
Ensure even pressure in all tires.
l Screw the valve caps back on.

Fig. 73

l Check adjustment and condition of scrapers 2

(Fig. 73), if necessary adjust or replace the
teeth.
l In order to adjust the scrapers (2), slacken the
fastening screws (1) in the slots and push the

BW 124 DH-3/PDH-3
 scrapers towards the drum, leaving a gap be-
tween drum and scraper of about 25 mm .
l Retighten the fastening screws.

BW 124 DH-3/PDH-3
 Cleaning with cold cleansing agent
Every 250 operating h ours

5.12 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.
i Note
Dirt on fan blades and oil cooler reduce the cooling
effect. Dirt deposits in these areas are substantial-
ly supported by oil and fuel on these surfaces. For
this reason you should always seal any oil or fuel
leaks in the vicinity of the cooling fan or the oil
cooler and clean the cooling surfaces after.
Caution
In case of oily dirt spray the engine with a cold
cleansing agent and let it soak in for about 10
minutes.
Protect electrical equipment such as genera-
tor, regulator and starter against the direct wa-
ter jet.
l Spray the engine with a suitable cleansing
agent, e.g. cold cleanser, let it soak in for a
while and spray it off with a strong water jet.
l Reassemble the cooling air duct cover, run the
engine warm for a while to avoid corrosion.

Cleaning with compressed air

i Note
Start to blow out from the exhaust side.

Fig. 74

l Take the cooling air duct cover off and blow

the radiator (Fig. 74) out, starting from the air
discharge side.
l Remove all dirt that has been blown into the air
duct.

BW 124 DH-3/PDH-3
5.13 Cleaning the cooling fins on
the hydraulic oil cooler

Danger
Danger of injury!
Perform cleaning work only after the engine
has cooled down and with the engine stopped.

Caution
Do not damage any cooling fins on the cooler Fig. 76
core when cleaning.
l Unscrew both fastening screws (Fig. 76) from
the seat console and fold the seat forward.
i Note
Dirt on fan blades and oil cooler reduce the cooling
effect. Dirt deposits in these areas are substantial-
ly supported by oil and fuel on these surfaces. For
this reason you should always seal any oil or fuel
leaks in the vicinity of the cooling fan or the oil
cooler and clean the cooling surfaces after.

Cleaning with compressed air

i Note
Start to blow out from the exhaust side.

Fig. 77

l Blow the cooler (Fig. 77) out with compressed

air.

Cleaning with cold cleansing agent

Caution
In case of oily dirt spray the cooler with a cold
cleansing agent and let it soak in for about 10
minutes.
Protect electrical equipment such as genera-
Fig. 75 tor, regulator and starter against the direct wa-
ter jet.
l Blow the cooler (Fig. 75) out with compressed
air. l Spray the radiator with a suitable cleansing
agent, e.g. cold cleanser, let it soak in for a
while and spray it off with a strong water jet.
l Run the engine warm for a while to avoid cor-
rosion.

BW 124 DH-3/PDH-3
5.14 Checking the oil level in the
drive axle
Fig. 78
l Unscrew the oil level inspection plug (Fig. 78)
and check the oil level.
The oil level must reach the bottom edge of the
level bore.
l Top up oil, if necessary.
For quality of oil refer to the table of fuels and
lubricants.
l Turn the level inspection plug tightly back in.
5.15 Checking the oil level in the
left/right hand planetary
drives
Fig. 79
l Drive the machine, until both plugs 1 (Fig. 79)
are in horizontal position.
l Clean the plug and screw it out.
The oil level must reach the lower edge of the
bore, top up oil if necessary.
For quality of oil refer to the table of fuels and
lubricants.
l Screw the plug tightly back in.
l Repeat the same procedure on the opposite
side.
BW 124 DH-3/PDH-3
5.16 Check the oil level in the 5.16a Checking the oil level in the
drum drive gear rear drive axle pinion

Fig. 80

l Move the machine until the oil level inspection Fig. 78a
plug 1 (Fig. 80) is in horizontal position. l Unscrew the oil level inspection plug (Fig. 78a)
l Clean and unscrew the oil level inspection and check the oil level.
plug. For quality of oil refer to the table of fuels and
The oil level must reach the bottom edge of the lubricants.
bore. l Top up oil, if necessary.
l If necessary fill in oil through the filler and drain l Turn the level inspection plug tightly back in.
bore (2).

