Fayat BOMAG BW 100 ADM-5 Operating Instruction Download Page 7

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8 Maintenance

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139

8.1 Preliminary remarks and safety notes

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140

8.2 Preparations/concluding work

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142

8.2.1 Engine hood.............................................................................. 142

8.2.2 Maintenance flap....................................................................... 143

8.2.3 Articulation lock......................................................................... 143

8.3 Fuels and lubricants

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

145

8.3.1 Engine oil................................................................................... 145

8.3.2 Fuel........................................................................................... 146

8.3.3 Coolant...................................................................................... 148

8.3.4 Hydraulic oil............................................................................... 149

8.4 List of fuels and lubricants

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151

8.5 Running-in instructions

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

152

8.5.1 General...................................................................................... 152

8.5.2 After 50 operating hours............................................................ 152

8.6 Maintenance Table

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153

8.7 Every 50 operating hours

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

155

8.7.1 Checking radiator hoses and hose clamps............................... 155

8.7.2 Checking and cleaning the water separator.............................. 155

8.8 Every 250 operating hours

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

157

8.8.1 Change engine oil and oil filter cartridge................................... 157

8.8.2 Checking, tensioning the V-belt................................................. 159

8.8.3 Check the air intake lines.......................................................... 160

8.8.4 Checking radiator hoses and hose clamps............................... 160

8.8.5 Cleaning the radiator module.................................................... 161

8.8.6 Battery service........................................................................... 163

8.9 Every 500 operating hours

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

165

8.9.1 Draining the fuel tank sludge..................................................... 165

8.9.2 Replace the fuel filter................................................................. 165

8.9.3 Replacing the V-belt.................................................................. 167

8.9.4 Checking the anti-freeze concentration and the condition of the

coolant....................................................................................... 168

8.9.5 Checking the hydraulic lines...................................................... 168

8.10 Every 1000 operating hours

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

170

8.10.1 Checking, adjusting the valve clearance................................. 170

Table of contents

BW 100 ADM-5

Summary of Contents for BOMAG BW 100 ADM-5

Page 1: ...BW 100 ADM 5 Tandem vibratory roller Operating Instruction Maintenance Instruction Original Operating Instructions S N 101 462 12 1553 01 2021 008 206 66 EN ...

Page 2: ...uding toluene and benzene which are known to the State of California to cause cancer and birth defects or other reproductive harm WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the ou...

Page 3: ...y 25 3 2 2 Expert qualified person 25 3 2 3 Driver operator 26 3 3 Fundamentals 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...

Page 4: ...ation 46 3 7 5 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 5...

Page 5: ...socket 75 4 2 3 Travel lever 76 4 2 4 Driver s seat 78 4 2 5 Throttle lever 79 4 3 Outside of machine 80 4 3 1 Water level gauge 80 4 3 2 Fuel level gauge 80 4 3 3 Main battery switch 80 4 3 4 Warning indicator for seat belt 81 5 Checks prior to start up 83 5 1 Notes on safety 84 5 2 Visual inspections and function tests 86 5 3 Daily maintenance 87 5 3 1 Checking the engine oil level 87 5 3 2 Chec...

Page 6: ...1 6 6 6 ECONOMIZER 111 6 7 Water spraying system 114 6 8 ECOSTOP 115 6 9 Parking the machine in secured condition 117 6 10 Lifting lowering the edge cutter 119 6 11 Connecting disconnecting the hydraulic hammer 120 6 12 Emergency procedures 123 6 12 1 Actuating the emergency stop switch 123 6 12 2 Disconnecting the battery 123 6 12 3 Towing the machine 124 7 Loading transporting the machine 129 7 ...

Page 7: ...55 8 7 2 Checking and cleaning the water separator 155 8 8 Every 250 operating hours 157 8 8 1 Change engine oil and oil filter cartridge 157 8 8 2 Checking tensioning the V belt 159 8 8 3 Check the air intake lines 160 8 8 4 Checking radiator hoses and hose clamps 160 8 8 5 Cleaning the radiator module 161 8 8 6 Battery service 163 8 9 Every 500 operating hours 165 8 9 1 Draining the fuel tank sl...

Page 8: ... 184 8 13 1 Air filter maintenance 184 8 13 2 Cleaning the water spraying system 187 8 13 3 Measures if there is a risk of frost 188 8 13 4 Measures prior to extended shut down period 190 9 Setting up refitting 195 9 1 Adjusting the crabwalk 196 9 2 Edge cutter mounting and removing tools 198 10 Troubleshooting 201 10 1 Preliminary remarks 202 10 2 Starting the engine with jump leads 203 10 3 Fuse...

Page 9: ...1 Introduction Introduction BW 100 ADM 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 ADM 5 12 ...

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

Page 14: ...2 8 1627 64 2304 91 255 10 0 2194 86 28 1 1 12 0 5 1000 39 Dimensions in millimetres Dimensions in inches Weights Max operating weight 1900 4189 kg lbs Operating weight 1700 3748 kg lbs Average static linear load 8 5 48 kg cm pli Dimensions Technical data BW 100 ADM 5 14 ...

Page 15: ...30 Drive Engine manufacturer Kubota Type D902 Cooling Water Number of cylinders 3 Rated power ISO 14396 15 1 kW Rated power SAE J 1995 20 2 hp Rated speed 3000 min 1 Fixed engine speed 1 2100 min 1 Fixed engine speed 2 3000 min 1 Driven drum front rear Electric system Voltage 12 V Brakes Service brake hydrostatic Parking brake hydro mechanical Technical data BW 100 ADM 5 15 ...

Page 16: ...ng of drum to the right left 0 50 0 2 0 mm in Exciter system Vibrating drum front rear Drive system hydrostatic Frequency 1 2 42 63 2520 3780 Hz vpm Amplitude 0 40 0 016 mm in Centrifugal force 1 2 8 17 1798 3822 kN lbf Water sprinkler system Type of sprinkling Pressure Filling capacities Fuel diesel 30 7 9 l gal us Water 100 26 4 l gal us Technical data BW 100 ADM 5 16 ...

