Operating instructions

Maintenance instructions

BW 141 AD-4 / BW 151 AD-4

BW 151 AC-4 / BW 161 ADCV
S/N 101 920 00 ....> S/N 101 920 01 ....>
S/N 101 920 10 ....>

Tandem Vibratory Roller

Catalogue number
008 126 71 02/2006

BOMAG machines are products from the wide
F oreword
range of BOMAG compaction equipment.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your ma-
chine.
This manual comprises:
l Safety regulations
l Operating instructions
l Maintenance instructions
l Trouble shooting
Using these instructions will
l help you to become familiar with the machine.
l avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
l enhance the reliability of the machine on con-
struction sites,
l prolong the lifetime of the machine,
l reduce repair costs and downtimes.
BOMAG will not assume liability for the function of
the machine
l if it is handled in a way not complying with the
usual modes of use,
l if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-
age resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and mainte-
nance instructions are part of the machine.
BW 141/151 AD-4/BW 151 AC-4
Foreword
You should only operate the machine after you
have been instructed and in compliance with these
instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil En-
gineering Liability Association ”Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors” and all relevant accident prevention regula-
tions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Apart from that, the spare parts catalogue is avail-
able from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines in
soil and asphalt construction.
The above notes do not constitute an extension of
the warranty and liability conditions specified in the
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
BOMAG 3
Foreword

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

i Note Fig. 1
Supplement the above data together with the 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

4 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Table of Contents

Technical Data 7
Safety regulations 13
Indicators and Controls 21
3.1 General notes 24
3.2 Description of indicators and control elements 24
Operation 39
4.1 General notes 40
4.2 Tests before taking into operation 40
4.3 Starting the engine 41
4.4 Starting with jump wires 44
4.5 Driving the machine 45
4.6 Stopping the machine, operating the parking brake 47
4.7 Shutting the engine down 47
4.8 Switching the vibration on and off 48
4.9 Operating the crabwalk 51
4.10 Switching the pressure sprinkling system on and off 52
4.11 Sprinkling of edge cutter 53
4.12 Actuating the emergency stop switch 53
4.13 Adjusting the rotation stop for travel lever movement 54
4.14 Adjusting the driver’s seat 54
4.15 Opening or closing the cabin window 55
4.16 Towing 55
4.17 Transport 57
Maintenance 59
5.1 General notes on maintenance 60
5.2 Fuels and lubricants 61
5.3 Fuels, lubricants and filling capacities 63
5.4 Running-in instructions 64
5.5 Maintenance chart 65
5.6 Check the engine oil level 68
5.7 Check, clean the water separator 68
5.8 Check the fuel level 69
5.9 Check the hydraulic oil level 70
5.10 Check the water level 70
5.11 Checking the emulsion level (AC-machine) 71
5.12 Check condition of engine oil and hydraulic oil cooler, clean 72
5.13 Change the engine oil 73
5.14 Change the engine oil filter cartridge 74
5.15 Servicing the air conditioning (summer operation) 74
5.16 Service the battery 77
5.17 Change the fuel filter cartridge 79

BW 141/151 AD-4/BW 151 AC-4 BOMAG 5

Table of Contents

5.18 Change the fuel pre-filter cartridge 79

5.19 Change the oil in the drum drive gear 80
5.20 Checking, tensioning, lubricating the steering chain 81
5.21 Check the engine mounts 82
5.22 Check, tension, replace the V-belt 83
5.23 Checking, tensioning, replacing the refrigerant compressor V-belt 85
5.24 Changing the oil in the vibrator shaft tube 86
5.25 Check, adjust the valve clearance 87
5.26 Changing hydraulic oil and breather filter 89
5.27 Changing the hydraulic oil filter 90
5.28 Grease the articulated joint 91
5.29 Replace the injection valve 92
5.30 Check, clean, change the combustion air filter 94
5.31 Clean the water tank 96
5.32 Clean the water filter 97
5.33 Water sprinkler system, maintenance in the event of frost 98
5.34 Cleaning the emulsion filter (AC-machine) 99
5.35 Fill the provision tank for the windscreen washer system 100
5.36 Adjusting the scrapers 101
5.37 Checking the tire pressure 101
5.38 Tightening torques 102
5.39 Engine conservation 102
Trouble shooting 103
6.1 General notes 104
6.2 Engine 105

6 BOMAG BW 141/151 AD-4/BW 151 AC-4

 1 Technical Data

BW 141/151 AD-4/BW 151 AC-4 BOMAG 7

 Technical Data

Fig. 4

Dimensions in A B C D H H2 K L O W
mm
BW 141 AD-4 3300 1660 710 1220 2320 3000 400 4520 80 1500
BW 151 AD-4 3300 1660 715 1220 2320 3000 400 4520 80 1680

* BW 141 AD-4 BW 151 AD-4

Weights
Operating weight (CECE) kg 7500 7900
Operating weight (CECE) with kg 8000 8300
ROPS-cabin
Front axle load (CECE) kg 3700 3900
Rear axle load (CECE) kg 3800 4000
Static linear load front (CECE) kg/cm 24,7 23
Static linear load rear (CECE) kg/cm 25,3 24

Dimensions
Oscillation angle +/-° 6 6
Inner track radius mm 4490 4400

Travel characteristics
Travel speed (1) km/h 0-10,5 0-10,5
Max. gradability without/with vibra- % 40/35 40/35
tion (soil dependent)

8 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Technical Data

* BW 141 AD-4 BW 151 AD-4

Drive
Engine manufacturer Deutz Deutz
Type BF4M 2011 BF4M 2011
Cooling Oil Oil
Number of cylinders 4 4
Rated power ISO 9249 kW (PS) 60 60
Rated speed rpm 2500 2500
Electrical equipment V 12 12
Battery V/AH 12/100 12/100
Drive system hydrost. hydrost.
Driven drum front + rear front + rear

Brakes
Service brake hydrost. hydrost.
Parking brake mechanical mechanical

Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost.
Steering angle +/- degree 30 30
Crabwalk, lateral offsetting of mm 170 170
drum (right/left)

Vibration system
Drive system hydrost. hydrost.
Frequency 1/2 Hz 40/60 40/60
Amplitude 1/2 mm 0,64/0,28 0,64/0,28
Vibrating drum front + rear front + rear

Water sprinkler system

Type Pressure Pressure
Interval control (+) (+)

Filling capacities
Fuel (diesel) l 160 160
Water l 800 800
Hydraulic oil l 60 60
Engine oil l approx. 10 approx. 10
* The right for technical modifications remains reserved

BW 141/151 AD-4/BW 151 AC-4 BOMAG 9

 Technical Data

Fig. 5

Dimensions in A B C D H H2 K L O W
mm
BW 151 AC-4 3300 1660 715 1220 2320 3000 400 4520 80 1680
BW 161 ADCV 3300 1660 715 1220 2320 3000 400 4520 80 1680

* BW 151 AC-4 BW 161 ADCV

Weights
Operating weight (CECE) kg 8300 7900
Operating weight (CECE) with kg 8750 8300
ROPS-cabin
Front axle load (CECE), drum kg 4150 3900
Rear axle load, (CECE) wheels kg 4600 4000
Static linear load front (CECE) kg/cm 27,7 23
Static linear load rear (CECE) 24

Dimensions
Oscillation angle +/-° 6 6
Inner track radius mm 4400 4400

Travel characteristics
Travel speed (1) km/h 0-10,5 0-10,5
Max. gradability without/with vibra- % 40/35 40/35
tion (soil dependent)

10 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Technical Data

* BW 151 AC-4 BW 161 ADCV

Drive
Engine manufacturer Deutz Deutz
Type BF4M 2011 BF4M 2011
Cooling Oil Oil
Number of cylinders 4 4
Rated power ISO 9249 kW (PS) 60 60
Rated speed rpm 2500 2500
Electrical equipment V 12 12
Battery V/AH 12/100 12/100
Drive system hydrost. hydrost.
Driven drum front + rear front + rear

Drums and tires

Drum width mm 1680
Number of tires 4
Tire size 11,00-20 16 PR

Brakes
Service brake hydrost. hydrost.
Parking brake mechanical mechanical

Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost.
Steering angle +/- degree 30 30
Crabwalk, lateral offsetting of mm 170 170
drum (right/left)

Vibration system
Drive system hydrost. hydrost.
Frequency 1/2 Hz 40/60 40/60
Amplitude 1/2 mm 0,60/0,31 0,64/0,28
Vibrating drum front front + rear

Water sprinkler system

Type Pressure Pressure
Interval control (+) (+)

Filling capacities
Fuel (diesel) l 160 160
Water l 800 800
Hydraulic oil l 60 60
Engine oil l approx. 10 approx. 10
* The right for technical modifications remains reserved

BW 141/151 AD-4/BW 151 AC-4 BOMAG 11

Technical Data

The following noise and vibration data acc. to

- EC Machine Regulation edition 98/37/EC and

- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC

- Vibration Protection Regulation 2002/44/EC

were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.

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

Noise value
sound pressure level on the operator’s stand:
BW 141 AD-4 LpA = 80.0 dB(A) BW 161 AD-4, determined acc. to ISO 11204 and EN 500
BW 151 AD-4 LpA = 79,7 dB(A) BW 161 AD-4, determined acc. to ISO 11204 and EN 500
BW 151 AC-4 LpA = 87.0 dB(A) determined acc. to ISO 11204 and EN 500
BW 161 ADCV LpA = 79.7 dB(A) determined acc. to ISO 11204 and EN 500

Guaranteed sound capacity level:

BW 141 AD-4 LWA = 106 dB(A) determined acc. to ISO 3744 and EN 500
BW 151 AD-4 LWA = 106 dB(A) determined acc. to ISO 3744 and EN 500
BW 151 AC-4 LWA = 106 dB(A) determined acc. to ISO 3744 and EN 500
BW 161 ADCV LWA = 105 dB(A) determined acc. to ISO 3744 and EN 500

! Danger
Wear your personal noise protection means (ear defenders) before starting operation.

Vibration value
Vibration of the entire boy (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is <= 0.5m/sec2.

Hand-arm vibration values

The weighted effective acceleration value determined according to EN 500/ISO 5349 is 2,5 m/sec2.