For quality of oil refer to the table of fuels and

lubricants.

BW 124 DH-3/PDH-3
Every 500 operating h ours

5.17 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!
Fig. 82
For recharging remove the plugs from the bat-
l Remove the battery (Fig. 82) and clean the
tery to avoid the accumulation of highly explo-
battery compartment.
sive gases.
l Clean the outside of the battery.

Environment l Clean battery poles and pole clamps and

grease them with pole grease (Vaseline).
Dispose of the old battery environmentally.
l Check the fastening of the battery.
l On serviceable batteries check the acid level,
if necessary top up to the filling mark with dis-
tilled water.

Fig. 81

l Unscrew both fastening screws (Fig. 81) from

the seat console and fold the seat forward.

BW 124 DH-3/PDH-3
5.18 Draining the sludge from 5.19 Changing engine oil and oil
the fuel tank filter cartridge

Danger Caution
Fire hazard! The oil change at 500 operating hours refers to
the use of oils of oil quality class API CG-4/CH-
When working on the fuel system do not use
4 or ACAE E3-98/E4-98 respectively.
open fire, do not smoke.
Do not inhale any fuel fumes. When using oils of quality classes API CF/CF-
4 or ACAE E1-96/E2-96 the oil change intervals
must be halved (see chapter 5.2, fuels and lu-
Environment bricants).
Catch running out fuel, do not let it seep into Drain the engine oil only when the engine is
the ground. warm.
Do not spill any fuel.
l Remove the floor plate from under the engine. Danger
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil fil-
ter.

Environment
Catch running out oil and dispose of environ-
mentally together with the engine oil filter car-
tridge.

Fig. 83

l Disconnect the connection (Fig. 83) between

the two fuel tanks and drain off about 5 litres of
fuel.

Fig. 84

l Unscrew the drain plug (Fig. 84) and catch

running out oil.
l Turn the drain plug tightly back in.

BW 124 DH-3/PDH-3
Fig. 85 Fig. 87

l Unscrew the filter cartridge (Fig. 85) using an l Check the oil level again (Fig. 87), if necessary
appropriate filter wrench. fill up to the top dipstick mark.
l Clean the sealing face on the filter carrier from l Check filter cartridge and drain plug for leaks.
any dirt.
l Slightly oil the rubber seal on the 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. 86

l Fill in new engine oil (Fig. 86).

For quality and quantity of oil refer to the table

of fuels and lubricants.
l Tighten the oil filler cap properly.

BW 124 DH-3/PDH-3
5.20 Checking the V-belt tension, 5.21 Checking the V-belt tension
tightening for the dozer blade pump*,
tightening
Checking the V-belt
Checking the V-belt

Fig. 88

l Inspect the entire circumference of the V-belt Fig. 90

visually for damage and cracks.
l Replace damaged or cracked V-belts.
l Check with thumb pressure whether the V-belt
can be depressed more than 10 ... 15 mm be-
tween the V-belt pulleys (Fig. 88), retighten the
V-belt if necessary.
Retightening the V-belt
l Inspect the entire circumference of the V-belt
visually for damage and cracks (Fig. 90).
l Replace damaged or cracked V-belts.
l Check with thumb pressure whether the V-belt
can be depressed more than 10 ... 15 mm be-
tween the V-belt pulleys (Fig. 88), retighten the
V-belt if necessary.
Retightening the V-belt

Fig. 89

l Slightly slacken the fastening screw 1 (Fig. Fig. 91

89).
l Slightly slacken the fastening screw 1 (Fig.
l Press the idling pulley (2) in direction "I", until 91).
the correct V-belt tension is achieved.
l Tighten the fastening screws (1). * Optional equipment

BW 124 DH-3/PDH-3
l Turn the tensioning screw (2), until the correct
V-belt tension is achieved.
l Tighten the fastening screws (1).

