Bomag BW 100 AD-5 Operating & Maintenance Instructions Download

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3.10 Maintenance work

3.10.1 Preliminary remarks

Adhere to the specified operating, maintenance

and repair measures.
The machine must only be serviced by quali-

fied personnel authorised by the operating

company.
Keep unauthorised persons away from the

machine.
Perform maintenance work only with the

engine shut down.
Make sure that the engine cannot be acciden-

tally started during maintenance work.

3.10.2 Working on hydraulic lines

Relieve hydraulic pressures before working on

hydraulic lines. Hydraulic oil escaping under

pressure can penetrate the skin and cause

severe injury. Immediately call for medical

assistance if injured by hydraulic oil.
Do not step in front of or behind the machine

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!
Any hydraulic oil must be collected and dis-

posed of in an environmentally friendly way.
Always collect and dispose of hydraulic oils

separately.

Concerning your safety – Maintenance work

BW 100 AD-5

Summary of Contents for BW 100 AD-5

Page 1: ...BW 100 AD 5 Tandem vibratory roller Operating Instruction Maintenance Instruction Original Operating Instructions S N 861 880 41 1180 05 2018 008 202 52 EN ...

Page 2: ...2 ...

Page 3: ...undamentals for safe operation 27 3 3 1 Remaining dangers remaining risks 27 3 3 2 Regular safety inspections 27 3 3 3 Modifications and alterations to the machine 27 3 3 4 Damage defects misuse of safety devices 28 3 3 5 Roll Over Protective Structure ROPS 28 3 4 Handling fuels and lubricants 29 3 4 1 Preliminary remarks 29 3 4 2 Safety regulations and environmental protection regulations for han...

Page 4: ...7 6 Parking the machine 46 3 8 Refuelling 48 3 9 Emergency procedures 49 3 9 1 Actuating the emergency stop switch 49 3 9 2 Disconnecting the battery 49 3 9 3 Towing the machine 49 3 10 Maintenance work 51 3 10 1 Preliminary remarks 51 3 10 2 Working on hydraulic lines 51 3 10 3 Working on the engine 52 3 10 4 Maintenance work on electric components and battery 53 3 10 5 Cleaning work 53 3 10 6 Af...

Page 5: ...eration 97 6 1 Setting up the work place 98 6 1 1 Adjust the driver s seat 98 6 1 2 Sliding the driver s seat sideways 99 6 2 Electronic immobilizer 100 6 3 Starting the engine 101 6 4 Travel operation 104 6 4 1 Preliminary remarks and safety notes 104 6 4 2 Driving the machine 105 6 4 3 Stopping the machine applying the parking brake 105 6 5 Working with vibration 106 6 5 1 Preliminary remarks an...

Page 6: ...luding work 138 8 2 1 Articulation lock 138 8 2 2 Engine hood 140 8 3 Fuels and lubricants 141 8 3 1 Engine oil 141 8 3 2 Fuel 142 8 3 3 Coolant 144 8 3 4 Hydraulic oil 145 8 4 List of fuels and lubricants 146 8 5 Running in instructions 147 8 5 1 General 147 8 5 2 After 50 operating hours 147 8 6 Maintenance Table 148 8 7 Every 50 operating hours 150 8 7 1 Checking radiator hoses and hose clamps ...

Page 7: ...ter 166 8 11 Every 2000 operating hours 170 8 11 1 Changing the hydraulic oil 170 8 11 2 Changing the coolant 173 8 11 3 Replacing hoses 175 8 11 4 Check the injection valves 176 8 12 Every 3000 operating hours 177 8 12 1 Checking the fuel injection pump 177 8 13 As required 178 8 13 1 Air filter maintenance 178 8 13 2 Checking the water spraying system 182 8 13 3 Cleaning the water spraying syste...

Page 8: ...th jump leads 199 10 3 Fuse assignment 200 10 3 1 Notes on safety 200 10 3 2 Fuses in engine compartment 200 10 3 3 Central electrics 201 10 4 Engine faults 203 10 5 Trouble shooting ECONOMIZER 206 11 Disposal 209 11 1 Final shut down of machine 210 Table of contents BW 100 AD 5 8 ...

Page 9: ...1 Introduction Introduction BW 100 AD 5 9 ...

Page 10: ...enance instructions before taking your machine into operation Please observe the safety regulations strictly and follow all instructions to ensure safe opera tion If you are not yet acquainted with the controls and indicating elements on this machine you should thoroughly read the corresponding chapter Ä Chapter 4 Indicators and control elements on page 65 The description of the individual operati...

Page 11: ...ved fuels and lubri cants all warranty claims will become null and void For your own personal safety you should only use original parts from BOMAG For your machine we offer service kits to make maintenance easier In the course of technical development we reserve the right for technical modifications without prior notification These operating and maintenance instructions are also available in other...

Page 12: ...plate Please enter here Machine type 1 Serial number 2 Please enter here Engine type Fig 1 Engine number 2 Fig 1 Machine type plate example Fig 2 Engine type plate example Introduction Machine type plate and engine type plate BW 100 AD 5 12 ...

Page 13: ...2 Technical data Technical data BW 100 AD 5 13 ...

Page 14: ... 101 Dimensions in millimetres Dimensions in inch K L O S W 254 10 0 2529 100 36 1 4 13 0 5 1000 39 Dimensions in millimetres Dimensions in inch Height with protective roof and flashing beacon optional equipment 2890 114 mm in Dimensions Technical data BW 100 AD 5 14 ...

Page 15: ...ph Working speed with vibration 0 10 0 6 2 km h mph Max gradability without with vibration soil dependent 40 30 Drive Engine manufacturer Kubota Type D 1703 M E3B Cooling Water Number of cylinders 3 Rated power ISO 14396 24 3 kW Rated power SAE J 1995 32 6 hp Rated speed 2600 min 1 Fixed engine speed 1 2500 min 1 Fixed engine speed 2 2600 min 1 Driven drum front rear Technical data BW 100 AD 5 15 ...

Page 16: ...ering operation hydrostatic Steering angle 32 Oscillation angle 10 Inner track radius 2550 100 mm in Crabwalk lateral offsetting of drum right left 50 2 0 mm in Exciter system Vibrating drum front rear Frequency 1 2 63 67 3780 4020 Hz vpm Amplitude 0 5 0 02 mm in Centrifugal force 1 2 30 34 6744 7644 kN lbf Technical data BW 100 AD 5 16 ...

Page 17: ...2000 14 EU Noise Protection Directive 2003 10 EU n Vibration Protection Directive 2002 44 EU During operation these values may vary because of the prevailing operating conditions 2 1 1 Noise data LpA 84 dB A determined acc to ISO 11201 and EN 500 WARNING Loss of hearing caused by too high noise burdens Wear your personal protective equipment ear protection LWA 106 dB A determined acc to ISO 3744 a...

Page 18: ...alue determined according to ISO 7096 is 0 5 m s2 The weighted effective acceleration value determined according to EN 500 ISO 5349 is 2 5 m s2 Vibration of the entire body driver s seat Hand arm vibration Technical data Noise and vibration data BW 100 AD 5 18 ...

Page 19: ...3 Concerning your safety Concerning your safety BW 100 AD 5 19 ...

Page 20: ...ply with these safety regula tions If necessary the operating company must obtain the relevant signatures as confir mation Furthermore the following obviously also applies n applicable accident prevention instructions n generally accepted safety and road traffic regulations n country state specific safety regulations It is the duty of the operator to be acquainted with the safety regulations and t...

Page 21: ...ctions marked accordingly indi cate a dangerous situation that could lead to fatal or severe injuries if this warning is disregarded CAUTION Danger of injury if failing to comply Sections marked accordingly indi cate a dangerous situation that could lead to fatal or severe injuries if this warning is disregarded NOTICE Danger of material damage if failing to comply Sections marked accordingly indi...

Page 22: ...quip ment is required to be provided by the operating company Working clothes Tight fitting working clothes with low tear resistance tight sleeves and without any projecting parts protect against being caught by moving components Safety shoes To protect against heavy falling parts and slipping on slippery ground Protective gloves To protect the hands against excoria tion punctures or deep injuries...

Page 23: ...ts against sub stances or particles 3 1 4 Intended use This machine must only be used for n Compaction of bituminous material e g road surface layers n Compaction work in earth construction and road bases Intended use also includes compliance with the specified operating maintenance and repair measures 3 1 5 Improper use Dangers may arise from the machine when it is used for purposes other than th...