Page 17: ...ing 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 and EN 500 2 1 2 Vibration data The weighted effective acceleration value determined according to ISO 2631 is 0 5 m s2 The weighted effective acceleration value dete...

Page 18: ...Technical data Noise and vibration data BW 100 ADM 5 18 ...

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

Page 20: ...ly 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 to...

Page 21: ...tions 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: ...s or particles 3 1 4 Intended use This machine is intended for commercial use only The machine must only be used for n Compaction of bituminous material e g road surface layers n Compaction during earthwork and for road sub base construction Intended use also includes compliance with the specified operating maintenance and repair measures 3 1 5 Improper use Dangers may arise with the machine if it...

Page 24: ...g kerbs verges trenches pot holes n unauthorized use of public roads n Using the machine for towing Transporting persons except the machine driver is prohibited Starting and operating the machine in explo sive environments and in underground mining is prohibited 3 1 6 Estimated service life of the machine If the following general conditions are met the service life of the machine is usually in the...

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: ...ny 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 and...

Page 27: ...e 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 b...

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: ...e 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 ENVIRONMENT Diesel fuel is an environmentally hazardous substance Always keep diesel fuel in prope...

Page 31: ...ly 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 ADM 5 31 ...

Page 32: ...used 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 Immediately bind spilled oil with an oil binding agent Disp...

Page 33: ...d 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 CAUTION Health hazard caused by contact with hydraulic oil Wear your personal protective equipment protective...

Page 34: ...nding 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 ADM 5 34 ...

Page 35: ...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 36: ...tely 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 ADM 5 36 ...

Page 37: ...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 38: ...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 ADM 5 38 ...

Page 39: ... impaired in any way Always use appropriate lashing tackle at the lashing points Use lashing tackle only in the specified loading direction Lashing tackle must not be damaged by machine parts Secure the machine on the transport vehicle against rolling slipping and turning over Loads may only be attached and hoisted by an expert qualified person Only use lifting and lashing tackle with suffi cient ...

Page 40: ...ck 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 ADM 5 40 ...

Page 41: ...nting the machine check whether n persons or obstructions 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 Climb onto or off the machine only when the machine is standing Use...

Page 42: ...pilot or ether The machine must not be operated with dam aged missing or non functional safety installa tions After starting check all display instruments 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 lea...

Page 43: ...Do not start the engine by shorting the electric terminals on the starter motor because the machine may start to drive immediately Concerning your safety Starting up the machine BW 100 ADM 5 43 ...

Page 44: ...and Do not adjust the driver s seat while driving Do not climb onto or off the machine while the machine is driving Do not use the machine to transport persons In the case of unusual noises and appearance of smoke perform troubleshooting to determine the cause and have the fault corrected Match the speed to the working conditions Do not make extreme steering movements when driving with high speed ...

Page 45: ...e Soil conditions and weather influences impair the gradeability of the machine Wet and loose soil considerably reduces trac tion of the machine on inclinations and slopes Increased danger of accident 3 7 3 Cross slope The tipping angle was measured statically on level hard ground with the machine stopped and without steering The max permissible inclination of the machine may be limited by the max...

Page 46: ...uildings and underground supply lines gas water sewage electric power If neces sary stop compacting with vibration Do not activate the vibration on hard frozen concrete ground Components may get dam aged 3 7 5 Parking the machine Park the machine on horizontal level firm ground Before leaving the machine n shift all control levers to Neutral position Off or 0 n apply the parking brake n shut down ...

Page 47: ... 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 ADM 5 47 ...

Page 48: ... charging 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 sp...

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: ...eans 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 ADM 5 50 ...

Page 51: ...ulic 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 ...

Page 52: ... 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 in a separate specially marked con tainer and dispose of them in an environmen tally friendly way The settings for idle speed and highest speed must not be changed since this would affect the exhaust gas val...

Page 53: ...king 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 engine and exhaust system Never use gasoline or other easily inflammable substances for cleaning When cleaning with a high pressure cleaner do not subject elec...

Page 54: ...t both before and after shut down Ä Chapter 8 13 4 Measures prior to extended shut down period on page 190 It is not necessary to define a maximum storage period if these measures have been performed 3 10 7 After maintenance work Reassemble all guards and protective devices Close all maintenance flaps and maintenance doors again Concerning your safety Maintenance work BW 100 ADM 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 ADM 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 ADM 5 56 ...

Page 57: ...WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that are reproductive toxicants B 462 0013 Fig 10 Concerning your safety Signage BW 100 ADM 5 57 ...

Page 58: ...olant Spec MB 325 5 Deutz DQC CC 14 Hydraulic Oil 17 kg 50 Nm 008 303 29 1m 8 kg 80 Nm 30 cm Nm 50 80 ft lb 37 60 B 462 0014 Fig 11 Warning sticker Danger of tipping over B DEC 0206 Fig 12 Concerning your safety Signage BW 100 ADM 5 58 ...

Page 59: ...icker Foldable ROPS Warning sticker California Proposition 65 Fig 13 Fig 14 B DEC 0207 Fig 15 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that are reproductive toxicants B DEC 0316 Fig 16 Concerning your safety Signage BW 100 ADM 5 59 ...

Page 60: ...cker High pressure cleaning Instruction sticker Always wear your seat belt Information sticker Lifting point Information sticker Lashing point Fig 17 Fig 18 Fig 19 Fig 20 Concerning your safety Signage BW 100 ADM 5 60 ...

Page 61: ...oil Information sticker Engine oil drain Information sticker Disconnecting the battery Information sticker Ultra low sulphur fuel B DEC 0214 Hydraulic Oil Fig 21 B DEC 0211 Fig 22 B DEC 0219 Fig 23 Fig 24 Concerning your safety Signage BW 100 ADM 5 61 ...