BW 124 DH-3/PDH-3
Every 1000 operating hours

5.22 Check, adjust the valve

clearance

Caution
Before checking the valve clearance let the en-
gine cool down for at least 30 minutes. The en-
gine oil temperature must be less than 60 °C.

Valve clearance
Intake valve = 0.3 mm
Exhaust valve = 0.5 mm Fig. 94
l Open the engine hood completely and support l Crank the engine with the starter until both
it safely. valves on cylinder 1 (Fig. 94) are “overlap-
ping”.

i Note
Overlapping means that the exhaust valve is not
yet completely closed and the intake valve starts
to open.
The valves marked black (Fig. 94) can be checked
and adjusted.

Fig. 92

l Remove the valve cover (Fig. 92).

Fig. 95

l Turn the crankshaft another revolution (360

Fig. 93
l Press the engine shut-down lever 1 (Fig. 93)
against the stop (2) and fasten it with a wire.
Grad) further (for this purpose mark the fly-
wheel e.g. with chalk).
l Check the valves marked black and adjust if
necessary (Fig. 95).
l Assemble the cylinder head cover with a new
gasket.

BW 124 DH-3/PDH-3
Adjusting the valve clearance
5.23 Changing the oil in the drum
drive gear

Caution
Drain oil only at operating temperature.

Fig. 96

l Loosen the counter 2 (Fig. 96) and regulate

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

Caution Fig. 97

After a short test run check the engine for l Move the drum, until the drain plug 2 (Fig. 97)
leaks. is in bottom position.
l Clean and unscrew both the oil level inspec-
tion plug (1) and the drain plug.

Environment
Catch running out oil.

Fig. 98

l Once all oil has been drained off move the

drum, until the oil level inspection plug 1 (Fig.
98) is in horizontal position.
l Fill in oil, until it starts to run out through the
level inspection bore.

BW 124 DH-3/PDH-3
For quality and quantity of oil refer to the table
of fuels and lubricants. 5.24 Changing the oil in the drive
l Screw oil level inspection plug (1) and drain axle
plug (2) back in with new seal rings.

i Note
On other axle versions drain and filler plugs are of
slightly different design. Perform the oil change ac-
cordingly.

Caution
Drain oil only at operating temperature.

Environment
Catch old oil and dispose of environmentally.

Fig. 99

l Clean and unscrew all level inspection and

drain plugs (Fig. 99).
l Drain and catch all oil.
l Clean the drain plug and turn it back in with a
new seal ring.

BW 124 DH-3/PDH-3
 5.25 Changing the oil in the plan-
etary drive

Caution
Drain the oil only at operating temperature.
Change the oil on both sides of the axle.

Environment
Catch the old oil and dispose of environmetal-
Fig. 100 ly.
l Fill in oil through the oil level inspection bore
(Fig. 100), until it has reached the bottom edge
of the bore.

For quality and quantity of oil refer to the table

of fuels and lubricants.
l Retighten the filler and level inspection plug.

Fig. 101

l Move the drive wheel until the plug (Fig. 101)

is in lowest position.
l Clean the plug and screw it out.
l Drain the oil off and catch it.

BW 124 DH-3/PDH-3
 5.26 Changing the fuel pre-filter

Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.
Catch running out fuel, do not let it seep into
the ground.
Do not inhale any fuel fumes.
Fig. 102

l Move the drive wheel until the plug (Fig. 102)

in the housing is in horizontal position.
l Fill in oil, until it reaches the lower edge of the
bore.

For quality and quantity of oil refer to the table

of fuels and lubricants.
l Screw the plug back in.
l Repeat the oil change on the opposite side.

Fig. 103

l Remove the hose clamps and pull the fuel pre-

filter (Fig. 103) 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 fuel pre-filter.