Page 24: ...riving on subsoils with too low load bearing capacity n driving on slippery subsoils e g ice and snow n driving on surfaces of insufficient size danger of turning over n Passing over too high borders e g curb stones embankments trenches potholes n unauthorized use of public roads n Using the machine for towing transporting persons except the machine driver is prohibited starting and operation of t...

Page 25: ...ut any remaining dangers The operating company must determine whether there are special operational hazards such as a toxic atmosphere or limiting soil con ditions Such conditions require special addi tional measures to remove or reduce the hazard The operating company must make sure that all users read and understand the information concerning safety The operating company is responsible for the p...

Page 26: ...any aged 18 or more Observe your local laws and regulations Rights obligations and rules of conduct for driver or operator The driver or operator must n be instructed about his rights and obliga tions n wear protective equipment as appropriate for the application n have read and understood the operating instructions n have made himself familiar with the opera tion of the machine n be physically an...

Page 27: ...he actual danger zone of the machine Persons remaining in this area must pay partic ular attention to the machine so that they can react immediately in case of a possible mal function an incident or failure etc All persons remaining in the area of the machine must be informed about the dangers that arise from the operation of the machine 3 3 2 Regular safety inspections Have the machine inspected ...

Page 28: ...fective 3 3 5 Roll Over Protective Structure ROPS The frame of the machine must not be warped bent or cracked in the area of the ROPS fas tening The ROPS must not show any rust damage hairline cracks or open fractures The real machine weight must never exceed the testing weight for the ROPS No accessories may be welded or bolted on and no additional holes must be drilled without the consent of the...

Page 29: ...ame of substance n possible dangers n composition information on constituents n first aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitation and monitoring of exposure per sonal protective equipment n physical and chemical properties n stability and reactivity n toxicological data n environmental data n notes on waste disposal n informati...

Page 30: ...d Wear your personal protective equipment protective gloves protective clothing CAUTION Health hazard caused by contact with diesel fuel Wear your personal protective equipment protective gloves protective clothing Do not inhale any fuel fumes Avoid contact CAUTION Danger of slipping on spilled diesel fuel Immediately bind spilled diesel fuel with an oil binding agent Fig 4 Concerning your safety ...

Page 31: ... Always keep diesel fuel in proper containers Immediately bind spilled diesel fuel with an oil binding agent and dispose of properly Dispose of diesel fuel and fuel fil ters according to regulations Concerning your safety Handling fuels and lubricants BW 100 AD 5 31 ...

Page 32: ...otective clothing CAUTION Health hazard caused by contact with oil Wear your personal protective equipment protective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil Immediately bind spilled oil with an oil binding agent ENVIRONMENT Oil is an environmentally haz ardous substance Always keep oil in proper con tainers Continued on the ...

Page 33: ... Immediately bind spilled oil with an oil binding agent Dispose of oil and oil filter according to regulations Concerning your safety Handling fuels and lubricants BW 100 AD 5 33 ...

Page 34: ...nal protective equipment protective gloves protective clothing goggles Should pressure fluid penetrate the skin immediate medical help is required WARNING Danger of burning by ignited hydraulic oil Do not allow hydraulic oil to come into contact with hot com ponents Smoking and open fire is pro hibited Wear your personal protective equipment protective gloves protective clothing Fig 6 Concerning y...

Page 35: ...ntact CAUTION Danger of slipping on spilled oil Immediately bind spilled oil with an oil binding agent ENVIRONMENT Oil is an environmentally haz ardous substance Always keep oil in proper con tainers Immediately bind spilled oil with an oil binding agent Dispose of oil and oil filter according to regulations Concerning your safety Handling fuels and lubricants BW 100 AD 5 35 ...

Page 36: ...sed by contact with coolant and coolant addi tives Wear your personal protective equipment protective gloves protective clothing Do not inhale any fumes Avoid contact CAUTION Danger of slipping on spilled coolant Immediately bind spilled coolant with an oil binding agent ENVIRONMENT Coolant is an environmentally hazardous substance Always keep coolant and coolant additives in proper containers Con...

Page 37: ...ately bind spilled coolant with an oil binding agent and dis pose of it according to regula tions Dispose of coolant according to regulations Concerning your safety Handling fuels and lubricants BW 100 AD 5 37 ...

Page 38: ...n or eyes immediately with lots of clean water Immediately call for medical advice in case of cauterization WARNING Danger of injury caused by exploding gas mixture Remove the plugs before starting to recharge the battery Ensure adequate ventilation Smoking and open fire is pro hibited Do not lay any tools or other metal objects on the battery Do not wear jewellery watch bracelets etc when working...

Page 39: ...ENVIRONMENT Battery acid is an environmen tally hazardous substance Dispose of battery and battery acid according to regulations Concerning your safety Handling fuels and lubricants BW 100 AD 5 39 ...

Page 40: ...lways use appropriate lifting and lashing means on the lifting and lashing points Use lifting and lashing gear only in the pre scribed direction of load application Lifting and lashing gear must not be damaged by machine components Secure the machine on the transport vehicle against rolling slipping and turning over Loads must only be attached and hoisted by an expert capable person Use only lifti...

Page 41: ...ock again as otherwise the machine would not be steerable Operate the machine only with the ROPS folded up and the fastening screws tightened with the correct tightening torque Concerning your safety Loading transporting the machine BW 100 AD 5 41 ...

Page 42: ...s are beside or under the machine n the machine is free of oily and combustible materials n all access steps grips and platforms are free of obstacles grease oils fuel dirt snow and ice n all safety elements are in place n all maintenance flaps and doors are closed and locked Use only the intended access steps and grips to mount the machine Before start up carry out all required visual inspections...

Page 43: ...Do not inhale exhaust fumes because they contain toxic substances which could cause damage to health unconsciousness or even death For operation in closed or partly closed rooms ensure adequate ventilation 3 6 3 Starting the engine with jump leads Connect positive with positive and negative with negative ground cable always connect the ground strap last and disconnect it first A wrong connection w...

Page 44: ...not drive on bases with insufficient load bearing capacity Do not drive on ice and snow If the machine has contacted high voltage power lines n do not leave the operator s stand n warn others from coming close to or touching the machine n if possible drive the machine out of the danger zone n have the power switched off Operate the machine only from the operator s platform Do not adjust the driver...

Page 45: ...ient distance when passing through subways under bridges tun nels electric power lines etc 3 7 3 Driving up and down slopes Do not drive on gradients or slopes exceeding the maximum gradeability of the machine Ä Chapter 2 Technical data on page 13 Drive extremely carefully on gradients and always directly up or down the slope Soil conditions and weather influences impair the gradeability of the ma...

Page 46: ...over and the related risk of severe or even fatal accidents For rollers with a drum width of 1 meter or less there is a considerable risk of tipping over near edges e g curbstones embankments trenches potholes when driving over these edges 3 7 5 Working with vibration When compacting with vibration you must always check the effect of the vibration on nearby buildings and underground supply lines g...

Page 47: ...he main battery switch n secure the machine against unauthorized use Do not jump off the machine but use hand grips and access steps Mark machines which could be in the way with a clearly visible sign When parking on ascents or descents use appropriate means to secure the machine against rolling Concerning your safety Driving the machine working operation BW 100 AD 5 47 ...

Page 48: ...arging than diesel fuel with a higher sulphur content You should therefore always make sure that the filling system is properly grounded and that there is equipotential bonding to the machine If necessary use a connecting cable between filling system and vehicle ground Monitor the entire refuelling process Do not spill any fuel Collect leaking fuel do not let it seep into the ground Wipe off spill...

Page 49: ... use the emergency stop switch as a service brake 3 9 2 Disconnecting the battery In events of emergency e g in case of a cable fire disconnect the battery from the vehicle network Pull out the main battery switch or lift off the battery pole to do so 3 9 3 Towing the machine Tow the machine only in case of emergency or to avoid an accident Before releasing the parking brake apply suit able measur...

Page 50: ...means are able to withstand the load and are fastened at the points pro vided for this purpose Before removing the towing facility apply appropriate measures to secure the machine against unintended rolling Concerning your safety Emergency procedures BW 100 AD 5 50 ...

Page 51: ...lieve hydraulic pressures before working on hydraulic lines Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury Immediately call for medical assistance if injured by hydraulic oil Do not step in front of or behind the machine when performing adjustment work in the hydraulic system Do not change the setting of pressure relief valves Drain the hydraulic oil at operat...