12 BOMAG BW 141/151 AD-4/BW 151 AC-4

 2 Safety regulations

BW 141/151 AD-4/BW 151 AC-4 BOMAG 13

Safety regulations
General notes
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.
l medium to heavy compaction work in earth
construction (road sub-bases)
l You should only operate the machine with fully
functional safety equipment.
l Have the machine inspected by an expert
once every year.
14
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.
BOMAG BW 141/151 AD-4/BW 151 AC-4

Caution
! Towing the machine
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 stable loading ramps of sufficient load
bearing capacity. The ramp inclination must be
less than the gradability of the machine.
Switch only to first speed range (do not activate
the crabwalk).
Secure the machine against tipping or slipping off.
Secure the machine on the transport vehicle
against rolling, 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 an instruction and during loading.
The machine must not swing about when being lift-
ed.
Use only safe lifting gear of sufficient load bearing
capacity
Fasten the lifting gear only at the specified lifting
points.
BW 141/151 AD-4/BW 151 AC-4
Safety regulations
You should generally use a tow bar.
Max. towing speed 1 km/h, max. towing distance
500 m.
Before releasing the parking brake secure the ma-
chine against rolling.
Checking the Roll Over Protection
Structure (ROPS)
The machine frame must not be distorted, bent or
cracked in the area of the ROPS fastening points.
The ROPS must not show any signs of corrosion,
damage, hairline cracks or open fractures.
The ROPS must not rattle about when driving.
This would indicate that it is not sufficiently fas-
tened. All screw connections must be in accord-
ance with the respective specifications and
correctly tightened (observe the tightening tor-
ques). Screws and nuts must not be damaged,
bent or deformed.
Neither must any additional parts be welded or
bolted on, nor must any holes be drilled without the
permission of the manufacturer, since this may im-
pair the strength of the structure.
Starting the machine
Before starting
The machine must only be operated from the driv-
er’s seat.
Use only machines which are serviced at regular
intervals.
Become acquainted with the equipment, the con-
trol elements, the working principle of the machine
and the working area.
Wear your personal protective outfit (hard hat,
safety boots, ear defenders, etc.).
Before mounting the machine check whether:
l persons or obstructions are beside or under
the machine
l the machine is free of oily and combustible
material
l all grips, steps and platforms are free of
grease, oils, fuel, dirt, snow and ice
l Maintenance doors must be closed and
locked.
BOMAG 15
Safety regulations
Use steps and grips to mount the machine.
Before starting the machine check whether:
l the machine shows any obvious faults
l all guards and safety elements are in place
l steering, brakes, control elements, light sys-
tem and warning horn work correctly
l the seat is correctly adjusted
l mirrors (if present) are clean and correctly ad-
justed.
Do not start the machine with defective gauges,
control lights or control elements.
Do not take any loose objects with you or fasten
them to the machine.
On machines with roll over protection system you
must always wear your seat belt!
Starting
Start and operate the machine only from the driv-
er’s seat (seat contact switch).
For starting set all control levers to 'neutral posi-
tion'.
Do not use any starting aids like start pilot or ether.
Wear ear defenders before starting work.
After starting check all gauges and control lights.
Starting with jump wires
Connect positive with positive and negative with
negative (ground cable) – always connect the
ground strap last and disconnect it first! A wrong
connection will cause severe damage in the elec-
tric system.
Do not start the engine by shorting the electric ter-
minals on the starter motor, because the machine
may start to drive immediately.
Starting in closed rooms
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Driving the machine
Persons in the danger area
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.
16
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.
Keep the cabin doors closed.
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.
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.
BOMAG BW 141/151 AD-4/BW 151 AC-4

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 apply the parking brake
l shut the engine down, pull the ignition key off
l close the cabin
l secure the machine against unauthorized use.
l pull the key off the main battery switch.
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.
Parking on slopes and inclinations
Secure the machine against rolling, place metal
chocks in front of and behind the wheels.
Filling in fuel
Do not inhale any fuel fumes.
Refuel only with the engine stopped and the auxil-
iary heater switched off.
Always use access steps.
Do not refuel in closed rooms.
BW 141/151 AD-4/BW 151 AC-4
Safety regulations
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 dirt and water away
from the fuel.
A leaking fuel tank can cause an explosion. En-
sure tight fit of the fuel tank cover, if necessary re-
place immediately.
Fire protection measures
Familiarise yourself with the location and the oper-
ation of fire fighting equipment. Observe all fire re-
porting and fire fighting possibilities.
Maintenance work
Comply with the maintenance work described in
the operating and maintenance instructions, in-
cluding the information concerning the replace-
ment of parts.
Maintenance work must only be performed by
qualified and authorized persons.
For overhead maintenance and assembly work
use the access steps and working platforms pro-
vided or other secure means. Do not use machine
parts 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 horizontal, level, firm ground.
Pull the key out of the ignition switch.
pull the key off the main battery switch.
Work on hydraulic lines
Relieve hydraulic pressures before working on hy-
draulic lines. Hydraulic oil escaping under pres-
sure can penetrate the skin and cause severe
injury. When being injured by hydraulic oil consult
a medical doctor immediately, as otherwise this
may cause severe infections.
Do not step in front of or behind the drums/wheels
when performing adjustment work in the hydraulic
system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature –
danger of scalding!
BOMAG 17
Safety regulations
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always catch and dispose of hydraulic oils sepa-
rately.
Do not start the engine after draining the hydraulic
oil.
Once all work is completed (with the system still
depressurized!) check all connections and fittings
for leaks.
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at reg-
ular intervals.
Hydraulic hoses must be immediately replaced if:
l the outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
l the outer layer is brittle (formation of cracks in
the hose material)
l the hose shows deformations in pressurized
and depressurized condition, which do not
comply with the genuine shape of the hydrau-
lic hose
l the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, forma-
tion of blisters
l parts of the hose are leaking.
l hoses are not correctly installed.
l the hydraulic hose has separated from the fit-
ting
l the fitting shows corrosion that impairs both
function and strength.
l hoses are mixed up by mistake.
l fittings are damaged or deformed, whereby
the function and strength of the hose/hose
connection is impaired.
Only genuine BOMAG replacement hydraulic hos-
es ensure that the correct hose type (pressure
range) is used at the right location.
Working on the engine
Shut the engine down before opening the service
doors.
Drain the engine oil at operating temperature –
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
18
Store used filters and other oil contaminated ma-
terials in a separate, specially marked container
and dispose of environmentally.
Do not leave and tools or other objects, that could
cause damage, in the engine compartment.
Check and change coolant only when the engine
is cold.
Catch coolant and dispose of environmentally.
Working on electric parts of the machine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire haz-
ard!
Disconnect the battery before starting welding
work on the machine.
Working on the battery
When working on the battery do not smoke, do not
use open fire!
Do not let acid come in contact with hands or
clothes! When injured by acid flush off with clear
water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must
not come in contact with the battery poles – dan-
ger of short circuit and burning!
When recharging serviceable batteries remove all
plugs, to avoid the accumulation of explosive gas-
es.
Observe the applicable instructions when starting
with an auxiliary battery.
Dispose of old batteries according to regulations.
Switch off the charging current before removing
the charging clamps.
Ensure sufficient ventilation, especially if the bat-
tery is to be charged in a closed room.
Working on the fuel system
Do not inhale any fuel fumes.
No open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground and dispose off environmentally.
Cleaning work
Do not perform cleaning work while the engine is
running.
BOMAG BW 141/151 AD-4/BW 151 AC-4
 Safety regulations

Do not use gasoline or other easily inflammable

substances for cleaning.
When cleaning with steam cleaning equipment do
not subject electrical parts and insulation material
to the direct jet of water, or cover it beforehand.
l Do not guide the water jet into the exhaust and
into the air filter.

After maintenance work

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

Repair
Attach a warning tag to the steering wheel if the
machine is defective.
Repairs must only be performed by qualified and
authorized persons. Refer to our repair instruc-
tions.
Exhaust fumes are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!

Test
Depending on the type of application and the op-
erating conditions vibratory equipment has to be
examined by a specialist whenever required, but
at least once every year.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 19

Safety regulations

20 BOMAG BW 141/151 AD-4/BW 151 AC-4

 3 Indicators and Controls

BW 141/151 AD-4/BW 151 AC-4 BOMAG 21

 Indicators and Controls

Fig. 6

22 BOMAG BW 141/151 AD-4/BW 151 AC-4


1 E-Vib display*
2 Instrument cluster, left
3 Emergency stop push button
4 Rotary switch for hazard light system*
5 Instrument cluster, right
6 Speedometer*
7 Ignition switch
8 Rotary switch for chip spreader*
9 Rotary momentary contact switch for chipping
quantity control*
10 Rotary momentary contact switch for engine
speed
11 not used!
12 Rotary switch for tire sprinkling system (only
AC-4)
13 Rotary switch for sprinkling pumps
14 Rotary switch for vibration, drum pre-selection
15 Rotary switch for vibration, manual - zero - au-
tomatic
16 Rotary switch for amplitude pre-selection
17 Rotary switch for direction indicators left/right*
* Optional equipment
BW 141/151 AD-4/BW 151 AC-4
Indicators and Controls
18 Rotary switch for lighting (StVZO)*
19 Rotary switch for working head lights*
20 Lever, swivelling of driver’s seat
21 Momentary contact push button to raise the
edge cutter
22 Momentary contact push button to lower the
edge cutter
23 Travel lever, right
24 Push button for manual vibration
25 Push button for warning horn
26 Rotary switch for edge cutter sprinkler system*
27 Interval switch for pressure sprinkler system
28 Travel lever, left
29 Momentary contact push button for crabwalk,
left
30 Momentary contact push button for crabwalk,
right
31 Push button for manual vibration
32 Lever, lateral sliding of driver’s seat
33 Rotation stop for travel lever movement
34 2-pole socket
BOMAG 23
Indicators and Controls

3.1 General notes 3.2 Description of indicators

and control elements
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.

Fig. 7
No. 1 = EVIBdisplay*
is a compaction measuring unit for continuous dis-
play of the load bearing characteristics (MN/m2)
during the compacting pass.

EVIB value
Increase = higher load bearing capacity
Constant = end of compaction

Fig. 8
No. 2 = Instrument cluster, left

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

* Optional equipment

24 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Indicators and Controls

a red flash- m = Operating hour meter, counts the op-

ing = Overheating of engine, higher than erating hours while the engine is run-
110°C, warning buzzer sounds. ning. All maintenance work must be
Switch off vibration, run engine with performed according to the indicated
idle speed or shut down engine if operating hours.
necessary, clean engine oil cooler n = Fuel tank filling level
and radiator, if necessary repair en-
gine.
b red flash- i Note
ing = Engine oil pressure too low, engine is Nine green and one red LED.
shut down after 10 seconds. Check When falling below the lowest filling level the last
engine oil level, repair the engine if green LED will light and the red LED will addition-
necessary. ally come on.
c yellow = Engine air filter, air filter cartridge When the fuel tank is empty only the red LED will
soiled, clean or replace if necessary. flash.
d yellow = Charge control mlight, batteries are
not being charged, check V-belt, re-
pair the generator if necessary
e yellow = Hydraulic oil filter, check hydraulic
system, replace hydraulic oil filter.
f yellow = Seat contact monitoring while ma-
chine is travelling, warning buzzer
sounds, engine is shut down after 4
seconds.
g red = Parking brake, with lever shifted to
parking brake position, with driver’s
seat unoccupied.
h green
Fig. 9
flashing = Travel direction indicator, with travel
direction lever actuated. No. 3 = Emergency stop push button
i yellow = Water separator in fuel pre-filter, if
the water proportion in the transpar- ! Danger
ent section of the fuel pre-filter reach- Danger of accident!
es the contacts.
Use only in events of emergency during oper-
j red flash-
ation.
ing = Optional; coolant provision (filling lev-
el) Do not use as parking brake.
* Restart the machine only after the danger that
k yellow = Pre-heating and after-heating
caused the actuation of the emergency stop
= Between -30°C and +10°C pre-heat-
switch has been eliminated.
ing in ignition switch position I and
momentary contact switch for engine The machine is braked immediately, the engine
speed in idle speed position. After is shut down.
light goes out start within 14 seconds. actuate = press the button completely
l red flash- down, it automatically locks in
ing = Hazard light, with hazard light switch fully pressed position.
depressed switch off/un-
lock = Turn button clockwise. Re-
start the engine.
* Optional equipment

BW 141/151 AD-4/BW 151 AC-4 BOMAG 25

Indicators and Controls

d yellow = Fast travel range, vibration goes out

or cannot be switched on
e yellow = Crabwalk, with crabwalk actuated to
left/right, goes out in middle position
f yellow = Air condition failure.
g red flash-
ing = Fault light/ failure of Asphalt Manager
control*
h green = Chip spreader switched on.
i empty = not used
j green = maximum speed switched on.
Fig. 10 k yellow = Minimum fuel filling level, reserve
No. 4 = Rotary switch for hazard light l red flash-
Position ing = no function; hydraulic oil temperature
"Left" = Hazard light switched off, control m = Water tank filling level
lights off.
Position
"Right" = Hazard light system switched on,
i Note
Nine green and one red LED.
warning light (l) in left hand instru-
ment cluster flashes red and switch When falling below the lowest filling level the last
flashes red. green LED will light and the red LED will addition-
ally come on.
When the fuel tank is empty only the red LED will
flash.