BW 124 DH-3/PDH-3
5.27 Changing the fuel filter car- 5.28 Checking the fastenings on
tridge the diesel engine

Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.
Catch running out fuel, do not let it seep into
the ground.
Do not inhale any fuel fumes.

Fig. 105

l Check the fastening of intake and exhaust

tubes (Fig. 105) on the cylinder heads for tight
fit.
l Check sockets and clamps between air filter,
exhaust turbocharger and charge air line as
well as the lubrication air line for tight fit and
leaks.
l Check fastening and tightness of the lubrica-
tion oil sump.
Fig. 104

l Unscrew the fuel filter cartridge (Fig. 104) us-

ing an appropriate filter wrench.
l Clean the 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 contacts.
l Tighten the fuel filter cartridge for another half
turn.
l After the test drive check the filter cartridge for
leaks. Fig. 106

l Check the condition and tight fit of the engine

pillow blocks (Fig. 106).
i Note
Bleeding of the fuel system is not necessary.

BW 124 DH-3/PDH-3
5.29 Tightening the fastening of 5.30 Tightening the wheel nuts
the axle on the frame

Fig. 108

Fig. 107 l Tighten the wheel nuts (Fig. 108) in a cross-

l Check all fastening nuts for the axle studs for wise pattern.
tight fit (Fig. 107). Tightening torques 550 Nm (405 ft-lb)
(M22x1,5)

BW 124 DH-3/PDH-3
5.31 Checking the ROPS 5.31a Changing the oil in the rear
drive axle pinon
i Note
Caution
On machines with cabin the ROPS (roll over pro-
Drain oil only at operating temperature.
tection structure) is an integral part of the cabin.
Please observe also the corresponding section in Environment
the safety regulations in this manual. Catch old oil and dispose of environmentally.

Fig. 109

l Inspect the ROPS structure (Fig. 109) for

cracks, corrosion, damage and missing fas-
tening parts.

i Note Fig. 99
Unusual movements and noises (vibrations) dur- l Clean and unscrew all level inspection and
ing operation are signs for damage or loosened drain plugs (Fig. 99).
fastening elements.
l Drain and catch all oil.
l Check the fastening screws to the operator’s l Clean the drain plug and turn it back in .
stand for tightness.
l Check the rubber buffers of the operator’s plat-
For quality and quantity of oil refer to the table
form suspension for condition and tight fit.
of fuels and lubricants.
l Check the condition and fastening of the seat
l Retighten the filler and level inspection plug.
belts.

BW 124 DH-3/PDH-3
Every 2000 operating hours

5.32 Changing hydraulic oil and

breather filter

i Note
See also chapter 5.1 "Notes on the hydraulic sys-
tem".

Caution
Apart from the normal oil change intervals, the
hydraulic oil must also be changed after major
repairs in the hydraulic system. Fig. 110

Perform the oil change when the hydraulic oil l Unscrew the plug (Fig. 110) and drain off all
is warm. hydraulic oil.

Clean the area round hydraulic oil tank, filler l Check the seal ring, replace if necessary and
opening and breather filter. turn the plug tightly back in.
Do not use any detergents to clean the system.
Do not start the engine after draining the hy-
draulic oil.
Replace the hydraulic oil filter element with
every hydraulic oil change.

Danger
Danger of scalding!
Danger of scalding by hot oil.

Environment
Catch running out oil and dispose of environ- Fig. 111
mentally. l Unscrew both fastening screws (Fig. 111) from
the seat console and fold the seat forward.
i Note
Generally replace the hydraulic oil filter element
after the test run.