Page 52: ...res Wait until the engine has stopped then wait approx another 15 minutes Keep out of the danger zone during the initial test run In case of leaks return to the workshop immedi ately Drain the engine oil at operating temperature danger of scalding Wipe off spilled oil collect leaking oil and dis pose of it in an environmentally friendly way Store used filters and other oil contaminated materials i...

Page 53: ...n the battery smoking or open fire is prohibited Do not lay any tools or other metal objects on the battery Do not wear jewellery watch bracelets etc when working on the battery The connection cables of the battery must not touch or rub against machine parts 3 10 5 Cleaning work Do not perform cleaning work while the motor is running Allow the engine to cool down before starting cleaning work on e...

Page 54: ...nto the exhaust pipe and into the air filter 3 10 6 After maintenance work Reassemble all guards and protective devices Close all maintenance flaps and maintenance doors again Concerning your safety Maintenance work BW 100 AD 5 54 ...

Page 55: ...arning sign Only operate the machine after it has been repaired Repairs must only be performed by an expert qualified person When replacing safety relevant components only original spare parts must be used Concerning your safety Repair BW 100 AD 5 55 ...

Page 56: ...2 Signage Keep stickers and signage in good and legible condition and comply with their meaning Replace damaged and illegible stickers or sig nage immediately Concerning your safety Signage BW 100 AD 5 56 ...

Page 57: ...B 880 0149 Hydraulic Oil 20 kg 200 Nm 25 kg 75 Nm 1 m Nm 75 200 ft lb 55 147 30 cm 20 kg 200 Nm 25 kg 75 Nm 1 m Nm 75 200 ft lb 55 147 30 cm Fig 10 Concerning your safety Signage BW 100 AD 5 57 ...

Page 58: ...B 880 0150 Fig 11 Warning sticker Danger of tipping over B DEC 0206 Fig 12 Concerning your safety Signage BW 100 AD 5 58 ...

Page 59: ...llow operating instructions Warning sticker Danger of crushing Warning sticker Foldable ROPS Prohibition sticker High pressure cleaning Fig 13 Fig 14 B DEC 0207 Fig 15 Fig 16 Concerning your safety Signage BW 100 AD 5 59 ...

Page 60: ...your seat belt Information sticker Lifting point Information sticker Lashing point Information sticker Filler opening for hydraulic oil Fig 17 Fig 18 Fig 19 B DEC 0214 Hydraulic Oil Fig 20 Concerning your safety Signage BW 100 AD 5 60 ...

Page 61: ... Information sticker Hydraulic oil drain Information sticker Coolant drain Information sticker Disconnecting the battery B DEC 0211 Fig 21 B DEC 0210 Fig 22 B DEC 0212 Fig 23 B DEC 0219 Fig 24 Concerning your safety Signage BW 100 AD 5 61 ...

Page 62: ...ttery switch plus side Operation sticker Throttle lever Information sticker Low sulphur fuel Information sticker Guaranteed sound capacity level Fig 25 B DEC 0236 Fig 26 Fig 27 Fig 28 Concerning your safety Signage BW 100 AD 5 62 ...

Page 63: ...Information sticker Foldable ROPS operation Machine type plate example B DEC 0208 20 kg 200 Nm 25 kg 75 Nm 1 m Nm 75 200 ft lb 55 147 30 cm Fig 29 Fig 30 Concerning your safety Signage BW 100 AD 5 63 ...

Page 64: ...Concerning your safety Signage BW 100 AD 5 64 ...

Page 65: ...4 Indicators and control elements Indicators and control elements BW 100 AD 5 65 ...

Page 66: ...8 9 10 6 2 3 4 5 1 Fig 31 Overview of driver s stand 1 Operating console 2 Starter switch 3 12 V DIN socket 4 Travel lever right 5 Travel lever left optional equipment 6 Throttle lever Indicators and control elements Driver s stand BW 100 AD 5 66 ...

Page 67: ...4 Rotary switch for hazard light system optional equipment 5 Rotary switch for flashing beacon optional equipment 6 Rotary switch for drum pre selection 7 Rotary switch for vibration pre selection 8 Emergency stop switch 9 Instrument cluster 10 ECONOMIZER display optional equipment 11 Rotary switch for seat heating optional equipment 12 Rotary switch for water spraying system Indicators and contro...

Page 68: ...esponding side are flashing Optional equipment 4 1 1 2 Rotary switch for working lights Position Left Working lights off Position Right Working light on 4 1 1 3 Rotary switch for lighting Position Left Light off Position Middle Side light on Position Right Travel light on Optional equipment B SWI 1081 Fig 33 Fig 34 Fig 35 Indicators and control elements Driver s stand BW 100 AD 5 68 ...

Page 69: ...on off Position Right Flashing beacon on Optional equipment 4 1 1 6 Rotary switch for drum pre selection Position left Vibration of front drum Position middle Vibration of front and rear drums Position right Vibration of rear drum Drum pre selection is only acti vated if the vibration has been switched off beforehand Fig 36 Fig 37 B SWI 1488 Fig 38 Indicators and control elements Driver s stand BW...

Page 70: ...or off via the vibration push button in the travel lever Position middle Vibration off Position right Pre selection vibration in automatic mode Vibration is automatically switched on or off when the travel speed exceeds or falls below a certain value B SWI 1485 Fig 39 Indicators and control elements Driver s stand BW 100 AD 5 70 ...

Page 71: ...lly locks in end position The machine will be braked immediately The engine is shut down switch off unlock Turn the Emergency Stop switch clockwise and let it go NOTICE In case of frequent use the wear on the multi discs brakes will be very high Do not use the emergency stop switch as service brake Fig 40 Indicators and control elements Driver s stand BW 100 AD 5 71 ...

Page 72: ...eat warning light Lights up when the driver s seat is not occu pied If the machine is travelling the warning buzzer will sound and the engine is shut down after 2 seconds If the travel lever is shifted to any travel direc tion the engine is shut down If the engine stops occupy the driver s seat and restart the engine Pre heating control light Lights up during pre heating Control and warning lights...

Page 73: ...r the engine Charge control light Lights up if the battery is not being charged Check V belt if necessary repair the generator Indicator control light Parking brake warning light Lights up when the parking brake is applied Central warning light Flashes in case of a fault of the rotation angle sensor or rotary switch for the water spraying system Each actuation of the function key F2 switches betwe...

Page 74: ...equipment 4 1 1 11 Rotary switch for seat heating Position left Seat heating off Position right Seat heating on The control light in the switch lights up Optional equipment 4 1 1 12 Rotary switch for water spraying system Position 0 Spraying off Position 1 to 4 Interval spraying Position MAX Permanent spraying Fig 43 Fig 44 B SWI 1493 Fig 45 Indicators and control elements Driver s stand BW 100 AD...

Page 75: ... lights up Position III Turn further against spring pressure the engine starts Turn the ignition key back to position I when the engine starts The starter switch is designed with a re start lock The ignition key must first be turned back to position 0 before a new starting attempt can be made 4 1 3 12 V DIN socket Permanent current loadable up to 10 A Fig 46 Fig 47 Indicators and control elements ...

Page 76: ... I I I I I I 0 I I II II 0 Fig 48 R Travel lever right L Travel lever left optional equipment On machines with double travel lever the two travel levers are mechanically connected to each other Indicators and control elements Driver s stand BW 100 AD 5 76 ...

Page 77: ...h 6 mph Pull back Backward travel n Position I up to approx 5 km h 3 mph n Position II up to approx 10 km h 6 mph Position middle Service brake position Position middle right travel lever right Parking brake position Position middle left travel lever left Indicators and control elements Driver s stand BW 100 AD 5 77 ...

Page 78: ...r on right hand side Optional equipment 4 Lower edge cutter on right hand side Optional equipment 5 Lift edge cutter on left hand side Optional equipment Extend crabwalk The front drum is extended to the right Optional equipment 6 Lower edge cutter on left hand side Optional equipment Retract crabwalk The front drum is retracted Optional equipment Indicators and control elements Driver s stand BW ...

Page 79: ...tle lever Position MIN Idle speed position Position MAX I Full load position I Position MAX II Full load position II MIN MAX II MAX I B 880 0159 Fig 50 Indicators and control elements Driver s stand BW 100 AD 5 79 ...