Fig. 11
No. 5 = Instrument cluster, right

Fig. 12
i Note
With the ignition switch in position I all gauges and No. 6 = Speedometer*
instruments are switched on for 3 seconds. Shows the travel speed of the machine.
a red flash- black display
ing = No function; immobilizer scale = km/h
b empty = not used red display
scale = M.P.H.
c yellow = Remaining water quantity, warning
buzzer sounds

26 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Indicators and Controls

Fig. 13 Fig. 14
No. 7 = Ignition switch No. 8 = Rotary switch for chip spreader*
Position "P"/"0" = Ignition off, key can be pulled Position
out left = Chip spreader switched off
Position "I" = Ignition on, all instruments in Position
the instrument cluster light up right = Chip spreader switched on
for 3 seconds. The lighting
system can be switched on.
i Note
Control light (h) in right hand instrument cluster
i Note lights up.
The engine can only be started if both travel levers
are in “neutral”.
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"
(Start) = turn further against spring
pressure, start engine, return
ignition key to position "I".

i Note
Perform the starting process for maximum 15 – 20
Fig. 15
seconds without interruption and pause for about
a minute between starting attempts. Should the No. 9 = Rotary momentary contact switch for
engine not start in this time, perform trouble shoot- chip quantity**
ing and rectify the cause. Position left = Reduce chip quantity
Position right = Increase chip quantity
! Caution
Run the engine warm for a short while before
starting work. Do not allow the engine to run
longer than 10 minutes with idle speed.
Do not shut the engine down all of the sudden
from full speed, but let it idle for a while for
* Optional equipment
temperature equalization.
** Optional equipment

BW 141/151 AD-4/BW 151 AC-4 BOMAG 27

Indicators and Controls

Fig. 16 Fig. 17
No. 10 = Rotary momentary contact switch for No. 12 = Rotary momentary contact switch for
engine speed tire sprinkling system (only AC-ma-
Electric engine speed adjustment chines)

turn clockwise = Idle speed position Position "left" = 5 sec. on / 20 sec. off (interval)
emulsion sprinkling
Position "0" = Sprinkler system switched off
i Note
Normal position for engine start. Momentary con-
tact switch
turn clockwise = Full load position, operating "right" = 5 sec. emulsion sprinkling on
position for driving and vibra-
tion

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

! Caution
Always drive and vibrate with max. engine Fig. 18
speed! Control the travel speed with the travel No. 13 = Rotary switch for sprinkling pumps
lever.
Position left = Sprinkling pump I switched on
No. 11 = not used Position middle = Sprinkling pumps switched off
Position right = Sprinkling pump II switched on

i Note
Sprinkling pumps I and II switched on alternately

28 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Indicators and Controls

falling below a certain slow

travel speed.
Position "mid-
dle" = Vibration off

Fig. 19
No. 14 = Rotary switch for vibration, drum pre-
selection

i Note
Fig. 21
Vibration change-over is only activated if the vibra-
No. 16 = Rotary switch for vibration, amplitude
tion is switched off beforehand.
selection
Position "left" = Vibration of front drum Position "left" = low amplitude, high frequency
Position "mid- Position "right" = high amplitude, low frequency
dle" = Vibration of front and rear
drums
Position "right" = Vibration of rear drum

Fig. 20
No. 15 = Rotary switch for vibration, manual or
automatic
Position "left" = Pre-selection for vibration acti-
vation during travel via the vi-
bration push button in the
travel lever
Position "right" = Pre-selection for automatic ac-
tivation and deactivation of vi-
bration when exceeding or
Fig. 22
No. 17 = Rotary switch for direction indicators
left / right*
Position "mid-
dle" = Direction indicators disabled
Position "left or
right" = The front and rear direction in-
dicators for the corresponding
side of the machine light up,
the control light (h) in the in-
strument cluster flashes
* Optional equipment

BW 141/151 AD-4/BW 151 AC-4 BOMAG 29

 Indicators and Controls

Fig. 23 Fig. 25
No. 18 = Rotary switch for light system (StV- No. 20 = Lever, swivelling of driver’s seat
ZO)*
Position "left" = Light off Danger
!
Position "mid- Danger of accident!
dle" = Sidelights on, with ignition
switch in position "I" or with Always lock the driver’s seat in one of the lock-
only ignition on. ing positions while driving.

Position "right" = Travel light on, with ignition
switch in position "I"
Do not swivel the driver’s seat while driving.
swivel = Stop he machine, apply the
parking brake. Pull the lever
and swivel the driver’s seat to
the desired position. Let lever
click securely into place.

Fig. 24
No. 19 = Rotary switch for working lights**
Position "left" = Light off
Position "right" = Working lights on, with ignition Fig. 26
switch in position "I" No. 21 = Momentary contact push button to
raise the edge cutter***
press = Edged cutter is raised.
release = Edge cutter remains in position
reached last.

* Optional equipment
** Optional equipment *** Optional equipment

30 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Indicators and Controls

the warning buzzer will sound and warning light (f)

in the instrument cluster will light up.
If the engine speed drops under load when driving
on steep gradients, take the travel lever slightly
back towards neutral. This relieves the hydraulic
system and reduces the load on the diesel engine.
Position "III" = notched position to the right =
parking brake, starting of en-
gine

i Note
The parking brake control light (g) in the left hand
Fig. 27 instrument cluster lights up.
No. 22 = Momentary contact push button to
lower the edge cutter*
press = Edged cutter is lowered.
release = Edge cutter remains in position
reached last.

Fig. 29
No. 24 = Momentary contact push button for
manual vibration, right
press = to switch manual vibration on
and off.
Fig. 28
No. 23 = Travel lever, right
Position „0“ = start forward and backward
travel from position ’’0“. From
forward or backward travel to
position ’’0“ = service brake
Position "I" = Forward travel
Position "II" = Backwards travel

i Note
The right hand travel lever is mechanically linked
with the left hand travel lever.
Fig. 30
When leaving the seat (seat contact switch) with
the engine is running and/or the machine driving, No. 25 = Push button for warning horn
the engine will be shut down after the 4 seconds,
* Optional equipment

BW 141/151 AD-4/BW 151 AC-4 BOMAG 31

 Indicators and Controls

i Note
In travel lever position ’’0“ the sprinkling system is
switched off, except in position 12 (permanent
sprinkling).
further positions
to the right, be-
tween 11 and 1 = various sprinkling intervals

Fig. 31
No. 26 = Rotary switch, edge cutter sprinkler
system*
Position right = Edge cutter sprinkling system
switched on.

i Note
The edge cutter sprinkler system works when the
Fig. 33
rotary switch has been switched to sprinkling
pump I or II. No. 28 = Travel lever, left

Position left = Edge cutter sprinkling system Position „0“ = start forward and backward
switched off travel from position ’’0“. From
forward or backward travel to
position ’’0“ = service brake
Position "I" = Forward travel
Position "II" = Backwards travel

Fig. 32
No. 27 = Interval switch for pressure sprinkler
system
Position 12 left = permanent sprinkling when
pressure sprinkling is enabled
i Note
The left hand travel lever is mechanically linked
with the right hand travel lever.
When leaving the seat (seat contact switch) with
the engine is running and/or the machine driving,
the engine will be shut down after the 4 seconds,
the warning buzzer will sound and warning light (f)
in the instrument cluster will light up.
If the engine speed drops under load when driving
on steep gradients, take the travel lever slightly
back towards neutral. This relieves the hydraulic
system and reduces the load on the diesel engine.
Position "III" = notched position to the left =
parking brake, starting of en-
gine

* Optional equipment

32 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Indicators and Controls

i Note i Note
The parking brake control light (g) in the left hand Control light (e) in right hand instrument cluster
instrument cluster lights up. lights up.
Control light goes out when middle position is
reached.
release = Crabwalk remains in position
reached last.

Fig. 34
No. 29 = Momentary contact push button for
crabwalk, left
press = the crabwalk is infinitely ad-
justed to left. Fig. 36
No. 31 = Momentary contact push button for
i Note manual vibration, left
Control light (e) in right hand instrument cluster press = to switch manual vibration on
lights up. and off.
Control light goes out when middle position is
reached.
release = Crabwalk remains in position
reached last.

Fig. 37
No. 32 = Lever, lateral sliding of driver’s seat

! Danger
Fig. 35 Danger of accident!
No. 30 = Momentary contact push button for
Always lock the driver’s seat in one of the lock-
crabwalk, right
ing positions while driving.
press = the crabwalk is infinitely ad-
Do not slide the driver’s seat while driving.
justed to right.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 33

Indicators and Controls

sliding = Stop machine, apply parking

brake, pull lever and slide driv-
er’s seat sideways to desired
position. Let lever click secure-
ly into place.

Fig. 40
No. 35 = Main battery switch
The main battery switch is installed in the engine
compartment.
inserted and
Fig. 38 turned in = machine can be started.
No. 33 = Rotation stop for travel lever move- removed = engine cannot be started, (an-
ment ti-theft protection)
Turn anti-clock-
wise = long travel lever movement

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

i Note
machine can be driven with reduced speed in ac-
cordance with the length the stop is screwed in.

Fig. 41
No. 36 = Fuses in electric junction box

Fuses
(1), 30A = (F01) main fuse
(2), 15A = (F05) Socket
(3), 10A = (F93) control potential 30
(4), 20A = (F105) engine speed
(5), 25A = (F37) sprinkler pump
(6), 20A = (F61) sprinkler pump
Fig. 39 (7), 15A = (F07) hazard light
No. 34 = 2-pole socket (8), 7,5A = (F119) engine
Permanent current when main battery switch is (9), 5A = (F25) solenoid valve for driving and
switched on. braking

34 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Indicators and Controls

(10), 10A = (F14) engine solenoid

(11), 15A = (F129) MD+
(12), 5A = (F04) gauges
(13), 10A = (F23) warning horn
(14), 10A = (F03) vibration
(15), 15A = (F08) direction indicators and work-
ing head lights
(16), 10A = (F101) Variomatic, potential 15
(17), 10A = (F06) water sprinkling system
(18), 10A = (F09) parking and tail light, left hand
side
Fig. 43
(19), 10A = (F10) parking and tail light, right hand
No. 38 = Control elements, cabin*
side
(20), 10A = (F11) head lights, left hand side
(21), 10A = (F12) head lights, right hand side

! Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.

Fig. 44

a = toggle switch for flashing beacon

b = toggle switch for front windscreen wiper/

washer
up = windscreen wiper moves to
end position and stops.
down = Switches on wiping of front
windscreen.
Fig. 42
No. 37 = Main fuse for battery Push button = Front windscreen is sprayed
during wiping.
The battery main fuse is located inside the battery
compartment. c = toggle switch for rear windscreen wiper/
(1), 125A = (F00) main fuse for battery washer
up = windscreen wiper moves to
end position and stops.
! Caution
down = Switches on wiping of rear
Risk of total discharge of battery.
windscreen.
Push button = Rear windscreen is sprayed
during wiping.