BW 124 DH-3/PDH-3

Fig. 112
l Remove the filler cap (Fig. 112).
l Fill in new hydraulic oil through the screen.
i Note
We recommend to use the filling and filtering unit
(BOMAG part-no. 079 930 35) with fine filter to fill
the hydraulic system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the hy-
draulic oil filter and protects the hydraulic system.
l Check the oil level in the inspection glass.
Nominal value:
approx. 3 cm below the upper edge of the inspec-
tion glass
For quality and quantity of oil refer to the table
of fuels and lubricants.
i Note
The breather filter for the hydraulic oil tank is inte-
grated in the filler cap, you must therefore replace
the complete filler cap.
l Close the tank with a new filler cap (breather
filter).
5.33 Changing the hydraulic oil
filter
Danger
Danger of scalding!
There is a danger of scalding by hot oil when
unscrewing the filter.
Caution
If the filter has to be changed together with the
hydraulic oil, the filter should in any case be
changed after the oil change and the test run.
Do not use the oil in the filter bowl.
Environment
Catch running out oil, dispose of oil and filter
element environmentally.
i Note
The filter element must be changed with every hy-
draulic oil change and after major repairs in the hy-
draulic system.
Fig. 113
l Unscrew the cap nut 4 (Fig. 113) and take the
filter bowl (5) with the filter element (3) off.
l Examine the sealing face on the filter element
thoroughly for any visible dirt.
Caution
Visible impurities may be an early indicator for
a failure of system components and predict the
BW 124 DH-3/PDH-3
possible malfunction of important parts. In
such a case you should perform trouble shoot-
ing and replace or repair the defective compo-
nents. Nonobservance may lead to total
damage of the hydraulic system.
Do not clean or reuse the filter element.
l Take the old filter element (3) out and clean
the filter bowl and the thread.
l Reinstall the filter bowl with the new filter ele-
ment, check the condition of the O-rings (1)
and (2), replace if necessary.
l After a test run check the filter for leaks.

BW 124 DH-3/PDH-3
Every 3000 operating hour s

5.34 Replacing the toothed belt

Caution
The toothed belt must only be changed by a
specialist workshop or by the After Sales Serv-
ice of BOMAG.
Do not retension toothed belts, replace them
together with the idler pulley.
Replace a toothed belt at the latest after 5
years, even if the number of operating hours
has not yet been reached.

Fig. 114

l Have the toothed belt (Fig. 114) replaced by a

specialist workshop.

BW 124 DH-3/PDH-3
As r equired

5.35 Checking, cleaning, chang- i Note

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

Caution
Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter ele-
ment.
Do not use gasoline or hot fluids to clean the
filter element.
After cleaning the filter element must be in-
spected for damage using a torch.
Air filter elements with damaged paper bellows
or seal lips must be replaced in any case.
Fig. 116
The main filter element must be replaced after
3 times cleaning, but at the latest after one l Remove the maintenance cover (Fig. 116).
year, irrespective of the operating hours.
Each cleaning interval must be marked with 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 filter element.
Incorrectly handled filter elements may be-
come ineffective because of damage (e.g.:
cracks) and cause engine damage.

Fig. 117

l Release the locking hook (Fig. 117) and take

the filter hood off.
l Clean filter hood and dust discharge valve.

Fig. 115
Maintenance of the dry air filter is due when con-
trol light “e” (Fig. 115) in the instrument cluster
lights permanently when the engine is running, but
at the latest after one year.