Page 80: ...olates the batteries from the on board electrics in case of cable fire and fire in the engine compartment as well as protection against unauthorized use Individual control units may still be connected to the board electrics despite the main battery switch being pulled out Optional equipment B 880 0033 Fig 51 Indicators and control elements Engine compartment BW 100 AD 5 80 ...

Page 81: ...5 Checks prior to start up Checks prior to start up BW 100 AD 5 81 ...

Page 82: ...nd lubricants Safety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Ä Chapter 3 4 Handling fuels and lubri cants on page 29 WARNING Danger of injury caused by rotating parts Before starting work on the machine make sure that the engine can not be started CAUTION Danger of being injured by the engine hood dropping down Always secure an open...

Page 83: ...Open and secure the engine hood Ä Chapter 8 2 2 1 Open and secure the engine hood on page 140 Close the engine hood again after work is com pleted Checks prior to start up Notes on safety BW 100 AD 5 83 ...

Page 84: ...aks 4 Check bolted connections for tight fit 5 Check engine and exhaust system for leaks 6 Check belt drive for damage 7 Check machine for contamination and damage 8 Check function of steering 9 Check function of brake 10 Check emergency stop function 11 Check function of backup alarm system 12 Check function of seat contact switch Checks prior to start up Visual inspections and function tests BW ...

Page 85: ...g clothes n Safety shoes n Protective gloves 1 Pull the dipstick out wipe it off with a lint free clean cloth and reinsert it to the end stop 2 Pull the dipstick out again ð The oil level must be between the MIN and MAX marks 3 For topping up clean the area around the filling port 4 Unscrew the cap and fill with engine oil up to the MAX mark 5 Push the dipstick in 6 Close the cap MIN MAX 2 1 B 880...

Page 86: ...Never run the fuel tank empty as otherwise the fuel system needs to be bled Monitor the entire refuelling process Contaminated fuel can cause malfunction or even damage of the engine If necessary fill in fuel through a screen filter Use only fuel of the permitted specification Ä Chapter 8 3 2 Fuel on page 142 0 1 4 3 4 1 h 1 2 B DIS 0005 Fig 53 Checks prior to start up Checking the fuel level topp...

Page 87: ...hes n Safety shoes n Protective gloves 1 Clean the area around the filling port 2 Unscrew the cap and fill with fuel 3 Close the cap B 880 0187 Diesel Fig 54 Checks prior to start up Checking the fuel level topping up fuel BW 100 AD 5 87 ...

Page 88: ...l of the permitted specification Ä Chapter 8 3 4 Hydraulic oil on page 145 Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 For checking and topping up clean the area around the filling port 2 Remove the cap and check the hydraulic oil level on the dipstick 3 The hydraulic oil level must always be between the MIN and MAX marks ð Top up hydraulic oil 4 Close the cap B 88...

Page 89: ... page 144 Protective equip ment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 WARNING Danger of scalding by hot fluid Open the compensation tank only when the engine is cold Wear your personal protec tive equipment protective gloves protective clothing goggles Check the coolant level in the compensa tion tank 2 To refill remove the cover and fill up to the MAX mark with c...

Page 90: ...otective gloves 1 Check the air filter on the maintenance indicator 2 If the yellow pin has reached the red area 1 conduct maintenance of the air filter Ä Chapter 8 13 1 Air filter mainte nance on page 178 1 B 880 0084 Fig 57 Checks prior to start up Checking the air filter BW 100 AD 5 90 ...

Page 91: ... maintenance instructions in case of frost Ä Chapter 8 13 4 Measures if there is a risk of frost on page 186 NOTICE Dirty or contaminated water can block the water spraying system Fill only with clean water 1 Check the filling level on the water level gauge fill up if necessary B 880 0188 Water Fig 58 Checks prior to start up Checking the water level topping up BW 100 AD 5 91 ...

Page 92: ...fill in clean water through the strainer 2 3 Make sure that the ventilation bore in the filler cap is free 4 Close the cap 1 2 B 880 0189 Water Fig 59 Checks prior to start up Checking the water level topping up BW 100 AD 5 92 ...

Page 93: ...rs Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Check the condition of the scrapers 1 and clean them 2 Replace worn scrapers Fig 60 Checks prior to start up Checking adjusting the scrapers BW 100 AD 5 93 ...

Page 94: ...l indicator which must be checked at operating temperature 1 Make sure that no persons are in the danger zone during maintenance work 2 Drive the machine onto level firm ground 3 Shift the travel lever to Middle position and engage it in parking brake position ð The machine will decelerate down to a standstill and the parking brake will be applied after approx 2 seconds The parking brake warning l...

Page 95: ...ressed in the hydraulic oil filter is in good condition 10 If the pin pops out replace the hydraulic oil filter Ä Chapter 8 10 5 Replacing the hydraulic oil filter on page 166 11 Close the engine hood Ä Chapter 8 2 2 2 Closing the engine hood on page 140 12 Shift the throttle lever to position MIN idle speed 13 NOTICE Danger of engine damage Do not shut down the engine all of a sudden from full lo...

Page 96: ...Checks prior to start up Checking the hydraulic oil filter BW 100 AD 5 96 ...

Page 97: ...6 Operation Operation BW 100 AD 5 97 ...

Page 98: ...2 Adjust the seat in longitudinal direction dis engage lever b and push the seat forward or back to do so 3 Adjust to the weight of the operator using lever a The adjustment lever a is locked in upwards direction To release the lock press the lever down against the end stop Then adjust to the weight of the operator by sliding the lever down Fig 65 a Weight adjustment b Longitudinal adjustment c Ba...

Page 99: ...g the driver s seat sideways 1 Pull the lever up and slide the driver s seat sideways 2 Always lock the driver s seat safely in one of the locking positions Fig 66 Operation Setting up the work place BW 100 AD 5 99 ...

Page 100: ...obilizer armed the light emitting diode a flashes slowly 1 Slowly enter the six digit user code ð When entering the code the light emit ting diode 6 lights up with every digit 2 Press the diamond button ð The electronic immobilizer is now dis armed and the engine can be started within the next 15 minutes Fig 67 Operation Electronic immobilizer BW 100 AD 5 100 ...

Page 101: ...rerequisites n Main battery switch if present switched on n Emergency stop switch is unlocked n Travel lever in parking brake position When closing the dashboard cover the emergency stop switch will lock automatically and must be unlocked before starting again 1 Set the throttle lever to position MIN MIN MAX II MAX I B 880 0159 Fig 68 Operation Starting the engine BW 100 AD 5 101 ...

Page 102: ...ignition key must first be turned back to position 0 before a new starting attempt can be made NOTICE Components may get dam aged Run 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 determine the cause Turn the ignition key through position II to position III ð The starter cranks the ...

Page 103: ...NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under full load Operation Starting the engine BW 100 AD 5 103 ...

Page 104: ...the machine Wet and loose soil considerably reduces trac tion of the machine on inclinations and slopes Greater danger of accident When driving up and down slopes move the travel lever slowly back towards neutral to brake the machine If the operator leaves his seat while travelling the driver s seat warning light lights up The warning buzzer sounds After approx 3 seconds the machine brakes to a st...

Page 105: ...on 6 4 3 Stopping the machine applying the parking brake 1 Shift the travel lever to Middle position and engage it in parking brake position ð The machine will decelerate down to standstill and the parking brake will be applied after approx 2 seconds The parking brake warning lamp lights up MIN MAX II MAX I B 880 0160 Fig 73 I I II II 0 B 880 0008 Fig 74 Fig 75 Operation Travel operation BW 100 AD...

Page 106: ...vibration on hard frozen concrete ground Vibration at standstill causes transverse marks n Switch the vibration on only after shifting the travel lever to the desired travel direction n Switch the vibration off before stopping the machine In automatic operation vibration is automati cally activated when a certain low travel speed is reached The vibration is automatically switched off when falling ...

Page 107: ...on is only acti vated if the vibration has been switched off beforehand 2 Set the throttle lever to position MAX I or MAX II 6 5 3 Manual vibration 1 Turn the rotary switch for vibration pre selection to position Left B SWI 1488 Fig 76 MIN MAX II MAX I B 880 0160 Fig 77 B SWI 1486 Fig 78 Operation Working with vibration BW 100 AD 5 107 ...