Page 62: ...ormation sticker Low ash engine oil Information sticker Coolant Information sticker ECOSTOP Fig 25 Fig 26 B DEC 0221 Part No 009 940 03 20 l Engine Coolant Spec MB 325 5 Deutz DQC CC 14 Fig 27 B DEC 0360 Fig 28 Concerning your safety Signage BW 100 ADM 5 62 ...

Page 63: ...er Information sticker for the operation of the foldable ROPS Machine type plate example B DEC 0236 Fig 29 B DEC 0007 17 kg 50 Nm 1m 8 kg 80 Nm 30 cm Nm 50 80 ft lb 37 60 Fig 30 Fig 31 Concerning your safety Signage BW 100 ADM 5 63 ...

Page 64: ...is a danger zone Before starting the machine and during opera tion the driver operator must ensure that nobody is in the danger zone Give warning signals if necessary Stop work immediately if persons are in the danger zone Concerning your safety Danger zones BW 100 ADM 5 64 ...

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

Page 66: ...r hazard light system optional equipment 5 Rotary switch for flashing beacon optional equipment 6 Rotary switch for hydraulic breaker optional equipment 7 Rotary switch for drum pre selection 8 Rotary switch for vibration pre selection 9 Emergency stop switch 10 Instrument cluster 11 ECONOMIZER display optional equipment 12 Rotary switch for seat heating optional equipment 13 Rotary switch for wat...

Page 67: ...g side are flashing Optional equipment 4 1 2 Rotary switch for working lights Position Left Working lights off Position Right Working light on 4 1 3 Rotary switch for lighting Position Left Light off Position Middle Side light on Position Right Travel light on Optional equipment Fig 34 Fig 35 Fig 36 Indicators and control elements Operating console BW 100 ADM 5 67 ...

Page 68: ... flashing beacon Position Left Flashing beacon off Position Right Flashing beacon on Optional equipment 4 1 6 Rotary switch for the hydraulic hammer Position Left Hydraulic hammer off Position Right Hydraulic hammer on The parking brake is applied Optional equipment Fig 37 Fig 38 B SWI 0695 Fig 39 Indicators and control elements Operating console BW 100 ADM 5 68 ...

Page 69: ...ry switch for vibration pre selection Position left Pre selection vibration in manual mode Vibration is switched on 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 1488 Fig 40 B SWI 1485 Fig ...

Page 70: ... 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 42 Indicators and control elements Operating console BW 100 ADM 5 70 ...

Page 71: ...t 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 will be shut down after 2 seconds If the travel lever is shifted to any travel direc tion the engine will be 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 warnin...

Page 72: ... the engine Charge control light Lights up if the battery is not being charged Check the V belt if necessary repair the gen erator 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 F2 button switches between...

Page 73: ...uipment 4 1 12 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 13 Rotary switch for water spraying system Position 0 Spraying off Position 1 to 4 Interval spraying Position MAX Permanent spraying Fig 45 Fig 46 B SWI 1763 Fig 47 Indicators and control elements Operating console BW 100 ADM 5...

Page 74: ...3 5 4 6 1 2 B 462 0020 Fig 48 1 Starter switch 2 12 V DIN socket 3 Travel lever right 4 Driver s seat 5 Travel lever left optional equipment 6 Throttle lever Indicators and control elements Driver s stand BW 100 ADM 5 74 ...

Page 75: ... key up to 10 seconds in position II 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 2 2 12 V DIN socket Permanent current loadable up to 10 A Fig 49 Fig 50 Indica...

Page 76: ...vel n Position I up to approx 5 km h 3 mph n Position II up to approx 10 km h 6 2 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 2 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 ADM 5 76 ...

Page 77: ...ment depends on the machine s equip ment 1 2 3 4 B ELE 0303 1 Vibration on off 2 Warning horn 3 Lift edge cutter on right hand side optional equipment 4 Lower edge cutter on right hand side optional equipment Indicators and control elements Driver s stand BW 100 ADM 5 77 ...

Page 78: ...rrect driver s weight has been set Press down the handle against the end stop the weight adjustment automatically switches back to the top position 2 Length adjust ment Pull the lever up and push the seat forward or back 3 Backrest inclina tion Relieve the backrest and pull the lever up Indicators and control elements Driver s stand BW 100 ADM 5 78 ...

Page 79: ...le 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 53 Indicators and control elements Driver s stand BW 100 ADM 5 79 ...

Page 80: ... 4 3 3 Main battery switch Position on Main battery switch locked Normal position operation Turn anticlock wise Main battery switch can be pulled out Disconnects the batteries from the on board electrics e g to prevent unauthorised use Optional equipment B 462 0022 Fig 54 B 462 0023 Fig 55 B 462 0024 Fig 56 Indicators and control elements Outside of machine BW 100 ADM 5 80 ...

Page 81: ... seat belt Seat belt fastened Warning indicator for seat belt on Seat belt not fas tened Warning indicator for seat belt off Optional equipment B 880 0222 Fig 57 Indicators and control elements Outside of machine BW 100 ADM 5 81 ...

Page 82: ...Indicators and control elements Outside of machine BW 100 ADM 5 82 ...

Page 83: ...5 Checks prior to start up Checks prior to start up BW 100 ADM 5 83 ...

Page 84: ...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 85: ...pen and secure the engine hood Ä Chapter 8 2 1 1 Open and secure the engine hood on page 142 Close the engine hood again after work is com pleted Checks prior to start up Notes on safety BW 100 ADM 5 85 ...

Page 86: ...Check the bolted connections are tight and secure 5 Check the engine and exhaust system for leaks 6 Check the belt drive for damage 7 Check the 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 f...

Page 87: ...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 If the engine oil level is higher than the MAX mark find the cause and change the engine oil if necessary 4 For topping up clean the area around the filling port 5 Unscrew the cap and ...

Page 88: ...uge 2 Check the filling level at the fuel level indi cator optional equipment in the instru ment cluster 3 Refuel if required but only after shutting down the engine first Fuel level gauge B 462 0023 Fig 59 Instrument cluster 0 1 4 3 4 1 h 1 2 B DIS 0005 Fig 60 Checks prior to start up Daily maintenance BW 100 ADM 5 88 ...