BW 124 DH-3/PDH-3
Fig. 118
l Carefully loosen the main filter element (Fig.
118).
The main filter element is located directly on the air
intake tube, thereby providing a seal on the inside
of the filter cover. Carefully remove the main filter
element, in order to reduce the released amount of
dust. To release the seal pull the main filter ele-
ment carefully up, down and sideways or turn it
(Fig. 118).
Caution
Avoid contact between main filter element and
housing.
Fig. 119
l Pull the main filter element (Fig. 119) carefully
out of the housing.
Fig. 120
l Clean the sealing face on the outlet tube (Fig.
120).
Dust on the outer diameter of the outlet tube can
impair effective sealing.
l Check the old main filter element.
The old main filter element can be of help to dis-
cover foreign particles on the sealing face, which
could lead to leaks. A line of dust on the clean air
side of the filter may be a sign for such a leak.
Eliminate this problem before installing a new
main filter element.
l If the main filter element is damaged, the safe-
ty element must be replaced as well.
l Clean or replace the main filter element.
i Note
We generally recommend to change the filter. A
new filter element is far less expensive than a pos-
sible engine damage.
l Examine the main filter element thoroughly for
damage.
Before installing the new main filter element check
it for possible damage from transport, cleaning or
incorrect handling. Especially on the inside of the
open end (sealing area). Do not install damaged
filter elements.
l If necessary use safety elements.
BW 124 DH-3/PDH-3
Fig. 121
l Insert the main filter element (Fig. 121).
The radial sealing area is located at the inside of
the open filter edge. This critical sealing area must
be under slight tension after the filter has been in-
stalled. In order to achieve a tight seal apply pres-
sure to the outer edge of the filter and not to the
moveable centre.
l Reinstall the filter hood with the dust discharge
valve.
Caution
The dust discharge valve must point vertically
downwards.
Dry cleaning of the main filter element
Danger
Eye injury!
Wear protective clothing (goggles, gloves).
BW 124 DH-3/PDH-3
Fig. 122
i Note
For cleaning purposes fit a tube to the compressed
air gun (Fig. 122), 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 el-
ement, until 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 ele-
ment.
Changing the safety filter element
Caution
The safety filter element must not be cleaned
and should not be used again after it has been
removed.
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,
if the warning light comes on again after serv-
icing the main filter cartridge.
l Remove the housing cover and pull the main
filter element off.
Fig. 123
l Pull the safety element (Fig. 123) out by turn-
ing it lightly.
l Push in a new safety filter element.
l Reassemble main filter element and cover.
5.36 Adjusting the parking brake
Caution
Have adjustment work on the brakes only car-
ried out by a specialist! Always adjust both
sides.
l Secure the machine with wheel chocks
against rolling.
l Start the diesel engine to relieve the brake.
The parking brake is released
Fig. 124
l Unscrew the locking plate 2 (Fig. 124).
l Turn the square (1) in anti-clockwise direction
against the stop.
Fig. 125
l In order to adjust the brake clearance turn the
square 1 (Fig. 125) three turns back in clock-
wise direction.
BW 124 DH-3/PDH-3
l Fasten the locking plate again.
5.37 Changing the tires
l Pull the plug off the brake solenoid valve and
perform the drive test.
The machine must be braked. Danger
Danger of accident!
Observe all safety notes for the lifting of loads.
l Place a jack (min. 5 t bearing capacity) 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.

Fig. 126

l Attach the wheel (Fig. 126) and tighten the

wheel nuts crosswise with 550 Nm (405 ft. lb.).
l Check the tire pressure, see technical data.

BW 124 DH-3/PDH-3
5.38 Tightening torques 5.39 Engine conservation
If the engine is to be shut down for a longer period
of time (e.g. over winter), we recommend to apply
the following conserving measures to avoid corro-
sion:
l Clean the engine, including the cooling sys-
tem: With cold cleansing 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 still hot engine oil and fill in anti-
corrosion engine oil.

Fig. 127
l Drain off the coolant and fill in system protec-
tion agent.
* Strength classes for screws with untreated, non-
lubricated surface. The screw quality is stamped l Drain the fuel from the tank, mix it well with
on the screw heads. 10% anti-corrosion oil and fill it back in.
8.8 = 8G l Run the engine for 10 minutes until all lines, fil-
ters, pumps and nozzles with this conserving
10.9 = 10K
mixture and the new engine oil has been dis-
12.9 = 12K tributed to all parts.
l Axle - frame l Now crank the engine several times (without
M 24 = 880 Nm ignition) to spray the combustion chambers.

l Wheel nuts l Take the V-belts off and spray the grooves of
the V-belts with anti-corrosion oil. Remove the
M 22x1,5 = 550 Nm anti-corrosion oil before resuming operation.
The values result in a 90% utilization of the screws
l Close intake and exhaust openings tightly.
yielding point at a coefficient of friction of μ tot. =
0,14. The tightening torques are not valid when us-
ing MOS2 lubricants. i Note
Depending on the weather conditions these con-
serving measures will provide protection for ap-
i Note
prox. 6 to 12 months.
Self locking nuts must always be replaced after
they have been unscrewed. Before taking the engine back into operation all
conserving oil must be drained off and replaced by
regular engine oil, see chapter "Fuels and Lubri-
cants" according to the API-(MIL)-classification.