* Optional equipment

BW 141/151 AD-4/BW 151 AC-4 BOMAG 35

Indicators and Controls

h = toggle switch for working headlights Position 1, 2 and

3 = ventilator stages of different
strengths

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

f = Push button for air conditioning*

press = air conditioning switched on.

i Note
The light above the push button and control light (f)
Fig. 45 in the instrument cluster light up.
d = Fuse box in cabin With rotary switch (g) the air conditioning unit can
be regulated within the blue range.
! Danger press again = air conditioning switched off.
Fire hazard!
Do not use fuses with higher ampere ratings i Note
and do not bridge fuses. The light go out.
(1), 15A = (F41) flashing beacon g = Rotary switch for cabin heater (tempera-
(2), 15A = (F27) wiper/washer, front ture selector switch)
(3), 15A = (F28) wiper/washer, rear Position ’’Off“ = cabin heater switched off.
(4), 25A = (F31) cabin fan Position blue
(5), 25A = (F110) working head lights, front/rear range = temperature selection for air
conditioning.
(6), 5A = (F15) cabin heater
Position red
(7), 10A = (F68) potential 30 range = Temperature selection for cab-
(8), 20A = (F40) cabin heater in heater.

Fig. 46

e = Rotary switch for cabin ventilator

Position ’’Off“ = cabin ventilator switched off.
* Optional equipment

36 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Indicators and Controls

Fig. 47 Fig. 49
No. 40 = Vents for air conditioning, ventilation
i = reading and dshboard light
and heating, right hand side **
j = toggle switch for reading and dashboard
light

k = toggle switch for cabin light

l = cabin light

Fig. 48
No. 39 = Vents for air conditioning, ventilation
and heating, left hand side*

* Optional equipment ** Optional equipment

BW 141/151 AD-4/BW 151 AC-4 BOMAG 37

Indicators and Controls

38 BOMAG BW 141/151 AD-4/BW 151 AC-4

 4 Operation

BW 141/151 AD-4/BW 151 AC-4 BOMAG 39

Operation

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 proper maintenance of the machine
l right and left hand service doors closed and
locked

i Note
For a description of the following tasks refer to the
chapter "maintenance every 10 operating hours".
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.
l Check the coolant level, top up if necessary.

! Danger
Fire hazard!
Do not refuel in closed rooms.
l Check the fuel level, top up if necessary.

40 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Operation

l Check water separator in fuel system, drain if

necessary. 4.3 Starting the engine
l Fill water tanks
l Clean the scrapers, check their condition, re- ! Danger
place if necessary.
Wear ear defenders before starting work.
l Open the right hand service door.

Fig. 50

l Insert and lock the main battery switch (Fig.

50).
l Close the right hand service door.

Fig. 51

l Always start the engine from the driver’s seat

with seat contact switch (Fig. 51).

Danger
!

Danger of accident!
Always wear your seat belt.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 41

Operation

Fig. 52 Fig. 55

l Fasten your seat belt (Fig. 52). l Check, whether the emergency stop switch
(Fig. 55) is unlocked.

Fig. 53
Fig. 56
l Adjust the driver’s seat and let it click into
place (Fig. 53). l Turn the ignition key (Fig. 56) to position "I".

Fig. 54 Fig. 57

l Check, whether the travel lever (Fig. 54) is en- All control and warning lights (Fig. 57) and (Fig.
gaged in brake position (III). 58) in the fault monitoring board light up for ap-
prox. 3 seconds.

42 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Operation

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

Fig. 58
Charge control light (d), engine oil pressure warn-
ing light (b) and brake warning light (g) stay on.

Fig. 60
l After control light goes out start within 14 sec-
onds. l Turn the rotary momentary contact switch for
engine speed (Fig. 60) counter-clockwise to
position ”MIN” to run the engine warm.

Fig. 59

l Turn the ignition key to position "II" (Fig. 59),

the starter cranks the engine.

! Caution
Perform the starting process for maximum 20
seconds without interruption and pause for a
minute between starting attempts.
If the engine has not started after two attempts
perform trouble shooting.
l As soon as the engine ignites return the igni-
tion key to position "I".
Charge control light and engine oil pressure warn-
ing light go out. The brake warning light stays on.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 43

Operation

then to engine or chassis ground, as far away

4.4 Starting with jump wires from the battery as possible(Fig. 62).
l Start as described under 'Starting the engine'.

! Danger l Once the engine is running switch on a power-

ful consumer (working light, etc.).
Wear ear defenders before starting work.

!Caution
If no powerful consumer is switched on volt-
age peaks may occur when separating the con-
necting cables between the batteries, which
could damage electrical components.
l After starting disconnect the negative poles
(ground cable) first and the positive poles af-
ter.
l Switch off the consumer.
l Fasten the battery cover again.

Fig. 61

l Remove the battery cover (Fig. 61).

Fig. 62

!Caution
A wrong connection will cause severe damage
in the electric system.
l Only use a 12 Volt battery to bridge the ma-
chine.
l When jump starting with an external battery
connect both plus poles first.
l Then connect the ground cable first to the mi-
nus pole of the current supplying battery and

44 BOMAG BW 141/151 AD-4/BW 151 AC-4

 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-
Fig. 64
ing the maximum gradability of the machine
(see technical data).
Always give way to loaded transport vehicles! i Note
Control light j (Fig. 64) in right hand instrument
Before starting to drive make sure that the
cluster lights up.
drive range is absolutely safe.

Fig. 65
Fig. 63
l Disengage the travel lever (Fig. 65) from
l Turn the rotary momentary contact switch for
notched position III towards the inside.
engine speed clockwise to "MAX" (Fig. 63).

i Note i Note
The brake warning lamp (g) in the instrument clus-
The engine revs up to maximum speed.
ter goes out.
l Move the travel lever form "0"-position slowly
! Caution
to forward or reverse.
Always drive and vibrate with max. engine
speed! Control the travel speed with the travel
lever. i Note
The machine drives forward or backward with a
speed that corresponds with the actuation of the
travel lever.
l Move the travel lever back to "0"-position.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 45

Operation

i Note Danger
!

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

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

When stopping on inclinations and slopes en-

gage the travel lever towards the outside in
parking brake position.

Important notes on travel operation

! Caution
When changing the travel direction hold the
travel lever for a moment in "0"-position, until
the machine has stopped, before actuating to
the new travel direction.
Do not operate jerkily! Control the travel speed
Fig. 67
with the travel lever.
When driving up and down inclinations move
the travel lever slowly back towards neutral to i Note
brake the machine. The warning lights for seat occupation and parking
brake f and g (Fig. 67) in the left hand instrument
If the engine speed drops when driving up ex-
cluster light up.
treme inclinations move the ravel lever slightly
back, if necessary change to the lower speed l To continue travelling you must occupy the
range. seat and put on the seat belt within 4 seconds.
The warning lights go out and the warning
Seat contact switch horn stops sounding.
l If the engine stops restarting is required.

Fig. 66

i Note
In travel lever positions "I" and "II" the seat contact
switch is active (Fig. 66).

46 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Operation

4.6 Stopping the machine, op- 4.7 Shutting the engine down
erating the parking brake

Fig. 70

Fig. 68 l Return the travel lever (Fig. 70) slowly to "0"-

l Return the travel lever (Fig. 68) slowly to "0"-
position and engage it towards the outside in
notched position "III", parking brake position.
i Note
The machine is automatically braked by the hydro-
static drive and the parking brake is applied.
position and engage it towards the outside in
notched position "III", parking brake position.
i Note
The machine is automatically braked hydrostati-
cally.
The parking brake warning light in the left hand in-
strument cluster lights up.

Fig. 69
The parking brake warning light g (Fig. 69) in the
left hand instrument cluster lights up.
i Note
The parking brake also closes automatically when
shutting the engine down.
Fig. 71
l Turn the rotary momentary contact switch for
engine speed counter-clockwise to "MIN" (idle
speed) (Fig. 71).
i Note
The control light for maximum engine speed j in
the right hand instrument cluster goes out.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 47

Operation

Do not shut the engine down all of the sudden from

full speed, but let it idle for a while for temperature 4.8 Switching the vibration on
equalization. and off

i Note
Switch the vibration on only at maximum engine
speed.
Vibration at standstill causes transverse ruts,
therefore:
l switch the vibration on only after shifting the
travel lever to the desired travel direction.
l Switch the vibration off before stopping the
machine.

Fig. 72
Caution
!
l Turn the ignition switch (Fig. 72) to position "0" Danger of bearing damage!
or "P" and pull the ignition key out.
Do not activate the vibration on hard (frozen,
concrete) ground.
i Note
The parking brake closes automatically when
shutting the engine down. ! Danger
Risk of damage!
l Open the right hand service door.
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.

Pre-selecting the vibration

Fig. 73

l Remove the main battery switch (Fig. 73) and

store it in a safe place.
l Close the right hand service door.

Danger
!

Danger of accident! Fig. 74

Secure the machine against unauthorized use, l Pre-select amplitude/frequency with the rotary
pull the ignition key out, lock the cabin door. switch (Fig. 74).

48 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Operation

Fig. 75 Fig. 77

l Preselect the desired drum or drums with the l Turn the rotary momentary contact switch for
rotary switch (Fig. 75). engine speed clockwise to "MAX" (Fig. 77).

i Note i Note
The drum pre-selection "front/ both/ rear" can only Control light j in right hand instrument cluster lights
be changed after switching the vibration off. up.

Vibration in manual mode

Fig. 78

l Actuate the vibration push button (Fig. 78) in

Fig. 76 the left or right hand travel lever only after shift-
l Turn the rotary switch for vibration in manual ing the travel lever to the desired travel direc-
or automatic mode (Fig. 76) anti-clockwise to tion.
the symbol "Manual".
Switching the vibration off
Switch the vibration on l Press the vibration push button again.

! Caution i Note
Switch the vibration on only at max. engine Always switch the vibration off before stopping the
speed. machine.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 49

Operation

Vibration in automatic mode Switching the vibration off

Fig. 79 Fig. 81

l Turn the rotary switch (Fig. 79) clockwise to l Shift the travel lever (Fig. 81) towards "0"-po-
"Automatic". sition to brake the machine.

Switch the vibration on i Note

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

Fig. 80

l Shift the travel lever (Fig. 80) in direction for-

ward or backward.

i Note
The vibration comes on at a low travel speed.

50 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Operation

4.9 Operating the crabwalk

Fig. 84

i Note
Fig. 82
The crabwalk control light e (Fig. 84) in the right
hand instrument cluster lights up.
i Note
Control light goes out when middle position is
The maximum offset (Fig. 82) to right and left is reached.
170 mm.

Danger
!

Operate the crabwalk only at low travel speed,

in order to stay in track.

Fig. 85

l Press and hold the right hand push button

(Fig. 85) on the left hand travel lever.