Page 89: ...n 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 146 Protective equip ment n Working clothes 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 462 0026 Fig 61 Checks prior to start up Daily maintenance BW 100 ADM ...

Page 90: ...il of the permitted specification Ä Chapter 8 3 4 Hydraulic oil on page 149 Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Check the oil level in the inspection glass Normal level approx 2 3 height of inspection glass Minimum level Middle of inspection glass 2 For topping up clean the area around the filling port 3 Remove the cap and fill with hydraulic oil 4 Close th...

Page 91: ... page 148 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 92: ...e air filter Ä Chapter 8 13 1 Air filter maintenance on page 184 5 3 6 Checking the water level topping up Protective equip ment n Working clothes n Safety shoes n Protective gloves NOTICE Components may get damaged by frost Follow the special maintenance instructions in case of frost Ä Chapter 8 13 3 Measures if there is a risk of frost on page 188 1 B 462 0029 Fig 64 Checks prior to start up Dai...

Page 93: ...he filling level on the water level gauge fill up if necessary 2 Unscrew the cap 1 and fill in clean water through the strainer 2 3 Make sure that the ventilation bore in the filler cap is clear 4 Close the cap B 462 0022 Fig 65 1 2 B 462 0030 Fig 66 Checks prior to start up Daily maintenance BW 100 ADM 5 93 ...

Page 94: ...po nents Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components Protective equip ment n Working clothes n Safety shoes n Protective gloves The maintenance indicator is a mechanical 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 fir...

Page 95: ... on the left hand side of the machine if the pin of the maintenance indicator has popped out 8 Check the maintenance indicator at max imum engine speed 9 If the pin is visible press it in ð Should the pin remain pressed in the hydraulic oil filter is in good condition 10 If the pin pops out replace the hydraulic oil filter Ä Chapter 8 11 2 Replacing the hydraulic oil filter on page 177 11 Close th...

Page 96: ...ne 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 B ELE 0069 Fig 71 Checks prior to start up Daily maintenance BW 100 ADM 5 96 ...

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

Page 98: ...ce 1 Park the machine safely Ä Chapter 6 9 Parking the machine in secured condition on page 117 2 If necessary adjust the driver s seat Ä Chapter 4 2 4 Driver s seat on page 78 Operation Setting up the workplace BW 100 ADM 5 98 ...

Page 99: ...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 72 Operation Electronic immobilizer BW 100 ADM 5 99 ...

Page 100: ...erequisites 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 73 Operation Starting the engine BW 100 ADM 5 100 ...

Page 101: ...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 102: ...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 ADM 5 102 ...

Page 103: ...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 104: ...er optional equipment to the Left position 3 Set the throttle lever to position MAX I or MAX II 4 Disengage the travel lever out of braking position and move it slowly to the required travel direction B SWI 0695 Fig 78 MIN MAX II MAX I B 880 0160 Fig 79 B ELE 0262 Fig 80 Operation Travel mode BW 100 ADM 5 104 ...

Page 105: ...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 light lights up B ELE 0263 Fig 81 B SYM 0018 Fig 82 Operation Travel mode BW 100 ADM 5 105 ...

Page 106: ...chine in secured condition on page 117 2 Check the lighting 3 If necessary dismantle the tool pressure roller cutting wheel on the edge cutter optional equipment and remove the star handle screw Ä Chapter 9 2 Edge cutter mounting and removing tools on page 198 4 Switch off the working lights 5 Fasten your seat belt 6 If necessary set the rotary switch for the hydraulic hammer optional equipment to...

Page 107: ...ion ð The further the travel lever is moved for wards or backwards the faster the machine will travel Stick to the maximum speed of 8 km h 5 mph 10 Set the travel lever to Middle position to stop the machine ð The machine decelerates to a standstill 11 Always apply the parking brake when stop ping on inclinations or slopes MIN MAX II MAX I B 880 0160 Fig 84 B ELE 0262 Fig 85 Operation Driving the ...

Page 108: ...tion on hard frozen concrete ground Vibration at standstill causes transverse marks n Switch the vibration on only after the machine has reached its nominal speed n Switch the vibration off approx one machine length 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 fal...

Page 109: ...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 6 3 Manual vibration 1 Turn the rotary switch for vibration pre selection to position Left B SWI 1488 Fig 86 MIN MAX II MAX I B 880 0160 Fig 87 B SWI 1486 Fig 88 Operation Working with vibration BW 100 ADM 5 109 ...

Page 110: ...e again to switch off vibration 6 6 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 ELE 0264 ...

Page 111: ...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 112: ...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 ECONOMIZER on page 210 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 de...

Page 113: ...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 ADM 5 113 ...

Page 114: ... 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 1765 Fig 94 B SWI 1763 Fig 95 Operation Water spraying system BW 10...

Page 115: ...vel lever has been moved out of parking brake position once after engine start n Travel lever in parking brake position n Driver s seat not occupied n Engine on NOTICE The battery can become partly or fully discharged After the engine has been shut down ignition and possibly other consuming devices e g lighting may still be switched on If necessary switch off con suming devices and ignition B SYM ...

Page 116: ...1 Turn the ignition key to position 0 2 Start the engine Ä Chapter 6 3 Starting the engine on page 100 Starting the engine after ECOSTOP B ELE 0069 Fig 97 Operation ECOSTOP BW 100 ADM 5 116 ...

Page 117: ...fter 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 B ELE 0263 Fig 98 B SYM 0018 Fig 99 MIN MAX II MAX I B 880 0159 Fig 100 B ELE 0069 Fig 101 Ope...

Page 118: ...5 Turn the main battery switch if present anticlockwise and pull it out B SWI 0079 Fig 102 Operation Parking the machine in secured condition BW 100 ADM 5 118 ...