Page 108: ...in to switch off vibration 6 5 4 Vibration in automatic mode 1 Turn the rotary switch for vibration pre selection to position Right 2 Shift the travel lever slowly in the desired travel direction ð The vibration comes on at a low travel speed 3 To switch off vibration return the travel lever towards Middle position ð The vibration switches off when falling below a low travel speed B 880 0007 a Fig...

Page 109: ...he detection and selected re compaction of weak spots The acceleration transducer on the front drum measures the reaction of the road subbase on the vibrating drum The ECONOMIZER is automatically started by switching the ignition on The ECONOMIZER first of all runs an LED test The LEDs light up one after the other starting with LED 1 Once all LEDs are on the display goes out again in single steps ...

Page 110: ...the vibration motor has reached its nominal frequency n flashes if the drum is in jump operation n lights in case of faults Ä Chapter 10 5 Trouble shooting ECONO MIZER on page 206 In order to achieve the desired compaction condition of the road substructure or asphalt layer one must always perform a suitable ref erence measurement before compaction is started The reference measurement is used to d...

Page 111: ...The measuring values achieved with different tandem vibratory rollers can be made compa rable by calibration to a reference value Operation Working with vibration BW 100 AD 5 111 ...

Page 112: ...r the travel lever is actuated in travel direction or after the rotary switch for the water spraying system has been set to permanent spraying position MAX With the travel lever in neu tral spraying will continue for a short while 3 After the end of work turn the rotary switch for the water spraying system back to posi tion 0 B SWI 1494 Fig 84 B SWI 1493 Fig 85 Operation Water spraying system BW 1...

Page 113: ...applied after approx 2 seconds The parking brake warning light lights up 3 Shift the throttle lever to position MIN idle speed 4 NOTICE Danger of engine damage Do not shut down the engine all of a sudden from full load speed but let it idle for about two minutes Turn the ignition key to position 0 and pull it out 0 B 880 0012 Fig 86 MIN MAX II MAX I B 880 0159 Fig 87 B ELE 0069 Fig 88 Operation Pa...

Page 114: ...5 Turn the main battery switch if present anticlockwise and pull it out B SWI 0079 Fig 89 Operation Parking the machine in secured condition BW 100 AD 5 114 ...

Page 115: ...ire the minus terminal has been designed as a quick release pole clamp 1 Pull up the cap from the minus pole ð The pole clamp comes off the minus pole 2 Disconnect the pole clamp from the minus pole of the battery and lay it to the side 6 8 3 Towing the machine 6 8 3 1 Preliminary remarks and safety notes Tow the machine only in case of emergency or to prevent an accident Always use a tow bar Towi...

Page 116: ...ficient traction and braking power for the non braking towed load n tow bar and fastening means are able to withstand the load and are fastened at the points provided for this purpose The machine cannot be steered Operation Emergency procedures BW 100 AD 5 116 ...

Page 117: ...ow bar to the towing eye 1 4 WARNING Danger of burning on hot components Wear your personal protec tive equipment protective gloves protective clothing Avoid touching hot compo nents Open the engine hood and remove the covering from the travel pump Fastening the tow bar Fig 92 Short circuiting the travel pump B 880 0050 Fig 93 Operation Emergency procedures BW 100 AD 5 117 ...

Page 118: ...unter nuts tightening torque 22 Nm 16 ft lbf 9 WARNING Danger of injury caused by uncontrolled machine move ment Always secure the machine against unintended rolling Remove two plugs 10 Press both screws in against the springs 11 Tighten both screws alternately and step by step against the end stop tightening torque 35 Nm 25 ft lbf B HYD 0003 1 2 1 2 1 2 Fig 94 Releasing the brake B 880 0014 Fig 9...

Page 119: ...p ment n Working clothes n Safety shoes n Protective gloves WARNING Danger of injury caused by uncontrolled machine movement Always secure the machine against unintended rolling 1 After towing park the machine in a safe place and secure it against accidentally rolling away 2 Remove two plugs B 880 0014 Fig 97 B 880 0014 Fig 98 Operation Emergency procedures BW 100 AD 5 119 ...

Page 120: ...r nuts 2 on the high pressure limiting valves of the travel pump 7 Unscrew the socket head cap screws 1 against the end stop 8 Tighten the counter nuts tightening torque 22 Nm 16 ft lbf 9 Open the engine hood and assemble the covering on the travel pump Fig 99 B 880 0014 Fig 100 B HYD 0003 1 2 1 2 1 2 Fig 101 B 880 0050 Fig 102 Operation Emergency procedures BW 100 AD 5 120 ...

Page 121: ...rake to prevent the parking brake from opening 2 Close the engine hood 3 Set the throttle lever to position MIN 4 Start the engine and shut it down again after approx 2 3 seconds 5 Repeat this process after a short break 6 Pull off the ignition key 7 Open the engine hood and reconnect the plug Y04 to the solenoid valve for the parking brake 8 Close the engine hood B 880 0049 1 Fig 103 1 Plug Y04 M...

Page 122: ...1 Plug Y04 Operation Emergency procedures BW 100 AD 5 122 ...

Page 123: ...7 Loading transporting the machine Loading transporting the machine BW 100 AD 5 123 ...

Page 124: ...repare for transport 1 Close all flaps 2 Remove all loose objects from the machine or from the operator s stand or fasten them reliably Loading transporting the machine Prepare for transport BW 100 AD 5 124 ...

Page 125: ...ructing person should not be inside the travel range of the machine 1 DANGER Danger to life caused by the machine slipping or turning over Make sure that no persons are in the danger zone Drive the machine carefully onto the trans port vehicle 2 Move the steering to middle position 3 Shut down the engine pull off the ignition key 4 WARNING Danger of crushing by the articulating machine Do not step...

Page 126: ... the foldable ROPS Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Loosen the eye bolts and adjust the clamping plates vertically 2 CAUTION Head injuries caused by folding the foldable ROPS Do not step into the slewing area of the foldable ROPS Fold the foldable ROPS back B 650 0018 Fig 107 Loading transporting the machine Loading the machine BW 100 AD 5 126 ...

Page 127: ... only in the specified loading direction Lifting tackle must not be damaged by machine parts Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Fasten the lifting and lashing tackle on the marked lashing points on front or rear frame 2 Lash the machine securely to the transport vehicle B 880 0081 Fig 108 Loading transporting the machine Lashing the machine to the transpor...

Page 128: ...ng gear only in the pre scribed direction of load application Lifting tackle must not be damaged by machine components When lifting the machine avoid uncontrolled movements of the load If necessary hold the load with guide ropes 1 Shut down the engine 2 WARNING Danger of crushing by the articulating machine Do not step into the articula tion area of the machine while the engine is running Attach a...

Page 129: ...ing point 5 DANGER Danger to life caused by sus pended loads Do not step or stand under suspended loads Lift the machine carefully and lower it again at the intended location Fig 110 Loading transporting the machine Loading by crane BW 100 AD 5 129 ...

Page 130: ...ing and lashing points Use lifting and lashing gear only in the pre scribed direction of load application Lifting tackle must not be damaged by machine components When lifting the machine avoid uncontrolled movements of the load If necessary hold the load with guide ropes Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Shut down the engine 2 WARNING Danger of crushing ...

Page 131: ...e protective roof may get damaged when lifting Always fold the protective roof in Attach the lifting tackle to the central lifting point 5 DANGER Danger to life caused by sus pended loads Do not step or stand under suspended loads Lift the machine carefully and set down again at the intended location 650118 Fig 112 Loading transporting the machine Loading by crane BW 100 AD 5 131 ...

Page 132: ...ing machine Do not step into the articula tion area of the machine while the engine is running Loosen the articulation lock again and fasten it in the holding fixture Ä Chapter 8 2 1 2 Disengaging the articulation lock on page 139 7 6 1 Erecting the foldable ROPS Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Erect the clamping plates on both sides vertically B 650 00...

Page 133: ...nds into the slewing area of the foldable ROPS Fold up the foldable ROPS 3 Turn the clamping plates horizontally and tighten the eye bolts tightening torque 75 200 Nm 55 148 ft lbf B 650 0039 75 200 Nm 55 148 ft lbf Fig 114 Loading transporting the machine After transport BW 100 AD 5 133 ...

Page 134: ...Loading transporting the machine After transport BW 100 AD 5 134 ...

Page 135: ...8 Maintenance Maintenance BW 100 AD 5 135 ...