Fig. 83
i Note
the crabwalk is infinitely adjusted to right.
l Press and hold the left hand push button (Fig.
83) on the left hand travel lever. The crabwalk operates immediately, also in stand-
still.

i Note
The crabwalk is infinitely adjusted to left.
The crabwalk operates immediately, also in stand-
still.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 51

Operation

4.10 Switching the pressure i Note

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

Fig. 86
l Turn the rotary switch for the pressure sprin-
kling system (Fig. 86) to position "left" (sprin-
kling pump I) or position ’’right“ (sprinkling
pump II).
i Note
The pressure sprinkler system is switched on.
For sprinkling switch alternately between sprin-
kling pumps I and II to achieve even straining of
the sprinkling pumps.
Fig. 88
i Note
When the water tank is empty the warning light for
residual water quantity in water sprinkling system
c (Fig. 88) in the right hand instrument cluster will
light up and the warning buzzer will sound.
In the water tank filling level gauge (m) the last
green and the red LED will light or the red LED will
flash.
l Perform trouble shooting and rectify the
cause.

Fig. 87

l Set the interval switch for pressure sprinkling

system to the desired sprinkling interval (Fig.
87).

52 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Operation

4.11 Sprinkling of edge cutter* 4.12 Actuating the emergency

stop switch

! Danger
Danger of accident!
In events of emergency and in case of danger
actuate the emergency stop switch immediate-
ly.
Start travel operation of the machine only after
the danger that caused the actuation of the
emergency stop switch has been eliminated.

!Caution
Fig. 89
Do not use as service brake. The deceleration
l Turn the rotary sprinkling system switch (Fig. is extremely high. In case of frequent use the
89) to left or right. wear on the multi-dics brakes will be very high.

Fig. 90 Fig. 91
l Turn the rotary switch (Fig. 90) for edge cutter l Press the button of the emergency stop switch
sprinkling clockwise. (Fig. 91) completely down, it automatically
locks in fully pressed position.
i Note
The edge cutter is sprinkled in the same interval as i Note
the drums. Shuts the engine down and closes the brake.
l Turn the rotary switch to the left to switch off l Turn the button clockwise to unlock the emer-
the sprinkling system. gency stop switch.
l Start the engine again, see chapter "Starting
the engine".

* Optional equipment

BW 141/151 AD-4/BW 151 AC-4 BOMAG 53

Operation
4.13 Adjusting the rotation stop
for travel lever movement
i Note
Use the rotation stop only to adjust a predeter-
mined travel speed, then release the full travel le-
ver movement again.
Fig. 92
l Loosen the fastening nut.
l Turn the rotary stop (Fig. 92) in or out, until the
desired travel lever movement is reached.
l Retighten the fastening nut.
54
4.14 Adjusting the driver’s seat
! Danger
Danger of accident!
Do not adjust the driver’s seat while driving.
Fig. 93
a = Pull the lever and lock the driver's
seat (Fig. 93) in one of 9 possible ro-
tary positions.
b = Disengage the lever and adjust the
seat in longitudinal direction.
c = Operate the lever and adjust the back
rest.
d = Pull the lever and lock the driver's
seat in one of 9 possible lateral posi-
tions.
e = read the adjusted driver’s weight in
the window.
f = Adjust the weight of the driver with
the lever.
BOMAG BW 141/151 AD-4/BW 151 AC-4
 Operation

4.15 Opening or closing the cab- 4.16 Towing

in window
! Danger
! Caution Danger of accident!
Always keep the cabin doors closed while driv- Before releasing the brake secure the machine
ing. against unintended rolling.
Always lock the cabin windows in open posi-
tion or close them. ! Caution
Tow the machine only after releasing the park-
ing brake.
Towing speed 1 km/h, max. towing distance
500 m.

Releasing the parking brake

Fig. 94

l Open the locking (Fig. 94) of the cabin win-

dow.
l Swing out and lock the cabin window.

Fig. 96

l Open the left hand maintenance door (Fig.

96).

Fig. 95

l To close the cabin window press the locking

button (Fig. 95), swing the cabin window back
and lock it.

Fig. 97

l Press the emergency operation button (Fig.

97) completely down.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 55

Operation

Danger
!

Danger of accident!
If the emergency control button remains
pressed in, the automatic parking brake is out
of function.
When the machine is functional again, do not
forget to pull out the emergency operation
switch completely.

i Note
The pump lever extension bar is stored inside the
service door. Fig. 99

l Pull the emergency operation button (Fig. 99)

completely up.

Fig. 98

l Release the brake by operating the hand

pump (Fig. 98).

After towing

!Caution
Before detaching the tow bar block the ma-
chine with chocks to prevent unintended roll-
ing.

56 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Operation

4.17 Transport

! Danger
Danger of accident!
Use only stable loading ramps of sufficient
load bearing capacity. Make sure that persons
are not endangered by the machine tipping or
sliding off.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
Fig. 101
Do not stand or step under loads being lifted.
Always use shackles on the lifting points for l Remove circlip 2 (Fig. 101).
loading, tying or lifting the machine. l Lift up the articulation lock (1) and turn it to the
right, until the locking pin clicks into place.
! Danger

Danger of accident!
Do not drive with crabwalk onto the transport
vehicle.

Fig. 102

l Secure the articulation lock (1) with split pin 2

(Fig. 102).

Fig. 100

l Position of centre of gravity (Fig. 100).

Machine L H

BW 141 AD-4 1650 1020

BW 151 AD-4 1650 1000

BW 151 AC-4 1580 1010

i Note
Secure the machine with the articulation lock after
driving it on the transport vehicle.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 57

Operation

Fig. 103

l Lash the machine to the transport vehicle, fas-

ten the lashing gear (Fig. 103) to the front and
rear support legs.

Fig. 104

l Use the four lifting eyes (Fig. 104) to lift the

machine.

i Note
The tolerances account for all possible options,
such as cabin, additional weight etc.
Loading weight: see technical data.

58 BOMAG BW 141/151 AD-4/BW 151 AC-4

 5 Maintenance

BW 141/151 AD-4/BW 151 AC-4 BOMAG 59

Maintenance
5.1 General notes on mainte-
nance
When servicing the machine pay careful attention
to all applicable safety instructions.
Thorough maintenance of the machine ensures
maximum reliability and prolongs the lifetime of im-
portant components. The necessary effort can by
no means be compared with the faults which may
occur when not observing these instructions.
The terms left/right are always related to travel di-
rection forward.
l Clean machine and engine thoroughly before
starting maintenance work.
l For maintenance work park the machine on
level ground.
l Maintenance work must generally be carried
out with the engine shut down.
l Depressurize hydraulic lines before working
on them.
l Disconnect the battery and cover it with insu-
lation material before starting to work on elec-
trical components.
l Always attach the articulation lock (transport
lock) before starting to work in the articulation
area of the machine.
Environment
During maintenance work catch all oils and fu-
els and do not let them seep into the ground or
into the sewage system. Dispose of oils and
fuel environmentally.
Store used filters in a special waste container
and dispose of environmentally.
Always catch biodegradable oil separately.
Notes on the fuel system
The lifetime of the diesel engine is decisively de-
pending on the cleanliness of the fuel.
l Keep the engine free of dirt and water as this
could damage the injection elements of the en-
gine.
l When choosing the storage location for fuel
make sure that spilled fuel will not harm the en-
vironment.
60
l Do not let the suction hose disturb the sludge
on the bottom of the drum.
l Fuel left in the fuel drum is not suitable for the
engine and should only be used for cleaning
purposes.
Notes on the engine performance
Combustion air and fuel injection rates of the die-
sel engine have been carefully adjusted and deter-
mine the engine's performance and temperature
level as well as the quality of the exhaust gas.
If your machine has to work permanently in "thin
air" (at high altitudes) and with full load you should
consult or service department or the service de-
partment of the engine manufacturer.
Notes on the hydraulic system
When servicing the hydraulic system cleanliness if
of utmost importance. make sure that no dirt or
other contaminating systems can enter the sys-
tem. Small particles can flute valves, cause pumps
to seize and block restrictors and pilot bores,
thereby causing costly repairs.
l If during the daily oil level check the oil level is
found to have dropped, check all lines, hoses
and components for leakages.
l Seal leakages immediately. If necessary in-
form the responsible service department.
l Always use the filling and filtering unit
(BOMAG part-no. 007 610 01) to fill the hy-
draulic system. This unit is equipped with a
fine filter which cleans the hydraulic oil and
prolongs the lifetime of the filter.
l Clean fittings, filler caps and their immediate
surrounding area before removing them, so
that no dirt can fall in.
l Do not leave the tank opening unnecessarily
open, cover it so that no dirt can fall in.
BOMAG BW 141/151 AD-4/BW 151 AC-4
 Maintenance

fect the cold starting ability of the engine, but will

5.2 Fuels and lubricants not cause any engine damage.
Temperature related lubrication oil changes can
be avoided by using multi-purpose oils. The follow-
Engine oil ing oil change intervals apply also when using mul-
l Use winter grade engine oil for winter opera- ti-purpose oils.
tion!
Regular lubrication oil changes
The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the follow-
ing oil change intervals are not reached over a pe-
riod of 1 year, the oil change should be performed
at least once per year, irrespective of the operating
hours reached.

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

Lubrication oil change intervals

Fig. 105 Oil change intervals with oil quality
In order to assure perfect cold starting it is import
ACEA
to chose the viscosity (SAE-class) of the engine oil
according to the ambient temperature. E2-96 = 250 operating hours
For winter operation below -10 °C the oil change API
intervals must be shortened.
API CF/CF-4 = 250 operating hours
Lubrication oil with a too high viscosity index caus-
es starting difficulties. The temperature when ACEA
starting the engine is therefore of highest impor- E3-96/E5-02 = 500 operating hours
tance when choosing the viscosity of engine oil for
winter operation. API
CG-4/CH-4 = 500 operating hours
Oil viscosity
Since lubrication oil changes its viscosity with the ! Caution
temperature, the ambient temperature at the oper- These intervals apply only when using a diesel
ating location of the engine is of utmost impor- fuel with maximum 0.5 % sulphur by weight
tance when choosing the viscosity class (SAE- and for ambient temperatures higher than -10
class) (Fig. 105). °C.
Occasional falling short of the temperature limit
When using fuels with a sulphur content of
(e.g. use of SAE 15W/40 down to -15 °C) may ef-
more than 0.5% to 1% or under ambient tem-

BW 141/151 AD-4/BW 151 AC-4 BOMAG 61

Maintenance

peratures below -10 °C the oil change intervals
specified in the table must be halved. When us-
ing fuels with a sulphur content higher than 1%
to 1.5% the engine oil must have a TBN of ap-
prox. 12 x the S-content in % by weight when
halving the oil change intervals.
46 mm2/s at 40 °C. For topping up or for oil chang-
es use only high-quality hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils of
type HV according to ISO 6743/3. The viscosity in-
dex (VI) must be at least 150 (observe information
provided by manufacturer).

Lubrication oil quality classes Bio-degradable hydraulic oil

The oil manufacturer is solely responsible for as-
signing a product to a certain quality class.
i Note
When changing to a higher alloyed oil quality after
a longer period of operation, it is recommended to
perform the first oil change of the higher quality oil
already after 20 operating hours. The lubrication
oil filter cartridge must be changed at the same
time.
Fuels
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and
ensure strict cleanliness when filling in. A higher
sulphur content has a negative effect on the oil
change intervals. Use only winter-grade diesel fuel
under low ambient temperatures. The fuel level
should always be topped up in due time so that the
fuel tank is never run dry, as otherwise filter and in-
jection lines need to be bled.
The following fuel specifications are permitted:
DIN 51601; Nato Codes: F-54, F-75; BS 2869: A1
and A2; ASTM D 975-78: 1-D and 2-D; VV-F-800
a: DF-A, DF-1 and DF-2.
On request the hydraulic system can also be filled
with ester based biodegradable hydraulic oil, Pan-
olin HLP Synth. 46. This biologically quickly degra-
dable hydraulic oil Panolin HLP Synth.46 meets all
demands of a mineral oil based hydraulic oil ac-
cording 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 an 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.
Drum drive gear oil
For the gearbox use only multi-purpose transmis-
sion oil of API-class GL5 with viscosity class SAE
80W-90.
Lubrication grease
For lubrication purposes use an EP-high pressure
grease, calcium and/or lithium saponified (pene-
tration 2), acc. to DIN 51502 KP 2G.