Page 119: ...utton on the right travel lever ð The edge cutter is lowered 2 Press the top push button on the right travel lever ð The edge cutter is raised If the water spraying system is switched on the edge cutter is automatically sprayed while low ering When lifting the edge cutter spraying is switched off automati cally B ELE 0267 Fig 103 Operation Lifting lowering the edge cutter BW 100 ADM 5 119 ...

Page 120: ...ion and engage it to the right into parking brake position 2 Turn the ignition key to position 0 and pull it out 3 Turn the rotary switch for hydraulic hammer to the Left position Connecting the hydraulic breaker B ELE 0263 Fig 104 B ELE 0069 Fig 105 B SWI 0695 Fig 106 Operation Connecting disconnecting the hydraulic hammer BW 100 ADM 5 120 ...

Page 121: ...page 100 6 Turn the rotary switch for hydraulic hammer to the Right position 7 Set the throttle lever to position MAX II ð The hydraulic breaker can now be used B 462 0033 Fig 107 B SWI 0696 Fig 108 MIN MAX II MAX I B 880 0160 Fig 109 Operation Connecting disconnecting the hydraulic hammer BW 100 ADM 5 121 ...

Page 122: ...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 11 Disconnect the hydraulic hammer from the couplings Disconnecting the hydraulic hammer MIN MAX II MAX I B 880 0159 Fig 110 B SWI 0695 Fig 111 B ELE 0069 Fig 112 Operation Connecting disconnecting the hydraulic hammer BW 100 ADM 5 122 ...

Page 123: ... danger e g cable fire the minus ter minal has been designed as a quick release pole clamp Alternatively the machine can be equipped with a main battery switch optional equipment 1 Open the maintenance flap Ä Chapter 8 2 2 1 Opening the maintenance flap on page 143 2 Pull up the pole clamp cap from the minus pole ð The pole clamp comes off the minus pole 3 Disconnect the pole clamp from the batter...

Page 124: ...only out of the direct danger zone towing speed 1 km h 0 6 mph Before towing make sure that n the tractor vehicle has sufficient 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 Main battery switch optional equipment B SWI 0079 Fig 115 Operati...

Page 125: ...towing eye WARNING Danger of injury caused by uncontrolled machine movement Always secure the machine against unintended rolling 4 Remove two plugs 5 Press both screws in against the springs 6 Tighten both screws alternately and step by step against the end stop tightening torque 35 Nm 25 ft lbf B 462 0035 Fig 116 B 880 0014 Fig 117 Fig 118 Operation Emergency procedures BW 100 ADM 5 125 ...

Page 126: ...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 119 B 880 0014 Fig 120 Operation Emergency procedures BW 100 ADM 5 126 ...

Page 127: ...elease both screws to close the brake 4 Screw both plugs back in tightening torque 50 Nm 37 ft lbf 5 Close also the brake on the second drum Fig 121 B 880 0014 Fig 122 Operation Emergency procedures BW 100 ADM 5 127 ...

Page 128: ...Operation Emergency procedures BW 100 ADM 5 128 ...

Page 129: ...7 Loading transporting the machine Loading transporting the machine BW 100 ADM 5 129 ...

Page 130: ...cutter optional equipment and remove the star handle screw Ä Chapter 9 2 Edge cutter mounting and removing tools on page 198 2 Close all flaps 3 Remove all loose objects from the machine or the driver s stand or fasten them securely Loading transporting the machine Preparation for transport BW 100 ADM 5 130 ...

Page 131: ...ine 1 Fasten your seat belt 2 Set the throttle lever to position MAX I DANGER Danger to life caused by the machine slipping or turning over Make sure that no persons are in the danger zone 3 Drive the machine carefully onto the trans port vehicle 4 Observe the centre of gravity 5 Switch off the engine and remove the igni tion key 6 Attach and secure the articulation lock Ä Chapter 8 2 3 1 Engaging...

Page 132: ...cified loading direction Lashing 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 462 0038 Fig 124 Loading transporting the machine Lashing the machine to the transport vehicle BW 100...

Page 133: ...hing 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 Attach and secure the articulation loc...

Page 134: ...g tackle 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 B 880 0261 Fig 125 Loading transporting the machine Loading by crane BW 100 ADM 5 134 ...

Page 135: ... page 144 3 Fasten your seat belt 4 Set the throttle lever to position MAX I DANGER Danger to life caused by the machine slipping or turning over Make sure that no persons are in the danger zone 5 Drive the machine carefully off the trans port vehicle MIN MAX II MAX I B 880 0160 Fig 126 Loading transporting the machine After transportation BW 100 ADM 5 135 ...

Page 136: ...nt n Working clothes n Safety shoes n Protective gloves 1 Loosen the eye bolts on both sides 2 CAUTION Head injuries caused by folding the foldable ROPS Do not step into the slewing area of the foldable ROPS Erect the clamping plates on both sides vertically B 462 0043 Fig 127 B 462 0045 Fig 128 Loading transporting the machine Folding down and erecting the foldable ROPS BW 100 ADM 5 136 ...

Page 137: ...PS Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Erect the clamping plates on both sides vertically B 462 0041 Fig 129 B 462 0045 Fig 130 Loading transporting the machine Folding down and erecting the foldable ROPS BW 100 ADM 5 137 ...

Page 138: ... Fold up the foldable ROPS 3 Erect the clamping plates on both sides horizontally 4 Tighten the eye bolts on both sides tight ening torque 50 80 Nm 37 60 ft lbf B 462 0042 Fig 131 B 462 0046 Fig 132 50 80 Nm 37 60 ft lbf B 462 0044 Fig 133 Loading transporting the machine Folding down and erecting the foldable ROPS BW 100 ADM 5 138 ...

Page 139: ...8 Maintenance Maintenance BW 100 ADM 5 139 ...

Page 140: ...afety 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 CAUTION Danger of being injured by the engine hood dropping down Always secure an opened engine hood Wear your personal protective equipment Park the machine on horizontal level firm ground Keep unauthorised persons away from the ma...

Page 141: ... use the access steps and working platforms provided or other secure means Do not step on machine parts which are not intended for this purpose Always attach the 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 installation...