Page 136: ...handling fuels and lubricants Ä Chapter 3 4 Handling fuels and lubri cants on page 29 Wear your personal protective equipment Do not touch hot components Park the machine on horizontal level firm ground Perform maintenance work only with the engine shut down Make sure that the engine cannot be acciden tally started during maintenance work Thoroughly clean machine and engine before starting mainten...

Page 137: ...he articulation lock when working in the area of the articulated joint Do not leave any tools or other objects that could cause damage in or on the machine After all maintenance work is completed rein stall all guards and safety installations Close all maintenance flaps and doors after maintenance work has been completed The terms right left are always in relation to the travel direction Maintenan...

Page 138: ...urn all components to their operating condition 8 2 1 Articulation lock 8 2 1 1 Engaging the articulation lock Protective equip ment n Working clothes n Safety shoes n Protective gloves WARNING Danger of crushing by the articu lating machine Do not step into the articulation area of the machine while the engine is running 1 Move the steering to middle position and stop the machine 2 Switch off the...

Page 139: ... 126 8 2 1 2 Disengaging the articulation lock Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Erect the foldable ROPS and fasten it with the specified tightening torques Ä Chapter 7 6 1 Erecting the foldable ROPS on page 132 2 WARNING Danger of crushing by the articulating machine Do not step into the articula tion area of the machine while the engine is running Loose...

Page 140: ... 2 Push the hood to top position ð The hood is raised supported by the gas springs 8 2 2 2 Closing the engine hood 1 Push the hood at the handle into initial position 2 Lock the hood B 880 0192 Fig 117 B 880 0193 Fig 118 Maintenance Preparations concluding work BW 100 AD 5 140 ...

Page 141: ...iscosity Since engine oil changes its viscosity with the temperature the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class SAE class The temperature data of the SAE class always refer to fresh oils In travel operation engine oil ages because of soot and fuel residues This adversely affects the properties of the engine oil especial...

Page 142: ...urs reached If the sulphur content in the fuel is higher than 0 5 the oil change intervals must be halved 8 3 2 Fuel 8 3 2 1 Fuel quality We recommend using a diesel fuel with a sul phur content of less than 0 1 When using a diesel fuel with a high sulphur content of 0 5 to 1 0 the oil change inter vals must be halved Fuels with a sulphur content of more than 1 0 are not permitted In order to fulf...

Page 143: ...para tion At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel Diesel fuels suitable for temperatures down to 44 C 47 F are available for Arctic climates NOTICE Danger of engine damage The admixture of petroleum and the addition of flow enhancing additives fuel additives is not permitted 8 3 2 3 Storage Even traces of zinc lead and copper can c...

Page 144: ...For this engine you should use eth ylene glycol Before filling in the coolant mixed with anti freeze agent the radiator must be flushed with clean water This procedure should be repeated two to three times to clean the inside of radiator and engine block NOTICE Danger of engine damage Do not mix different coolants and additives of any other kind Mixing the coolant n Prepare a mixture of 50 anti fr...

Page 145: ...g agent it may cause the development of sludge which could damage the cooling system Anti freeze concen tration Freezing point 50 37 C 35 F 8 3 4 Hydraulic oil 8 3 4 1 Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 ISO with a kinematic viscosity of 46 mm2 s at 40 C 104 F and 8 mm2 s at 100 C 212 F When refilling or changing oil use only hydraulic oil type...

Page 146: ...sel Winter diesel fuel 35 l 9 2 gal us Specification Ä Chapter 8 3 2 Fuel on page 142 Coolant Mixture of water and anti freeze agent Specification Ä Chapter 8 3 3 Coolant on page 144 009 940 08 20 l 6 l 1 6 gal us Hydraulic system Hydraulic oil ISO HVLP 46 Specification Ä Chapter 8 3 4 1 Mineral oil based hydraulic oil on page 145 009 930 09 20 l 35 l 9 2 gal us Water spraying system Water Anti fr...

Page 147: ...e 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 8 5 2 After 50 operating hours 1 Check the engine for leaks 2 Tighten all bolted connections on air intake exhaust oil sump and engine mounts 3 Retighten the bolted connections on the machine Maintenance Running in instruction...

Page 148: ...ing brake 158 Every 500 operating hours 8 9 1 Replacing the fuel filter 159 8 9 2 Replacing the V belt 160 8 9 3 Checking the anti freeze concentration and the con dition of the coolant 161 8 9 4 Checking the hydraulic lines 162 Every 1000 operating hours 8 10 1 Checking adjusting the valve clearance 163 8 10 2 Checking the engine mounts 165 8 10 3 Checking the ROPS 165 8 10 4 Checking the travel ...

Page 149: ...cking the fuel injection pump 177 As required 8 13 1 Air filter maintenance 178 8 13 2 Checking the water spraying system 182 8 13 3 Cleaning the water spraying system 184 8 13 4 Measures if there is a risk of frost 186 Maintenance Maintenance Table BW 100 AD 5 149 ...

Page 150: ...responding parts must be immediately repaired or replaced by authorized service personnel NOTICE Danger of engine damage After work on the fuel system bleed the system perform a test run and check for leaks 8 7 2 Checking cleaning the water separator The service intervals for the water separator depend on the water con tent in the fuel and can therefore not be determined precisely After taking the...

Page 151: ...ce the transparent container under the drain plug 3 Slacken the drain plug for a few turns and collect leaking fluid 4 Drain the fuel off until there is no water left 5 Turn the plug tightly back in Check for leaks if necessary use a new seal ring 6 Dispose of collected fluid in an environ mentally friendly way Fig 119 Maintenance Every 50 operating hours BW 100 AD 5 151 ...

Page 152: ...r 8 4 List of fuels and lubri cants on page 146 Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 7 Parking the machine in secured condi tion on page 113 2 WARNING Danger of burning on hot components Wear your personal protec tive equipment protective gloves protective clothing Avoid touching hot compo nents Unscrew the drain plug and ...

Page 153: ...ort test run check the oil level on the oil dipstick 1 if necessary top up to the MAX mark 11 Check oil filter cartridge and drain plug for leaks 12 Dispose of the oil and filters in line with environmental regulations 8 8 2 Checking tensioning the V belt 8 8 2 1 Checking the V belt Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 7 Pa...

Page 154: ...on the generator 2 Press the generator towards the outside using a lever until the correct V belt ten sion is reached 3 Retighten clamping screw 1 and screw 2 8 8 3 Check the air intake lines Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 7 Parking the machine in secured condition on page 113 2 Allow the engine to cool down 3 Check t...

Page 155: ... fit of all radi ator hoses and hose clamps 4 If a radiator hose is swollen hardened or cracked both hose and hose clamp must be replaced immediately 8 8 5 Cleaning the radiator module NOTICE Components may get damaged Do not bend or damage cooling fins Do not clean with high pressure 1 Park the machine in secured condition Ä Chapter 6 7 Parking the machine in secured condition on page 113 2 Allow...

Page 156: ...g around Wear your personal protective equipment safety gloves protec tive working clothes goggles 1 Blow the cooler out with compressed air from inside the engine compartment 2 Blow the cooler out with compressed air from the outside Cleaning with com pressed air Fig 125 Fig 126 Maintenance Every 250 operating hours BW 100 AD 5 156 ...

Page 157: ...strong water jet 2 Run the engine warm for a while to avoid corrosion 8 8 6 Battery service Maintenance free batteries also need care Maintenance free only means that the fluid level does not need to be checked Every battery has a self discharge which may if not checked occasion ally even cause damage to the bat tery as a result of exhaustive dis charge Exhausted batteries batteries with formation...

Page 158: ...nt 3 Clean the outside of the battery 4 Clean battery poles and pole clamps and grease them with pole grease Vaseline 5 Install the battery and check the battery fastening 6 On serviceable batteries check the acid level if necessary top up to the filling mark with distilled water 8 8 7 Check the parking brake This work must only be performed by authorized service personnel Fig 127 Maintenance Ever...

Page 159: ...ne power stalls the engine and makes starting impossible Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 7 Parking the machine in secured condition on page 113 2 Loosen the hose clamps 1 on the fuel pre filter 3 Pull the hoses off the fuel pre filter 4 Install the new fuel pre filter and observe the flow direction arrow Fig 128 Mainte...

Page 160: ...rt into the clean side Slightly oil the rubber seal on the new fuel filter 9 Attach the fuel filter 1 with the quick lock and ensure correct coding 10 Close the quick lock 2 so that is engages noticeably 11 Screw in drain plug 3 12 Dispose of fuel and fuel filter in an environ mentally friendly manner 8 9 2 Replacing the V belt Perform this maintenance work at the latest after two years Fig 129 Fi...