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

Mineral oil based hydraulic oil

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

62 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Maintenance

5.3 Fuels, lubricants and filling

capacities

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil

ACEA: E3-96/E5-02 approx. 10 litres without

oil filter up to oil quantity
max.

API: CG-4/CH-4

SAE 10W/40 (-20 °C to +30 °C)

SAE 10W/40 (-10 °C to +40 °C)

SAE 30 SAE 10W

(+5 °C to +30 °C) (-5 °C to -30 °C)

SAE 40 SAE 20W/20

(+25 °C to +40 °C) (-10 °C to +10 °C)

Fuel

Diesel Winter diesel fuel (down 160 litres

to -12 °C)

Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity 60 litres

46 mm2/s at 40 °C or
ester based biodegradable hydraulic oil

Sprinkler system Water Anti-freeze mixture and 800 litres

water *

Emulsion approx. 40 litres

Drum SAE 15W/40 5,3 litres (BW 141 AD-4)

- Exciter shaft tube 6,3 litres (BW 151 AD-4)

6,3 liters (BW 151 AC-4)

Travel gear, drum SAE 80W-90, API GL5 approx. 1.5 litres

Steering chains High pressure grease (lithium saponified) as required

Oscillating articulated joint High pressure grease (lithium saponified) as required

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

BW 141/151 AD-4/BW 151 AC-4 BOMAG 63

Maintenance

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.

Maintenance after 50 operating hours

l Check the engine for leaks.
l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.

Maintenance after 250 operating hours

l 1st oil change in drum drive gear.
l Change the engine oil.
l 1. Oil change in the exciter shaft tube.

Maintenance after 500 operating hours

l 2. Oil change in drum drive gear.
l 2. Oil change in the exciter shaft tube.

Special intervals

l Switch the heating system* on every month for

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

* Optional equipment

64 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Maintenance

5.5 Maintenance chart

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 250 operating hours

every 500 operating hours

No. Maintenance work Remark

as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection X
glass
5.10 Check the water level X
5.11 Checking the emulsion level X
5.12 Clean the cooling fins on engine X
and hydraulic oil cooler
5.13 Change the engine oil* see foot note X
5.14 Change the engine oil filter car- min. 1x per year X
tridge*
5.15 Service the air conditioning (sum- X
mer operation)
5.16 Service the battery Pole grease X
5.17 Change the fuel filter cartridge X
5.18 Change the fuel pre-filter cartridge X
5.19 Change the oil in the drum drive see foot note X
gear**
5.20 Check, tension, lubricate the steer- X
ing chain
5.21 Check the engine mounts X
5.22 Check, tension, replace the V-belt X
5.23 Checking, tensioning, replacing X
the refrigerant compressor V-belt

BW 141/151 AD-4/BW 151 AC-4 BOMAG 65

Maintenance

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 250 operating hours

every 500 operating hours

No. Maintenance work Remark

as required
5.24 Change the oil in the vibrator shaft see foot note X
tube***
5.25 Check, adjust the valve clearance X
5.26 Change hydraulic oil and breather see foot note X
filter****
5.27 Changing the hydraulic oil filter at least every 2 X
years
5.28 Grease the articulated joint at least every 2 X
years
5.29 Replace the injection valve X
5.30 Service the combustion air filter min. 1x per X
year,
safety cartridge
at least every 2
years
5.31 Clean the water tank X
5.32 Clean the water filter X
5.33 Water sprinkler system, mainte- X
nance in the event of frost
5.34 Cleaning the emulsion filter X
5.35 Fill the provision tank for the wind- X
screen washer system
5.36 Adjusting the scrapers X
5.37 Checking the tire pressure X
5.38 Tightening torques X
5.39 Engine conservation X
* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Oil change after 250 h, after 500 h, then every 1000 h
*** Oil change after 250 h, after 500 h, then every 1000 h
**** Also after repairs in the hydraulic system.

66 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Maintenance

BW 141/151 AD-4/BW 151 AC-4 BOMAG 67

 Every 10 operating hours

Every 10 oper ating hours

5.6 Check the engine oil level 5.7 Check, clean the water sep-
arator

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 filter bowl initially every day for signs of
water.

Environment
Catch running out fuel and dispose of environ-
Fig. 106 mentally.

i Note
Park the machine horizontally, shut down the en-
gine and wait for 5 minutes.
l Open the right hand service door.
l Pull the dipstick (Fig. 106) out, wipe it off with
a lint-free, clean cloth and reinsert it until it bot-
toms.
l Pull the dipstick back out again.
l Check the oil level, top up to MAX-mark if nec-
essary.
l If the oil level is too low top up oil immediately. Fig. 107

For quality of oil refer to the table of fuels, lu- l Slacken the drain plug (Fig. 107) for a few
bricants and filling capacities. turns and catch running out fuel / water.

l Check the oil level again after running the en- l Tighten the drain plug again and check for
gine for approx. 1 minute. leaks, if necessary replace the seal ring.
l Open the fuel shut-off valve .
Caution
!

Before longer work periods you should always

top the oil up to the "MAX"-mark.

68 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 10 operating hours

5.8 Check the fuel level

! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke.
Catch running out fuel.
Do not refuel in closed rooms.
Do not inhale any fuel fumes.
Fig. 109

l Use access steps (Fig. 109).

Fig. 108

l Check the fuel level on the fuel gauge (Fig.

108). Fig. 110

l Clean the area around the filler opening.

i Note l Open the fuel tank cover (Fig. 110).
Do not drive the fuel tank empty, since this may
l If necessary top up with fuel (diesel or winter
damage the engine.
diesel).
Always bleed the fuel system after running the
tank empty. For specified fuel refer to the table of fuels, lu-
bricants and filling capacities.

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

BW 141/151 AD-4/BW 151 AC-4 BOMAG 69

Every 10 operating hours

5.9 Check the hydraulic oil level 5.10 Check the water level

! Caution ! Caution
In hydraulic systems filled with Panolin HLP Risk of damage!
Synth. 46 always use the same oil to top up.
Do not step on the water tank and do not place
With other ester based oils consult the lubrica-
any heavy objects on it.
tion oil service of the respective oil manufac-
turer.

Fig. 112

Fig. 111

l Check the oil level in the oil level inspection

i Note
In case of a pressure drop and when the water
glass (Fig. 111).
tank is empty the warning light for residual water
quantity in water sprinkling system c (Fig. 112) in
i Note the right hand instrument cluster will light up and
At a room temperature of approx. 20°C the oil level the warning buzzer will sound.
should reach approx. 2/3 way up the inspection In the water tank filling level gauge (m) the last
glass. green and the red LED will light or the red LED will
l If the oil level is too low top up hydraulic oil im- flash.
mediately.

For quality of oil refer to the table of fuels, lu-

bricants and filling capacities.

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

Fig. 113

l Use access steps (Fig. 113).

70 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 10 operating hours

5.11 Checking the emulsion level

(AC-machine)

! Caution
Risk of damage!
Do not step on the emulsion tank and do not
place any heavy objects on it.

Fig. 114

l Open the caps on both water tanks and top up

with water (Fig. 114) and screw the caps back
on.

i Note
If there is a risk of frost observe the special service
instructions under "water sprinkler system, main-
tenance in case of frost".
Make sure that the ventilation bore in the filler cap
Fig. 115
is free.
l Open the lid on the emulsion tank, replenish
the emulsion provision (Fig. 115) and close the
lid again.

i Note
Make sure that the ventilation bore in the filler cap
is free.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 71

 Every 250 operating hours

Every 250 operating h ours

5.12 Check condition of engine

oil and hydraulic oil cooler,
clean

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

Danger
!

Danger of injury!
Perform cleaning work only with engine
stopped and cooled down!

Fig. 116

l Remove dried on dirt from the cooling fins with

a suitable brush.
l Blow coolers (Fig. 116) out with compressed
air. Remove all dirt that has been blown into
the engine compartment.
l In case of oily dirt spray the cooler with a cold
cleansing agent and let it soak in for about 10
minutes.

Environment
Catch running off fluid and dispose of environ-
mentally.
l Clean off with water or steam jet.
l Repeat the process if necessary.

72 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 500 operating hours

Every 500 oper ating hours

5.13 Change the engine oil

! Danger
Danger of scalding!
Danger of scalding when draining off hot en-
gine oil!

i Note
Drain the oil only when the engine is warm.

For quality and quantity of oil refer to the sec- Fig. 118
tion on fuels and lubricants as well as the sec-
l Fill in new engine oil (Fig. 118) through the oil
tion on fuels, lubricants and filling capacities.
filler neck.
l Screw the cover back on.
Environment
Do not let old oil seep into the ground, but dis-
pose off environmentally.
l Open the right hand service door.
l Unscrew the oil filler cap.

Fig. 119

l After a short test run check the oil level on the

dipstick (Fig. 119). The oil level should reach
the MAX-mark, top up oil if necessary.

Fig. 117

l Unscrew the drain plug (Fig. 117), catch run-

ning out oil.
l Screw the plugs back in.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 73

Every 500 operating hours

5.14 Change the engine oil filter 5.15 Servicing the air condition-
cartridge ing* (summer operation)

! Danger Caution
!
Danger of scalding! Under very dusty conditions clean every day in
Danger of scalding by hot oil when unscrewing order to maintain the cooling power of the air
the filter cartridge. conditioning system.

Caution
! Danger
!

Catch running out oil, e.g. with a cloth. Danger of accident!

Do not clean with a hot water jet. Heat will
Environment cause extreme overpressure, which could
cause damage or explosion of the system.
Do not let old oil seep into the ground, but dis-
pose off environmentally.
Cleaning the condenser
l Open the right hand service door.

Fig. 121
Fig. 120
l Unscrew the condenser fastening screws and
l Loosen and unscrew the fuel filter cartridge fold the condenser forward.
(Fig. 120) using an appropriate filter wrench.
l Clean the condenser fins on front and back
l Wipe the sealing face clean. with compressed air or cold water (Fig. 121).
l Cover the rubber seal of the new filter car-
tridge slightly with clean oil.
!Caution
l Spin the new fuel filter cartridge on and tighten During cleaning work do not damage the cool-
it hand tight. ing fins and realign bent fins.
l Perform a short test run and inspect the en-
gine for leaks and check the oil level, top up oil Checking the refrigerant level
if necessary.
l Start the engine.