Anti-corrosion oils are those that comply with

the specification MIL-L-21260 B or TL 9150-
037/2 or Nato Code C 640/642.

A machine with a conserved engine must be

marked by attaching a clearly visible warning
tag.

BW 124 DH-3/PDH-3
 6 Trouble shooting

BW 124 DH-3/PDH-3
6.1 General notes

The following work must only be carried out by

qualified and trained personnel or by the sales
service.

Please observe strictly the safety regulations

in chapter 2 of these operating and mainte-
nance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serv-
iced. Therefore, whenever a fault occurs, read
through these instructions on correct operation
and maintenance. If you cannot locate the cause
of the fault or eliminate it yourself by following the
trouble shooting charts, you should contact our
customer service departments at our branch office
or dealers.

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

BW 124 DH-3/PDH-3
6.2 Engine problems

Fault Possible cause Remedy

Engine does not Starter defective or pinion does not en- Have examined by a specialist
start gage

Fuel tank empty Fill tank and bleed

Temperature below starting limit Choose winter fuel and engine oil accord-
ing to ambient temperatures.

Fuel filter clogged, in winter due to paraf- Change the filter, use winter fuel
fin separation

Fuel lines leaking Check all line connections for leaks and
tighten the fittings

Battery not charged or not connected Tighten the terminal clamps on the bat-
tery, check all cable connections

Injection valves or injection pump defec- Have examined by a specialist

tive

Poor starting of Battery power too low, terminal clamps Have the battery tested, clean the termi-
engine or en- loose or oxidized causing the starter to nal clamps, tighten and cover them with
gine works irreg- turn too slowly. acid-free grease
ularly with poor
power Especially during winter: use of too vis- Use an engine oil complying with the am-
cous engine oil bient temperatures

Fuel supply too low, fuel system clogged Change the fuel filter. Check the line con-
by paraffin separation during winter nections for leaks and tighten the fittings.
Use winter fuel under cold conditions

The specified valve clearance is not cor- Adjusting the valve clearance
rect

Injection valve defective Have examined by a specialist

Injection lines leaking Check lines for leaks

Dry air filter cartridge soiled Clean, if necessary use a new one

Excessive play in throttle cable Adjust the throttle cable, replace if neces-
sary

Excessive ex- Engine oil level too high Drain the oil down to the top dipstick mark
haust smoke
Dry air filter soiled Clean, if necessary use a new one

Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance

The specified valve clearance is not cor- Adjusting the valve clearance
rect

BW 124 DH-3/PDH-3
Fault Possible cause Remedy

Engine over- Cooling fins on radiator extremely dirty Clean the cooling fins
heating, engine (the warning light "Engine oil tempera-
must be shut ture" lights)
down immedi-
ately! Injection valve defective Have examined by a specialist

Engine oil level too low Top up engine oil up to the top dipstick
mark

Injection pump displacement not correctly Have corrected by a specialist

adjusted

Insufficient cooling air supply to the cool- Remove any clogging from the cooling air
ing fan duct

V-belt loose or broken Tension or replace the V-belt

Insufficient en- Engine oil level too high Drain the engine oil down to the top dip-
gine power stick mark

Dry air filter soiled Clean, if necessary use a new one

Incorrect valve clearance Adjusting the valve clearance

Injection valve defective Have inspected by a specialist

Engine oil pres- Engine oil level too low (control light "En- Top up oil
sure too low gine oil pressure" lights, warning buzzer
sounds)

Leaks in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten all
fittings

The charge con- Generator speed too low Check the V-belt tension, if necessary re-
trol light lights place the V-belt
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialist
buzzer sounds tery, because of defect on generator or
regular

BW 124 DH-3/PDH-3