Page 161: ...3 Checking the anti freeze concentration and the condition of the coolant Protective equip ment n Protective gloves n Safety goggles 1 Park the machine in secured condition Ä Chapter 6 7 Parking the machine in secured condition on page 113 2 Allow the engine to cool down 3 Remove the cover 1 from the compensa tion tank and check the anti freeze concen tration with a conventional tester 4 Check the...

Page 162: ...uine shape of the hydraulic hose e g layer separa tion formation of blisters crushed spots buckling n leaks on hose socket or fitting n the hydraulic hose has separated from the fitting n fittings are damaged or deformed whereby the function and strength of the hose fitting connection is impaired n the fitting shows corrosion that impairs both function and strength n incorrect installation squeezi...

Page 163: ... cool down for at least 30 minutes The engine oil temperature must be below 80 C 176 F Valve clearance Intake exhaust valve 0 18 mm to 0 22 mm 0 007 in to 0 009 in Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 7 Parking the machine in secured condi tion on page 113 2 Allow the engine to cool down 3 Remove the valve cover Fig 133 Ma...

Page 164: ...he crankshaft one full turn 360 fur ther 6 Check the valve clearance on the valves marked black adjust if necessary 7 Install the cylinder head cover with a new seal 8 After a short test run check the engine for leaks Fig 134 I Intake valve E Exhaust valve Fig 135 Fig 136 Checking the valve clear ance Maintenance Every 1000 operating hours BW 100 AD 5 164 ...

Page 165: ...low the engine to cool down 3 Check air intake and exhaust manifold fas tenings for tight fit 4 Check sockets and clamps between air filter exhaust turbocharger and charge air line as well as the engine oil lines for tight fit and leaks 5 Check fastening screws on the engine oil sump and engine mounts for tight fit 6 Check condition and tight fit of engine pillow blocks 8 10 3 Checking the ROPS Al...

Page 166: ...tening of the seat belts 8 10 4 Checking the travel control 1 Park the machine in secured condition Ä Chapter 6 7 Parking the machine in secured condition on page 113 2 Move the travel lever forward backwards and to braking position Thereby check for function light movement clearance and damage 3 In case of malfunction perform trouble shooting and replace the corresponding parts 4 Only operate the...

Page 167: ... changed after major repairs in the hydraulic system 1 Park the machine in secured condition Ä Chapter 6 7 Parking the machine in secured condition on page 113 2 Allow the engine to cool down Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Clean the area around the hydraulic oil filter 2 Unscrew filter bowl 4 and take it off with filter element 3 Preparations Hydraulic...

Page 168: ...r bowl 4 Clean the thread on the filter bowl 5 Reassemble the filter bowl with a new filter element and new O rings 1 2 Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Clean the area around the high pressure filter 2 Disconnect the hydraulic oil lines 1 from the high pressure filter 2 3 Remove the high pressure filter and install the new high pressure filter while payi...

Page 169: ...ck the hydraulic oil level top up if nec essary Ä Chapter 8 11 1 Changing the hydraulic oil on page 170 3 Dispose of the hydraulic oil and filter in line with environmental regulations Concluding work Maintenance Every 1000 operating hours BW 100 AD 5 169 ...

Page 170: ...ydraulic oil Do not use any detergents to clean the system Use only lint free cleaning cloths for cleaning When changing from mineral oil based hydraulic oil to an ester based biologically degradable hydraulic oil you should consult the lubrication oil service of the oil manufac turer or our customer service for details NOTICE Risk of damage Perform the oil change when the hydraulic oil is warm Us...

Page 171: ...opening and filler cap 3 Remove the cap from the hydraulic oil tank 4 WARNING Danger of burning on hot components Wear your personal protec tive equipment protective gloves protective clothing Avoid touching hot compo nents Unscrew the drain plug and collect any hydraulic oil running out 5 Screw the drain plug back in tightly B 880 0066 Fig 141 B 880 0182 Fig 142 Maintenance Every 2000 operating h...

Page 172: ...st filtration of the hydraulic oil prolongs the life time of the hydraulic oil filter and protects the hydraulic system Fill in new hydraulic oil 10 Check the hydraulic oil level on the dip stick 11 The hydraulic oil level must always be between the MIN and MAX marks 12 The breather filter for the hydraulic oil tank is integrated in the cap you must therefore replace the complete cap Close the tan...

Page 173: ...tem If oil has entered you must add a cleansing agent in order to remove any residues from the system Follow the instructions of the manufac turer If in doubt consult your Customer Service or the engine manufacturer When changing the coolant without any signs of contamination cleaning of the cooling system is not necessary NOTICE Danger of engine damage Use only coolant of the permitted specificat...

Page 174: ... the condition of the coolant 8 Thoroughly flush the cooling system if the coolant is contaminated by corrosion resi dues or other suspended matter 9 Remove the thermostat 10 Fill with clean water 11 Start the engine and flush the cooling system out for a short while 12 Allow the engine to cool down to approx 50 C 122 F 13 Drain off all water 14 If using a cleaning agent repeat the flushing proces...

Page 175: ...ure 22 Let the engine cool down and check the coolant level again if necessary top up in the compensation tank 23 Dispose of coolant in line with environ mental regulations 8 11 3 Replacing hoses This work must only be performed by authorized service personnel Perform this maintenance work at the latest after two years The following hoses need to be renewed n fuel hoses n air intake hoses B 880 01...

Page 176: ...8 11 4 Check the injection valves This work must only be performed by authorized service personnel Maintenance Every 2000 operating hours BW 100 AD 5 176 ...

Page 177: ...8 12 Every 3000 operating hours 8 12 1 Checking the fuel injection pump This work must only be performed by authorized service personnel Maintenance Every 3000 operating hours BW 100 AD 5 177 ...

Page 178: ...ement is covered with a sooty deposit Do not use gasoline or hot fluids to clean the filter element After cleaning the air filter must be inspected for damage using a torch Do not continue to use a dam aged air filter element If in doubt use a new air filter If the air filter is damaged the safety element must be replaced as well The safety element must not be cleaned We generally recommend to ren...

Page 179: ...est after one year 1 Park the machine in secured condition Ä Chapter 6 7 Parking the machine in secured condition on page 113 2 Allow the engine to cool down 3 Loosen both locking hooks on the housing cover and take the cover off 4 Clean housing cover and dust discharge valve 5 Pull out the main filter element with light turning movements Fig 149 Fig 150 Fig 151 Maintenance As required BW 100 AD 5...

Page 180: ...inside the element until it if free of dust 7 Examine the air filter element with a torch for cracks and holes in the paper bellows 8 In case of damage replace the air filter and the safety element 9 Slide the air filter carefully into the housing NOTICE Danger of engine damage The dust discharge valve must point vertically downwards Make sure that the cover locks engage correctly 10 Reassemble th...

Page 181: ...ed The safety element must be replaced if the air filter is damaged at the latest after one year if the air filter warning light comes on again after the air filter has been cleaned 1 Remove the housing cover and pull the air filter element off 2 Pull the safety element out by turning it lightly 3 Push in a new safety element 4 Insert the air filter and reassemble the housing cover Fig 155 Fig 156...

Page 182: ... ground 2 Shut down the engine 3 NOTICE The spraying pump may get damaged if the tank is empty Always keep the water tank filled with a sufficient amount of water Check the filling level on the water level gauge fill up if necessary 4 Turn the ignition key to position I B 880 0188 Water Fig 157 B ELE 0070 Fig 158 Maintenance As required BW 100 AD 5 182 ...

Page 183: ...l is activated only once Then the water pump is switched off again ð The water spraying system is switched on 6 Check water output and spray pattern on all nozzles 1 for both drums 7 Turn the rotary switch for pressure spraying to 0 to switch the water spraying system off 8 Turn the ignition key back to position 0 and pull it out B SWI 1495 Fig 159 B 880 0070 1 Fig 160 B SWI 1493 Fig 161 Maintenan...

Page 184: ...g the machine in secured condi tion on page 113 2 Remove the cap 1 3 Take the filling screen 2 out and clean it 4 Check the filling screen for damage replace if necessary 5 Close the cap 6 Open the drain cover on the water tank and let all water run out 7 Flush the water tank out with a strong water jet 8 Drain off all water and dirt 1 2 B 880 0189 Water Fig 162 B 880 0067 Fig 163 Maintenance As r...