* Optional equipment

74 BOMAG BW 141/151 AD-4/BW 151 AC-4


Fig. 122
l Switch the air conditioning (Fig. 122) on.
Fig. 123
l Choose a cooling temperature with the rotary
switch for cabin heater (Fig. 123) in the blue
section.
l Open the air outlet nozzles.
l Check, whether the out flowing air is noticea-
bly cooler.
i Note
The adjusted temperature must be below the actu-
al temperature inside the cabin, so that the com-
pressor will be switched on.
l Open the right hand service door.
BW 141/151 AD-4/BW 151 AC-4
Every 500 operating hours
Fig. 124
l Check whether the white float (Fig. 124) inside
the inspection glass of the drier/collector unit
floats right at the top.
i Note
The refrigerant level is correct.
Fig. 125
l If the white float (Fig. 125) inside the inspec-
tion glass of the drier/collector unit floats at the
bottom, inform the service department.
i Note
The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary
check the air conditioning system for leaks.
BOMAG 75
Every 500 operating hours

Checking the moisture level of the dry- arising from the handling and operation of
ing agent pressure reservoirs.

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

Fig. 126

l Check the moisture indication pearl (Fig. 126)

inside the inspection glass of the drier/collec-
tor unit.
blue = drying agent o.k.
purple = moisture level of drying agent too
high. Fig. 127

l Inform the service department. Replace drier/ l Check the drier/collector unit (Fig. 127) for me-
collector unit, check air conditioning system. chanical damage or rust.

!Caution
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.

Checking the condition of the drier/col-

lector unit

!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeated-
ly inspected by a specialist. In this sense
repeated inspections are external examina-
tions, normally on pressure reservoirs in oper-
ation. In connection with this inspection the
drier/collector unit must be visually examined
twice every year. During these inspections
special attention must be paid to corrosion
and mechanical damage. If the reservoir is not
in proper condition it must be replaced for
safety reasons, as a precaution to protect op-
erators and third parties against any danger

76 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 500 operating hours

Charging voltage recommendation

5.16 Service the battery

! Danger
Danger of cauterisation ! Danger of explosion!
When working on the battery do not use open
fire, do not smoke!
The battery contains acid. Do not let acid come
in contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!

Environment Fig. 128

Dispose of the old battery environmentally.

! Caution
i Note Exhausted batteries (batteries with formation
Maintenance free batteries also need care. Main- of sulphate on the plates are not covered un-
tenance free only means that the fluid level does der warranty!
not need to be checked. Each battery suffers un-
der self-discharge, which may, in not checked oc-
casionally, even cause damage to the battery as a
result of exhaustive discharge.

The following therefore applies for the service

life:
l Switch off all consumers (e.g. ignition, light, in-
side light, radio).
l Check open-circuit voltage of the battery at
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
Fig. 129
l Recharge the battery immediately after an
open-circuit voltage of 12.25 V or less is l Disassemble the battery compartment cover
reached. Do not perform boost charging. (Fig. 129).
The open-circuit voltage of the battery occurs ap- l Clean the battery compartment.
prox. 10 hours after the last charging process or
one hour after the last discharge.
l After each charging process allow the battery
to rest for one hour before taking it into service.
l For resting periods of more than one month
you should always disconnect the battery. Do
not forget to perform regular open-circuit volt-
age measurements.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 77

Every 500 operating hours

Fig. 130

l Clean the outside of the battery (Fig. 130).

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

78 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 1000 operating hours

Every 1000 operating hours

5.17 Change the fuel filter car- 5.18 Change the fuel pre-filter
tridge cartridge

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

Fig. 131 Fig. 132

l Unscrew the fuel filter cartridge (Fig. 131) us- l Close the fuel shut-off valve (Fig. 132).
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. 133
i Note
l Unscrew the fuel filter cartridge (Fig. 133) us-
Bleeding of the fuel system is not necessary.
ing an appropriate filter wrench.
l Clean the sealing face on the filter carrier from
any dirt.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 79

Every 1000 operating hours

5.19 Change the oil in the drum

drive gear

i Note
Drain oil only at operating temperature. Change
the oil in front right and rear left hand travel gears.

Danger
!

Danger of scalding!
Fig. 134 Danger of scalding when draining off hot gear
oil!
l Unscrew the water separator from the filter
cartridge.
Environment
Environmental damage!
Catch old oil and dispose of environmentally.

Fig. 135

l Apply a thin coat of oil to the rubber seal of the

water separator 1 (Fig. 135).
l Screw the water separator on by hand (2), until Fig. 136
the seal contacts.
l Clean and unscrew filler and drain plugs (Fig.
l Tighten the water separator for another half 136).
turn (3).
l Drain and catch all oil.
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter el- i Note
ement (5) and screw it on by hand, until the Move the drum for a quarter turn to bring the filler
seal contacts. opening in vertical position!
l Tighten the filter element for another half turn
(6).
l Check the filter cartridge for leaks after a short
test run.

80 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 1000 operating hours

5.20 Checking, tensioning, lubri-

cating the steering chain
l Unscrew the dashboard from the drive console
and lay down to the front.

Check

Fig. 137

l Fill in oil through the oil filler opening (Fig.

137), until it reaches the bottom edge of the oil
level inspection bore.

For quality and quantity of oil refer to the table

of fuels, lubricants and filling capacities.
l Clean the filler and level control plug and
screw it back in with a new seal ring fitted.
Fig. 138

l Unscrew the cover plate (Fig. 138) from the

steering chain and take it off.

Fig. 139

l Check the entire circumference of chain and

sprockets (Fig. 139).

BW 141/151 AD-4/BW 151 AC-4 BOMAG 81

Every 1000 operating hours

5.21 Check the engine mounts

Fig. 140

l Check the condition of the left hand sliding

block (Fig. 140), replace if necessary.
Fig. 142

l Tighten fastenings of intake and exhaust man-

ifolds (Fig. 142) on the cylinder heads.
l Check sockets and clamps between air filter,
exhaust turbocharger and charge air line as
well as the lubrication air lines for tight fit and
leaks.
l Retighten the fastening screws for oil sump
and engine mounts.

Fig. 141

l Check the condition of the right hand sliding

block (Fig. 141), replace if necessary.

Tension
l Loosen four fastening screws on the steering
column.
l Press the steering columns towards the out-
side and retighten the fastening screws.

Lubricating
l Cover the entire circumference of the chain
with grease.

For quality of grease refer to the table of fuels,

lubricants and filling capacities.

82 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 1000 operating hours

Retighten the V-belt

5.22 Check, tension, replace the
V-belt

Check the V-belt

Danger
!

Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.

Fig. 144

l Slightly slacken fastening screws 1, 2 and 3

(Fig. 144).
l Press the generator in direction "I", until the
correct V-belt tension is achieved.
l Tighten the fastening screws.

Changing the V-belt

Fig. 143

l Inspect the entire circumference of the V-belt

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, retighten the V-belt if
necessary (Fig. 143), if necessary retention
the V-belt.

Fig. 145

l Slacken the fastening screws 1, 2 and 3 (Fig.

145).
l Turn the generator in direction II and take off
the V-belt.
l Install the new ribbed V-belt.
l Turn the generator in direction I and tighten
the fastening screws.
l Measure the V-belt tension, tighten if neces-
sary.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 83

Every 1000 operating hours

l If necessary assemble and tighten the V-belt

for the air conditioning compressor.
i Note
The indicator arm remains in the measured posi-
l Fasten the fan again. tion.
l take the measuring unit carefully off, without
i Note moving the indicating arm.
Check the V-belt tension again after running the
engine for 20 minutes, retighten if necessary.

Checking the generator V-belt

Fig. 148

l Read the V-belt tension where the upper edge

of the indicating arm intersects with the meas-
uring scale (Fig. 148).
Fig. 146
First installation = approx. 450±50 N
l Press the indicator arm of the tester a (Fig. Retighten after
146) into the gap of the measuring scale. 15 minutes = approx. 300±50 N
l Lay the measuring unit loosely onto the back
of the fan V-belt.

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

Fig. 147

l Operate measuring unit b (Fig. 147) with a fin-

ger (I or II or III), until the pressure spring dis-
engages audibly or noticeably.

84 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 1000 operating hours

Tighten the V-belt.

5.23 Checking, tensioning, re-
placing the refrigerant com-
pressor V-belt

Danger
!

Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.

Check the V-belt

Fig. 150

l Slightly slacken fastening screws 1, 2 and 3

(Fig. 150).
l Press the compressor in direction of arrow, un-
til the correct V-belt tension is reached.
l Retighten all fastening screws.

Changing the V-belt

Fig. 149

l Inspect the entire circumference of the V-belt

(Fig. 149) visually for damage and cracks. Re-
place damaged or cracked V-belts.
l Check with thumb pressure whether the V-belt
can be depressed more than 10 to 15 mm (0.4
– 0.6 inches) between the V-belt pulleys,
retighten if necessary.

Fig. 151

l Slightly slacken the fastening screws 1, 2 and

3 (Fig. 151).
l Press the compressor against the direction of
arrow completely against the engine.
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
l Fasten the fan again.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 85

Every 1000 operating hours

! Caution
5.24 Changing the oil in the vi-
Check the V-belt tension after a running time of
30 minutes. brator shaft tube

! Caution
Change the oil in both drums.

Environment
Catch running out oil and dispose of environ-
mentally.

Fig. 152

l Move the drum until drain and filler plugs (Fig.

152) are exactly vertically in line.
l Clean and unscrew drain and filler plugs.
l Drain off and catch old oil.
l Clean and turn the oil drain plug back in tightly
after all oil has run out.

86 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 1000 operating hours

5.25 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 80 °C.

Valve clearance
Intake valve = 0,3 mm
Fig. 153 Exhaust valve = 0,5 mm
l Clean and unscrew the oil level inspection l Open the engine hood completely and support
plug (Fig. 153). it safely.
l Fill in oil through the filler bore, until it starts to
run out through the level inspection bore.

For quality and quantity of oil refer to the table

of fuels and lubricants.
l Turn oil filling and level inspection plugs tightly
back in.

Fig. 154

l Remove the valve cover (Fig. 154).

Fig. 155

l Unscrew the fastening screw from the plug of

the shut-down solenoid (Fig. 155) and pull off
the plug.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 87

Every 1000 operating hours

Adjusting the valve clearance

Fig. 156

l Crank the engine with the starter until both

Fig. 158
valves on cylinder 1 (Fig. 156) are “overlap-
ping”. l Loosen the counter 2 (Fig. 158) and regulate
the setscrew (1), until the feeler gauge can be
inserted and pulled out with little resistance af-
i Note
ter retightening the counter nut.
Overlapping means that the exhaust valve is not
yet completely closed and the intake valve starts
to open. Caution
!

After a short test run check the engine for

The valves marked black (Fig. 156) can be
leaks.
checked and adjusted.

Fig. 157

l Crank the engine with the starter until both

valves on cylinder 4 (Fig. 157) are “overlap-
ping” (360° rotation of the crankshaft).
The valves marked black (Fig. 157) can be
checked and adjusted.
l Assemble the cylinder head cover with a new
gasket.

88 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 2000 operating hours

Every 2000 operating hours

5.26 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
Fig. 159
repairs in the hydraulic system.
l Remove the filler cap (Fig. 159).
Perform the oil change when the hydraulic oil
is warm.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not use any detergents to clean the system.
Do not start the engine after draining the hy-
draulic oil.
Replace the hydraulic oil filter element with
every hydraulic oil change.

! Danger
Danger of scalding!
Danger of scalding by hot oil. Fig. 160

l Unscrew the plug (Fig. 160) and drain off all

Environment hydraulic oil.
Catch running out oil and dispose of environ- l Check the seal ring, replace if necessary and
mentally. turn the plug tightly back in.

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

Fig. 161

l Fill in new hydraulic oil through the screen

(Fig. 161).