Page 142: ... all maintenance flaps and doors again and return all components to their operating condition 8 2 1 Engine hood 8 2 1 1 Open and secure the engine hood 1 Open the locking 2 Push the hood to top position ð The hood is raised supported by the gas springs 8 2 1 2 Closing the engine hood 1 Push the hood at the handle into initial position 2 Lock the hood B 462 0075 Fig 134 B 462 0075 Fig 135 Maintenan...

Page 143: ...lap downwards by the handle 2 Insert the bottle holder 8 2 3 Articulation lock 8 2 3 1 Engaging the articulation lock Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Move the steering to middle position and stop the machine 2 Switch off the engine and remove the igni tion key B 462 0051 Fig 136 B 462 0052 Fig 137 Maintenance Preparations concluding work BW 100 ADM 5 14...

Page 144: ...ticulation lock Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Switch off the engine and remove the igni tion key 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 Loosen the articulation lock and fold it down B 880 0262 Fig 138 B 880 0263 Fig 139 Maintenance Preparations conclud...

Page 145: ...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 146: ... 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 fulfil national emission regulations one must strictly use the legally re...

Page 147: ...only winter diesel fuel to avoid clogging because of paraffin separa 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 per...

Page 148: ...types of anti freeze agents available 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 coo...

Page 149: ... 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 150: ...top up and do not mix oil types 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 Danger of damage to the hydraulic system After the changeover check the hydraulic oil filters increasingly for contamination Have regular oil anal...

Page 151: ...ter 8 3 2 Fuel on page 146 Coolant Mixture of water and anti freeze agent Specification Ä Chapter 8 3 3 Coolant on page 148 009 940 03 20 l 9 l 2 4 gal us Hydraulic system Hydraulic oil ISO HVLP 46 Specification Ä Chapter 8 3 4 1 Mineral oil based hydraulic oil on page 149 009 930 09 20 l 14 l 3 7 gal us or ester based biodegradable hydraulic oil Specification Ä Chapter 8 3 4 2 Bio degradable hydr...

Page 152: ...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 153: ...g and cleaning the water separator 155 Every 250 operating hours 8 8 1 Change engine oil and oil filter cartridge 157 8 8 2 Checking tensioning the V belt 159 8 8 3 Check the air intake lines 160 8 8 4 Checking radiator hoses and hose clamps 160 8 8 5 Cleaning the radiator module 161 8 8 6 Battery service 163 Every 500 operating hours 8 9 1 Draining the fuel tank sludge 165 8 9 2 Replace the fuel ...

Page 154: ... filter 177 8 11 3 Changing the coolant 179 8 11 4 Replacing hoses 182 8 11 5 Checking the injection nozzles 182 Every 3000 operating hours 8 12 1 Checking the exhaust gas recirculation system 183 As required 8 13 1 Air filter maintenance 184 8 13 2 Cleaning the water spraying system 187 8 13 3 Measures if there is a risk of frost 188 8 13 4 Measures prior to extended shut down period 190 Maintena...

Page 155: ...are found to be damaged the corresponding 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 and 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 de...

Page 156: ...ansparent container under the drain plug 3 Loosen the drain plug and drain the fluid until pure diesel fuel starts to run out 4 Collect the escaping fluid 5 Screw the drain plug back in tightly Check for leaks if necessary use a new seal ring 6 Dispose of collected fluid in line with envi ronmental regulations B 462 0047 Fig 140 Maintenance Every 50 operating hours BW 100 ADM 5 156 ...

Page 157: ...rsonal protective equipment protective gloves protective clothing Avoid touching hot components NOTICE Danger of engine damage Change the oil only with the engine at operating temperature Use only oil of the permitted specification Ä Chapter 8 3 1 Engine oil on page 145 Filling quantity Ä Chapter 8 4 List of fuels and lubricants on page 151 Maintenance Every 250 operating hours BW 100 ADM 5 157 ...

Page 158: ...e drain plug back in tightly 5 Thoroughly clean the outside of the oil filter cartridge 6 Unscrew the oil filter cartridge using an appropriate strap wrench 7 Remove any dirt from the sealing face of the filter carrier 8 Thinly apply oil to the rubber seal of the new oil filter cartridge 9 Screw on the oil filter cartridge and tighten by hand B 462 0048 Fig 141 B 462 0049 Fig 142 B 462 0050 Fig 14...

Page 159: ...ing clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down 3 Check the entire circumference of the V belt for damage and cracks 4 Replace a damaged or cracked V belt Ä Chapter 8 9 3 Replacing the V belt on page 167 5 Check with thumb pressure whether the V belt can be depressed more than...

Page 160: ...in secured condition Ä Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down 3 Check the condition and tight fit of all air intake lines and hose clamps 4 If fuel lines or hose clamps are found to be damaged the corresponding parts must be immediately replaced 8 8 4 Checking radiator hoses and hose clamps Protective equip ment n Working clothes n Protecti...

Page 161: ...st 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 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down Maintenance Every 250 operating hours BW 100 ADM 5 161 ...

Page 162: ...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 147 Fig 148 Maintenance Every 250 operating hours BW 100 ADM 5 162 ...

Page 163: ...trong 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 164: ...e battery and clean the battery compartment 3 Clean the outside of the battery 4 Clean the battery poles and terminals 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 B 462 0053 Fig 149 Maintenance Every 250 operating hours BW 100 ADM 5 164 ...

Page 165: ...plug and collect leaking fuel 4 Screw the drain plug firmly back in with a new seal ring tightening torque 6 8 Nm 4 5 6 ft lbf 5 Fill the fuel tank with clean fuel 6 Dispose of fuel in line with environmental regulations 8 9 2 Replace the fuel filter NOTICE Danger of engine damage Ensure strict cleanliness Thor oughly clean the area around the fuel filters Air in the fuel system causes irregular r...