Page 185: ...from the spray tube and let the water run out 12 Switch the water spraying system on for a short while to flush contaminants out of the lines 13 Switch off the water spraying system 14 Turn the ignition key back to position 0 and pull it out 15 Reassemble the caps and nozzles on the spray tube B 880 0126 1 2 Fig 164 1 1 2 B 880 0127 Fig 165 Maintenance As required BW 100 AD 5 185 ...

Page 186: ...ck on 4 Open the line connection in the articulation area and let all water run out 5 Close the line connection again 6 Route the water line on the spraying pump to the outside 7 Open the drain valve and drain off all water 8 Switch on the water spraying system for a short while to drain the water from the pump 9 Switch off the water spraying system 10 Turn the ignition key back to position 0 and ...

Page 187: ...e water line back into the machine 12 Unscrew the caps 1 and all nozzles 2 from the spray tube and let the water run out 1 Reassemble the caps and nozzles on the spray tube 1 1 2 B 880 0127 Fig 169 Before the next use Maintenance As required BW 100 AD 5 187 ...

Page 188: ...Maintenance As required BW 100 AD 5 188 ...

Page 189: ...9 Setting up refitting Setting up refitting BW 100 AD 5 189 ...

Page 190: ...he lifting and lifting points Use lifting tackle only in the specified loading direction Lifting tackle must not be damaged by machine parts Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 7 Parking the machine in secured condi tion on page 113 2 Slightly loosen the screws 1 Do not back out the screws too far 3 Disengage the articula...

Page 191: ...ift up the machine just above the ground 6 Shift the rear frame to the desired position left or right 7 Lower the machine to the ground 8 Retighten screws 1 650118 Fig 171 B 880 0072 1 Fig 172 Setting up refitting Manually adjusting the crabwalk BW 100 AD 5 191 ...

Page 192: ...ndition Ä Chapter 6 7 Parking the machine in secured condition on page 113 2 Mount the tool 2 using the star handle screw 1 on the edge cutter 3 Mount the unused tool to the brackets 1 Fig 173 Fig 174 Setting up refitting Edge cutter installing tool BW 100 AD 5 192 ...

Page 193: ...ffi cient load bearing capacity for the weight to be loaded Always use appropriate lifting and lashing means on the lifting and lashing points Use lifting and lashing gear only in the pre scribed direction of load application Lifting tackle must not be damaged by compo nents of the chip spreader When lifting the machine avoid uncontrolled movements of the load If necessary hold the load with guide...

Page 194: ...ts 1 3 DANGER Danger to life caused by sus pended loads Do not step or stand under suspended loads Lift the chip spreader and hook it carefully into the fixing points on the machine 4 Assemble the bolt 1 and secure it with the split pin 2 5 Connect the chip spreader hydraulically and electrically with the machine 1 B 880 0137 Fig 175 2 1 B 880 0135 Fig 176 B 880 0039 Fig 177 Setting up refitting M...

Page 195: ...6 7 Parking the machine in secured condi tion on page 113 3 Empty the chip spreader 4 Disconnect the chip spreader hydraulically and electrically from the machine 5 Fasten the lifting tackle at the lifting points 1 6 Attach the chip spreader to the lifting tackle B 880 0039 Fig 178 1 B 880 0137 Fig 179 Setting up refitting Mounting removing the chip spreader BW 100 AD 5 195 ...

Page 196: ...ds Do not step or stand under suspended loads Lift the chip spreader and lift it carefully out of the fixing points on the machine 9 Set the chip spreader safely down on level and firm ground 2 1 B 880 0135 Fig 180 Setting up refitting Mounting removing the chip spreader BW 100 AD 5 196 ...

Page 197: ...10 Troubleshooting Troubleshooting BW 100 AD 5 197 ...

Page 198: ...e Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance If you cannot locate the cause of a fault or rec tify it yourself by following the trouble shooting chart you should contact our customer service department Troubleshooting Preliminary remarks BW 100 AD 5 198 ...

Page 199: ...ngine or chassis ground as far away from the bat tery as possible 3 Start the engine Ä Chapter 6 3 Starting the engine on page 101 NOTICE Danger of damage to the elec tronic system If no powerful consuming device is switched on voltage peaks may occur when separating the con necting cables between the bat teries which could damage elec trical components 4 Once the engine is running switch on a pow...

Page 200: ...nger of injury by fire in the machine Do not use fuses with higher ampere ratings and do not bridge fuses 10 3 2 Fuses in engine compartment Pos Fuse Amperage Designation 1 F00 80 A Main battery fuse Fig 182 Troubleshooting Fuse assignment BW 100 AD 5 200 ...

Page 201: ...ion F04 7 5 A Instruments F05 10 A 12 V socket F06 5 A Rotary switch for water spraying system F07 15 A Hazard light system F08 15 A Direction indicators and working head lights F09 10 A Parking and tail light left F10 10 A Parking and tail light right F11 15 A Head lights left F12 15 A Head lights right F23 10 A Warning horn F30 10 A Potential 15 F37 10 A Water pump F45 10 A Edge cutter F48 40 A ...

Page 202: ...tial 15 F156 15 A Lighting F157 30 A Starter F241 15 A Optional headlights F274 10 A Chip spreader hydraulic cutting tool F275 5 A Economizer F276 10 A Emulsion pump JP1 5 A Vibration also with travel lever in position II Troubleshooting Fuse assignment BW 100 AD 5 202 ...

Page 203: ...a tion Check the engine oil level correct if necessary Check the engine oil filter replace if necessary Have the lubrication system examined by a specialist Poor starting of engine or engine works irregularly with poor power Battery power too low ter minal clamps loose or oxi dized causing the starter to turn too slowly Check the battery charge condition clean the terminal clamps tighten and cover...

Page 204: ...ng lamp for engine oil tempera ture lights Clean the cooling fins Engine oil level too low Check fill up if necessary Lack of coolant Check all pipes and hoses for good condition and leak tight ness Check the coolant level top up if necessary Do not use radiator sealant to seal leaks Anti freeze concentration too high Use coolant with the speci fied mixing ratio Air filter dirty Clean replace if n...

Page 205: ...sary Lubrication system leaking Have the lubrication system examined by a specialist The charge control light lights during operation the warning buzzer sounds Generator speed too low Check the generator belt for tension replace the belt if necessary Generator or regulator defec tive Have examined by a spe cialist Troubleshooting Engine faults BW 100 AD 5 205 ...

Page 206: ...ion sensor Cable breakage Inform our Customer Service Department LED a lights up The Economizer is unable to read a calibration value when starting Since this value is required for calculation the measuring values measuring operation is blocked Restart the Economizer Turn the ignition key back to posi tion 0 and then again to position I If the LED a remains on inform our Customer Service Departmen...

Page 207: ...rews of the acceleration sensor Weak spots in the road sub base are also measured when paving asphalt In unfavourable cases an excessively varying material composition or moisture in the road subbase can influ ence the measuring results On material which is too dry or moist lower measuring values will be displayed Troubleshooting Trouble shooting ECONOMIZER BW 100 AD 5 207 ...

Page 208: ...Troubleshooting Trouble shooting ECONOMIZER BW 100 AD 5 208 ...

Page 209: ...11 Disposal Disposal BW 100 AD 5 209 ...

Page 210: ...ns and environ mental protection regulations must be followed when handling fuels and lubricants Ä Chapter 3 4 Handling fuels and lubri cants on page 29 Protective equip ment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Remove the batteries and dispose of in compliance with legal regulations 2 Empty the fuel tank 3 Drain the hydraulic oil tank 4 Drain coolant from coolin...

Page 211: ......

Page 212: ...51 3470 6220 e mail brasil bomag com BOMAG CANADA INC 3455 Semenyk Court Missisauga Ontario L5C 4P9 CANADA Tel 1 905 361 9961 Fax 1 905 361 9962 e mail canada bomag com BOMAG China Construction Machinery Co Ltd No 2808 West Huancheng Road Shanghai Comprehensive Industrial Zone Fengxian Shanghai 201401 CHINA Tel 86 21 3365 5566 Fax 86 21 3365 5508 e mail china bomag com BOMAG France S A S 2 avenue ...

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Bomag BW 100 AD-5, Operating & Maintenance Instructions

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Summary of Contents for BW 100 AD-5

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