BW 141/151 AD-4/BW 151 AC-4 BOMAG 89

Every 2000 operating hours
i Note
We recommend to use the filling and filtering unit
(BOMAG part-no. 079 930 35) with fine filter to fill
the hydraulic system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the hy-
draulic oil filter and protects the hydraulic system.
l Check the oil level in the inspection glass.
Nominal value:
At a room temperature of approx. 20°C the oil level
should reach approx. 2/3 way up the inspection
glass.
For quality and quantity of oil refer to the table
of fuels and lubricants.
Fig. 162
i Note
The breather filter (Fig. 162) for the hydraulic oil
tank is integrated in the filler cap, you must there-
fore replace the complete filler cap.
l Close the tank with a new filler cap.
90
5.27 Changing the hydraulic oil
filter
! Danger
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter.
! Caution
If the filter has to be changed together with the
hydraulic oil, the filter must only be changed
after the oil change and after the test run.
Do not use the oil in the filter bowl again.
Environment
Catch running out oil, dispose of oil and filter
element environmentally.
i Note
Apart from the normal oil change intervals, the fil-
ter element must also be changed after major re-
pairs in the hydraulic system.
l Open the left hand maintenance door.
Fig. 163
l Unscrew filter bowls (Fig. 163) and take off
with filter elements.
l Examine the surface of the filter element thor-
oughly for any visible dirt.
BOMAG BW 141/151 AD-4/BW 151 AC-4
 Every 2000 operating hours

!Caution
5.28 Grease the articulated joint
Visible dirt may be an early sign for the failure
of system components and indicate the possi-
ble failure of components. In this case deter-
mine the cause and replace or repair the
defective components, if necessary. Negli-
gence may cause destruction to the entire hy-
draulic system.
Do not clean or reuse the filter element.
l Clean filter bowls with threads.
l Assemble the filter bowls with new filter ele-
ments, check the condition of the seal rings, if
necessary use new ones.
l After the test run check the filters for leaks.
Fig. 164

l Remove the water tank.

l Clean the grease nipple (Fig. 164) and lubri-
cate with approx. 5 shots of high pressure
grease from the grease gun.

For quality of grease refer to the section on

"fuels, lubricants and filling capacities”.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 91

 Every 3000 operating hours

Every 3000 operating hour s

5.29 Replace the injection valve

i Note
This work must only be performed by authorized
service personnel.

92 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Every 3000 operating hours

BW 141/151 AD-4/BW 151 AC-4 BOMAG 93

 As required

As requir ed

5.30 Check, clean, change the i Note

Once the air filter service indicator lights up, work
combustion air filter may be continued until the end of the day.
l Open the left hand maintenance door.
! Caution
Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter 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.
The main filter element must be replaced after
3 times cleaning, but at the latest after one Fig. 166
year, irrespective of the operating hours. l Fold three clips up and take the filter hood (Fig.
Each cleaning interval must be marked with a 166) off.
cross on the cover of the filter element. l Clean filter hood and dust discharge valve.
Cleaning does not make sense if the air filter
element is covered with a sooty deposit. Use a
new filter element.
Incorrectly handled filter elements may be-
come ineffective because of damage (e.g.:
cracks) and cause engine damage.

Fig. 167

l Carefully loosen the main filter element.

Fig. 165
Maintenance of the dry air filter is due when con-
trol light c (Fig. 165) in the left hand instrument
cluster lights permanently when the engine is run-
ning, but at the latest after one year.
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. 167).

94 BOMAG BW 141/151 AD-4/BW 151 AC-4


Fig. 168
! Caution
Avoid contact between main filter element and
housing.
l Pull the main filter element (Fig. 168) carefully
out of the housing.
Fig. 169
l Clean the sealing face on the outlet tube (Fig.
169).
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.
BW 141/151 AD-4/BW 151 AC-4
As required
Caution
!
The safety element must not be cleaned. It
must be replaced after three times cleaning of
the main filter element, but at least once every
year.
Do not run the engine without an intact safety
and main filter element.
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.
Fig. 170
l Insert the main filter element (Fig. 170).
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.
BOMAG 95
As required

Caution
!
5.31 Clean the water tank
The dust discharge valve must point vertically
downwards.

Dry cleaning of the main filter element

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

Fig. 172

l Unscrew both caps (Fig. 172) from the water

tank.

Fig. 171

i Note
For cleaning purposes fit a tube to the compressed
air gun (Fig. 171), the end of which should be bent
for approx. 90°.
The length should reach down to the bottom of the
element.
Fig. 173
l Blow the main filter element out with com-
pressed air (max. 5 bar) from inside to outside l Open the maintenance cover (Fig. 173) to gain
by moving the tube up and down inside the el- access to the water pumps.
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.

96 BOMAG BW 141/151 AD-4/BW 151 AC-4

 As required

5.32 Clean the water filter

Fig. 174

l Disconnect the quick lock coupling (Fig. 174)

on the water filter.
l Unscrew the water filter. Fig. 175

l Let all water with dirt run out. l Unscrew both water tank caps (Fig. 175), take
out and clean the filling screens.
l Fill the water tank with clean water.

i Note
Replace damaged filling screens.

Fig. 176

l Open the maintenance cover (Fig. 176) to gain

access to the water pumps.

BW 141/151 AD-4/BW 151 AC-4 BOMAG 97

As required

5.33 Water sprinkler system,

maintenance in the event of
frost

! Caution
If there is a risk of frost, the water sprinkler
system must be drained.
In this case frost protection measures are of
greatest importance in order to avoid freezing
of sensitive components like pump, solenoid
Fig. 177
valve and water filter.
l Disconnect the quick lock coupling (Fig. 177)
l Drain the water tank
on the water filter.
l Unscrew and clean the water filter.

i Note
Change a damaged water filter.

Fig. 178

l Disconnect the quick lock couplings (Fig. 178)

of the water lines from the water pumps and let
all water run out.

Fig. 179

l Disconnect the water pipe connection (Fig.

179) at the articulated joint and let all water run
out.

98 BOMAG BW 141/151 AD-4/BW 151 AC-4

 As required

5.34 Cleaning the emulsion filter

(AC-machine)

i Note
Drain the emulsion tank before cleaning the emul-
sion filter.

Environment
Catch running out emulsion and dispose of en-
vironmentally.
Fig. 180

l Open all water drain taps (Fig. 180) on the

sprinkler tubes and let all water run out.
l Unscrew all nozzles.

Fig. 181

l Open the shut-off cock (Fig. 181) and let the

emulsion fluid run out.

i Note
For complete drainage of the emulsion tank switch
the emulsion pump on.
l Close the shut-off cock again

BW 141/151 AD-4/BW 151 AC-4 BOMAG 99

As required

5.35 Fill the provision tank for

the windscreen washer sys-
tem
l Open the right hand service door.

Fig. 182

l Disconnect coupling 1 (Fig. 182) from the

emulsion pump.

Fig. 184

l Check the fluid level in the tank (Fig. 184), top

up if necessary.
l For winter operation fill in the appropriate
amount of ant-freeze agent; refer to the speci-
fications of the manufacturer of the ant-freeze
agent.

Fig. 183

l Unscrew filter bowl 2 (Fig. 183).

l Take the screen insert (1) out.
l Clean filter bowl and screen insert and rein-
stall.

i Note
Observe the condition of the seals, replace dam-
aged seals.

100 BOMAG BW 141/151 AD-4/BW 151 AC-4

 As required

5.36 Adjusting the scrapers 5.37 Checking the tire pressure

Fig. 185 Fig. 186

l Check the scrapers (Fig. 185), two each per l Check the tire pressure on wheel 1 (Fig. 186)
drum. with a pressure gauge.
Nominal value: 1 bar
i Note
Replace worn scrapers. i Note
Ensure equal pressure in all rubber tires!

BW 141/151 AD-4/BW 151 AC-4 BOMAG 101

As required

5.38 Tightening torques 5.39 Engine conservation

If the engine is to be shut down for a longer period
of time (e.g. during winter) we recommend the fol-
lowing conservation measures for the engine to
avoid corrosion:
l Clean the engine, including the cooling sys-
tem. With cold cleansing agent, or, even bet-
ter, with a steam cleaner.
l Run the engine warm and shut it down.
l Drain the still warm engine oil and fill in anti-
corrosion engine oil.

Fig. 187
* Strength classes for screws with untreated and
non-lubricated surface. The quality designation of
the screws is stamped on the screw heads.
8.8 = 8G
10.9 = 10K
12.9 = 12K
The values result in a 90% utilization of the screws
yielding point at a coefficient of friction of tot. =
0,14. The tightening torques are not valid when us-
ing MOS2 lubricants.
i Note
Self locking nuts must always be replaced after
they have been unscrewed.
l Drain the coolant and fill it back in with fresh
anti-freeze agent.
l Drain the fuel from the fuel tank, mix it well with
10% anti-corrosion oil and fill it in again.
l Run the engine for 10 minutes until all lines, fil-
ter, pump and nozzles are filled with the con-
serving mixture and the new engine oil is
distributed to all parts.
l Crank the engine several times by hand (with-
out ignition) in order to spray all combustion
chamber.
l Take the V-belt off and spray the grooves of
the V-belt pulleys with anti-corrosion oil. The
anti-corrosion oil must be removed before tak-
ing the machine back into service.
l Close the air intake opening on the air filter
and the exhaust opening.

i Note
Depending on the weather condition these con-
serving measures will provide protection for ap-
prox. 6 - 12 months.
The conserving oil must be replaced by engine oil
according to the API- (MIL) classification before
taking the machine into operation. Refer to the
section "Fuels and lubricants".

Anti-corrosion oils are those that comply with

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

Mark a machine with conserved engine by at-

taching a clearly visible warning tag.

102 BOMAG BW 141/151 AD-4/BW 151 AC-4

 6 Trouble shooting

BW 141/151 AD-4/BW 151 AC-4 BOMAG 103

Trouble shooting

6.1 General notes

The following work must only be carried out by

qualified and trained personnel or by the sales
service.

Please observe strictly the safety regulations

in chapter 2 of these operating and 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.

104 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Trouble shooting

6.2 Engine

Faults Possible cause Remedy

The engine Starter defective or pinion not engaging Have examined by a specialist
does 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.

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

Fuel lines leaking Check all line connections for leakages

and tighten the fittings.

Battery discharged or not connected Tighten the pole clamps, check the cable
connections

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

tive

The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature

Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

Injection lines leaking Check the lines for leakages

Turbo charger defective Have examined by a specialist

Dry air filter dirty clean, replace if necessary

Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary

BW 141/151 AD-4/BW 151 AC-4 BOMAG 105

Trouble shooting

Faults Possible cause Remedy

Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary

Exhaust gas turbo-charger defective Have examined by a specialist

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

Incorrect valve clearance Adjust the valve clearance

Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Injection valve defective Have examined by a specialist

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

Filling capacity of the injection pump not Have adjusted by a specialist

correctly adjusted

Cooling air flow restricted Clean the cooling air duct

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

Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark

Dry air filter dirty clean, change if necessary

Exhaust gas turbo-charger defective Have examined by a specialist

Charge air hose leaking Check fastening and connections

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

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

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

The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective

106 BOMAG BW 141/151 AD-4/BW 151 AC-4

 Trouble shooting

BW 141/151 AD-4/BW 151 AC-4 BOMAG 107

Trouble shooting

108 BOMAG BW 141/151 AD-4/BW 151 AC-4