Page 166: ...er and observe the flow direction arrow 5 Unscrew the drain plug and collect the escaping fuel 6 Unscrew the filter 7 Remove any dirt from the sealing face of the filter carrier 8 NOTICE Danger of engine damage Never fill filters beforehand to avoid the entry of dirt into the clean side Spread a thin layer of fuel on the sealing surface of the new filter and attach the filter B 462 0055 Fig 151 B ...

Page 167: ... short test run 14 Dispose of fuel and filter element in line with environmental regulations 8 9 3 Replacing the V belt Perform this maintenance work at the latest after two years Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down B 462 0057 Fig 154 B ...

Page 168: ...ne in secured condition Ä Chapter 6 9 Parking the machine in secured condition on page 117 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 condition of the coolant 5 Thoroughly flush the cooling system if the coolant is contaminated by corrosion resi dues or other suspended matter Ä Cha...

Page 169: ... 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 squeezing shearing or chafing points n paint covered hyd...

Page 170: ...engine cool down for at least 30 minutes The engine oil temperature must be below 80 C 176 F Valve clearance Intake exhaust valve 0 15 mm 0 006 in Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down 3 Remove the valve cover B 462 0081 Fig 158 Maintenan...

Page 171: ... 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 1 2 3 I E I E I E B KUB 0007 Fig 159 I Intake valve E Exhaust valve 1 2 3 I E I E I E B KUB 0008 Fig 160 B 462 0081 Fig 161 Checking the valve clear ance Maintenance Every 1000 operating hours BW 100 ADM 5 171 ...

Page 172: ...in secured condition Ä Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow 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 t...

Page 173: ...s must comply with the specifications and should be absolutely tight observe the tightening torques Screw and nuts must not be damaged bent or deformed Unusual movements and noises vibrations during operation are signs for damage or loos ened fastening elements 1 Inspect the ROPS structure for cracks cor rosion damage and missing fastening parts 2 Check the fastening screws for the ROPS to the ope...

Page 174: ...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 175: ...ve the cover 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 leakage oil line on the vibra tion motor at the front right side and collect the leaking hydraulic oil 5 Reattach the leakage oil line tightly B 462 0058 Fig 164 B 462 0059 Fig 165 Maintenanc...

Page 176: ...inest 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 in the inspec tion glass Normal level approx 2 3 height of inspection glass Minimum level Middle of inspection glass 11 The breather filter for the hydraulic oil tank is integrated in the cap you must therefore replace...

Page 177: ...h 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 housing again Apart from the normal oil change intervals the filter element must also be changed after major repairs in the hydraulic system 1 Park the machine safely Ä Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down Prepa...

Page 178: ...termine the cause and replace or repair the defec tive components if necessary Do not clean or reuse the filter element 2 Take out the filter element 1 and clean the filter housing 3 Clean the thread on the filter housing 4 Reassemble the filter housing with a new filter element and a new O ring 2 5 Tighten the filter housing tightening torque max 30 Nm max 22 ft lbf Hydraulic oil filter 3 2 1 B H...

Page 179: ...er 8 11 1 Changing the hydraulic oil on page 174 3 Dispose of the hydraulic oil and filter in line with environmental regulations 8 11 3 Changing the coolant Perform this maintenance work at the latest after two years Do not start the engine after draining off the coolant In case of lubrication oil entering into the cooling system or a suspicious turbidity caused by corrosion residues or other sus...

Page 180: ...gine damage Use only coolant of the permitted specification Ä Chapter 8 3 3 Coolant on page 148 Do not mix different coolants and additives of any other kind Filling quantity Ä Chapter 8 4 List of fuels and lubricants on page 151 Protective equip ment n Working clothes n Protective gloves n Safety goggles 1 Park the machine safely Ä Chapter 6 9 Parking the machine in secured condition on page 117 ...

Page 181: ... until the level reaches the bottom edge of the filler socket 11 Screw the cover back on again 12 Fill in coolant up to the MAX mark on the compensation tank 13 Close the cap 14 Start the engine and run to operating tem perature 15 Let the engine cool down and check the coolant level again if necessary top it up in the compensation tank B 462 0066 Fig 172 2 1 B 462 0064 Fig 173 B 462 0065 Fig 174 ...

Page 182: ...ersonnel Perform this maintenance work at the latest after two years The following hoses need to be renewed n fuel hoses n air intake hoses n hoses in connection with the oil separator 8 11 5 Checking the injection nozzles This work must only be performed by authorized service personnel Maintenance Every 2000 operating hours BW 100 ADM 5 182 ...

Page 183: ...12 Every 3000 operating hours 8 12 1 Checking the exhaust gas recirculation system This work must only be performed by authorized service personnel Maintenance Every 3000 operating hours BW 100 ADM 5 183 ...

Page 184: ... 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 Protective equip ment n Working clothes n Safety shoes n Protective gloves n Safety goggles Carry out the air filter maintenance when the yellow pin of the maintenance indicator has reached the red area 1 but after one year at the latest 1 Park the machine sa...

Page 185: ...in the filter housing thoroughly CAUTION Danger of eye injuries caused by particles flying around Wear your personal protective equipment safety gloves protec tive working clothes goggles 8 Blow the air filter out with dry compressed air max 2 1 bar 30 psi from inside to outside by moving the gun up and down inside the element until it is free of dust B 462 0076 Fig 177 B 462 0077 Fig 178 Fig 179 ...

Page 186: ...g NOTICE Danger of engine damage The dust discharge valve must point vertically downwards Make sure that the cover locks engage correctly 12 Reinstall the cover 13 After maintenance has been completed press the button 1 on the maintenance indicator ð The maintenance indicator is reset Fig 180 B 462 0077 Fig 181 1 B GEN 0054 Fig 182 Maintenance As required BW 100 ADM 5 186 ...

Page 187: ...achine in secured condition on page 117 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 rear door 7 Open the drain cover on the water tank and let all water run out 8 Flush the water tank out with a strong water jet 9 Drain off all water and dirt 1 2 B 462 0030 Fig 183 B 462 0078 Fig 184 Maintenan...

Page 188: ...nants out of the lines 14 Switch off the water spraying system 15 Turn the ignition key back to position 0 and pull it out 16 Reinstall all caps and nozzles 8 13 3 Measures if there is a risk of frost Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 9 Parking the machine in secured condition on page 117 2 Open the rear door B 462 0079...

Page 189: ...ng pump to the outside 9 Open the drain valve and drain off all water 10 Switch on the water spraying system for a short while to drain the water from the pump 11 Switch off the water spraying system 12 Turn the ignition key back to position 0 and pull it out 13 Close the drain valve on the water pump and route the water line back into the machine 14 Close the maintenance flap Ä Chapter 8 2 2 2 Cl...

Page 190: ... Grease the bare piston rods of all hydraulic cylinders well and pull them in as far as possible 4 Spray a thin oil film onto to all lever joints and bearing points without lubrication 5 Repair damaged paint preserve bare areas thoroughly with anti corrosive agent 6 Clean the water separator 7 Fill the fuel tank with diesel fuel to prevent the formation of condensation water in the tank 8 Change e...

Page 191: ...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 on the battery Wear your personal protective equipment protective gloves protective clothing goggles Protective equip ment n Working clothes n Protective gloves n Safety goggles 1 Switch off all consuming devices e g igni tion light 2 Measure the op...

Page 192: ... always disconnect the battery Do not forget to perform regular open circuit voltage measurements 8 13 4 3 Measures before restarting 1 Replace the fuel filter 2 Replace the air filter 3 Change engine oil and oil filter 4 Check the coolant level 5 Check the charge condition of the bat teries recharge if necessary Check the battery fluid level before and after charging 6 Connect the ground straps t...

Page 193: ... keep an eye on the gauges for engine oil pressure and coolant temperature 12 Check the oil levels 13 Check the function of electric system steering and brakes 14 Clean the machine thoroughly Maintenance As required BW 100 ADM 5 193 ...

Page 194: ...Maintenance As required BW 100 ADM 5 194 ...

Page 195: ...9 Setting up refitting Setting up refitting BW 100 ADM 5 195 ...

Page 196: ...lashing tackle only in the specified loading direction Lashing 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 9 Parking the machine in secured condition on page 117 2 If necessary loosen the articulation lock 2 Ä Chapter 8 2 3 2 Disengaging the articu lation lock on page 144 3 Slightly loo...

Page 197: ... just above the ground 6 Shift the rear frame to the desired position on the left or right 7 Lower the machine to the ground 8 Tighten the screws 1 again tightening torque 300 Nm 221 ft lbf B 880 0261 Fig 192 B 880 0072 1 Fig 193 Setting up refitting Adjusting the crabwalk BW 100 ADM 5 197 ...

Page 198: ...lic traffic disassemble the tool from the edge cutter and holding fixture and remove the star handle screw Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 9 Parking the machine in secured condition on page 117 2 Use the star handle screw to mount the tools to or remove them from the edge cutter B 462 0070 Fig 194 Setting up refitting...

Page 199: ...3 Use the star handle nut to mount the tools to or remove them from the holding fixture B 462 0071 Fig 195 Setting up refitting Edge cutter mounting and removing tools BW 100 ADM 5 199 ...

Page 200: ...Setting up refitting Edge cutter mounting and removing tools BW 100 ADM 5 200 ...

Page 201: ...10 Troubleshooting Troubleshooting BW 100 ADM 5 201 ...

Page 202: ... 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 ADM 5 202 ...

Page 203: ...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 100 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 204: ...e central electrics against the end stop The printed circuit board is equipped with a fuse test socket Fuse Test When plugging in an intact fuse an LED lights up Fuse Amperage Designation F241 15 A Optional headlights F274 10 A Hydraulic hammer F119 10 A Engine F153 10 A Potential 15 F68 10 A Potential 30 F23 10 A Warning horn F06 5 A Rotary switch for water spraying system F30 10 A Potential 15 F...

Page 205: ...A Engine solenoid F275 5 A Economizer F48 40 A Preheating system F10 10 A Parking and tail light right F09 10 A Parking and tail light left F157 30 A Starter F45 10 A Edge cutter F37 10 A Water pump F05 10 A 12 V socket F276 10 A Emulsion pump F04 7 5 A Instruments JP1 5 A Vibration also with travel lever in position II 10 3 3 Main fuse B 462 0074 Fig 198 Troubleshooting Fuse assignment BW 100 ADM...

Page 206: ...Fuse Amperage Designation F00 80 A Main fuse Troubleshooting Fuse assignment BW 100 ADM 5 206 ...

Page 207: ...lty or runs irregu larly at low power Battery power is too low con nection terminals are loose and oxidised causing the starter to rotate slowly Check the battery charge clean and tighten the connec tion terminals and coat them with acid free grease Fuel supply is too low fuel filter is clogged in winter due to paraffin separation Replace the fuel filter Check all line connections for leaks tighte...

Page 208: ...oo low Check refill if necessary Lack of coolant Check all lines hoses and engine for condition and leaks Check the coolant level refill if necessary Do not use radiator sealant to seal leaks Anti freeze concentration too high Use coolant with prescribed mixing ratio Thermostat defective Check the thermostat replace it if necessary Injection nozzle is defective Have examined by a spe cialist Corro...

Page 209: ...too low Check refill if necessary The charge control light lights up during opera tion warning buzzer sounds Generator speed too low Check the tension of the gen erator belt if necessary replace the belt Generator or governor defec tive Have examined by a spe cialist Troubleshooting Engine malfunctions BW 100 ADM 5 209 ...

Page 210: ...on 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 Department...

Page 211: ...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 ADM 5 211 ...

Page 212: ...Troubleshooting Trouble shooting ECONOMIZER BW 100 ADM 5 212 ...

Page 213: ...11 Disposal Disposal BW 100 ADM 5 213 ...

Page 214: ...hazard caused by fuels and 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 Protective equip ment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Remove the batteries 2 Empty the fuel tank 3 Drain the hydraulic oil tank 4 Drain the coolant from ...

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