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Maintenance

BOMAG

BW 100/120/125 AD-4/AC-4

6.4

Running-in instructions

The following maintenance work must be per-
formed when running in new machines or
overhauled engines:

Caution

Up to approx. 250 operating hours check the
engine oil level twice every day.

Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.

Maintenance after 50 operating hours

Change engine oil and filter

Check the engine for leaks

Retighten the fastening screws on air filter, ex-
haust and other attachments.

Check screw connections on the machine,
retighten as necessary.

Содержание BW 100 AC-4

Страница 1: ...Catalogue No 008 053 01 BW 100 AD 4 BW 120 AD 4 BW 125 AD 4 BW 100 AC 4 BW 120 AC 4 BW 125 AC 4 S N 101 880 06 S N 101 880 16 S N 101 880 08 S N 101 880 14 S N 101 880 10 S N 101 880 07 S N 101 880 17...

Страница 2: ......

Страница 3: ...his manual was written for operators and mainte nance personnel on construction sites Always keep this manual close at hand e g in the tool compartment of the machine or in a specially provided contai...

Страница 4: ...ype Fig 3 Engine number Fig 3 Note i Supplement the above data together with the com missioning protocol During commissioning our organisation will in struct you in the operation and maintenance of th...

Страница 5: ...and off 54 5 11 Switching the gravity sprinkling system on and off 57 5 12 Switching the pressure sprinkling system on and off 57 5 13 Switching the tire sprinkling system on and off only AC 59 5 14...

Страница 6: ...usting the scrapers 97 Every 500 operating hours 99 6 24 Battery service 99 6 25 Change the fuel filter 100 6 26 Drain the fuel tank sludge 101 Every 1000 operating hours 103 6 27 Checking adjusting t...

Страница 7: ...Table of Contents BOMAG 7 BW 100 120 125 AD 4 AC 4 7 Trouble shooting 119 7 1 General notes 120 7 2 Engine 121 8 Disposal 123 8 1 Final shut down of machine 124...

Страница 8: ...Table of Contents BOMAG 8 BW 100 120 125 AD 4 AC 4...

Страница 9: ...BOMAG 9 BW 100 120 125 AD 4 AC 4 2 Technical Data...

Страница 10: ...2475 255 2475 38 23 1200 1 BW 100 AD 4 BW 120 AD 4 BW 125 AD 4 Weights Operating weight with ROPS CECE kg 2400 2600 3150 Operating weight with ROPS CECE and empty chip spreader2 kg 2520 2730 3150 Mea...

Страница 11: ...ydrost hydrost hydrost Parking brake hydro mech hydro mech hydro mech Steering Type of steering Oscill articul Oscill articul Oscill articul Steering operation hydrost hydrost hydrost Steering oscilla...

Страница 12: ...13 1200 BW 125 AC 4 1728 1276 474 700 1800 2475 255 2475 38 23 1200 1 BW 100 AC 4 BW 120 AC 4 BW 125 AC 4 Weights Operating weight with ROPS CECE kg 2250 2400 2950 Axle load drum CECE kg 1150 1240 16...

Страница 13: ...205 60 15 205 60 15 Brake Service brake hydrost hydrost hydrost Parking brake hydro mech hydro mech hydro mech Steering Type of steering Oscill articul Oscill articul Oscill articul Steering operatio...

Страница 14: ...Technical Data BOMAG 14 BW 100 120 125 AD 4 AC 4 1 Subject to technical alterations...

Страница 15: ...ay vary because of the existing operating conditions Noise value Sound pressure level on the place of the operator LpA 84 dB A determined acc to ISO 11204 and EN 500 Guaranteed sound power level LWA 1...

Страница 16: ...Technical Data BOMAG 16 BW 100 120 125 AD 4 AC 4...

Страница 17: ...BOMAG 17 BW 100 120 125 AD 4 AC 4 3 Safety regulations...

Страница 18: ...ded use is the sole re sponsibility of the customer or driver operator the manufacturer cannot be made liable Examples for unintended use are l work with vibration on hard concrete cured bi tumen laye...

Страница 19: ...ng and maintenance instructions Danger Paragraphs marked like this highlight possible dangers for persons Caution Paragraphs marked like this highlight possible dangers for machines or parts of the ma...

Страница 20: ...attached the machine must not be towed backwards Max towing speed 1 km h max towing distance 500 m Before releasing the multi disc brake secure the machine against unintended rolling Checking the Rol...

Страница 21: ...mediately Starting and operation of the machine is closed rooms and trenches Exhaust gases are highly dangerous Always en sure an adequate supply of fresh air when starting and operating in closed roo...

Страница 22: ...d therefore always drive straight up or down a slope For rollers with a drum width of 1 m or less there is a considerable risk of tipping over near edges e g curbstones embankments trenches potholes w...

Страница 23: ...ated joint with the articulation lock Working on hydraulic lines Always depressurize the hydraulic lines before starting to work on them Hydraulic oil escaping under pressure can penetrate the skin an...

Страница 24: ...e of old batteries environmentally Switch the charging current off before removing the charge clamps Ensure good ventilation especially when charging the battery in a closed room Working on the fuel s...

Страница 25: ...he safety of compaction equipment must be checked by a specialist as required in dependence on the application and the operating conditions however at least once every year Information and safety stic...

Страница 26: ...sticker Guaranteed sound capac ity level 11 Information sticker Lashing point 12 Information sticker Lifting point 13 Information sticker Engine oil drain 14 Prohibition sticker High pressure cleaner...

Страница 27: ...ed sound capac ity level 11 Information sticker Emulsion 12 Information sticker Lashing point 13 Information sticker Lifting point 14 Information sticker Engine oil drain 15 Prohibition sticker High p...

Страница 28: ...1 Fig 11 Instruction sticker Always wear your seat belt2 Fig 12 Operation sticker Central lifting device3 Fig 13 Information sticker Main battery switch4 Fig 14 Information sticker Biodegradable hydra...

Страница 29: ...6 Operation sticker Edge cutter2 Fig 17 Information sticker Ball valve vibration 3 stages3 only AD Fig 18 Operation sticker Chip spreader 4 Fig 19 Warning sticker Chipping temperature 5 1 Optional equ...

Страница 30: ...Safety regulations BOMAG 30 BW 100 120 125 AD 4 AC 4...

Страница 31: ...BOMAG 31 BW 100 120 125 AD 4 AC 4 4 Indicators and Controls...

Страница 32: ...Indicators and Controls BOMAG 32 BW 100 120 125 AD 4 AC 4 Fig 20...

Страница 33: ...Emergency stop push button 9 Push button for warning horn 10 Rotary switch for direction indicators1 11 Rotary switch for gravity feed sprinkling sys tem 12 Interval switch for pressure sprinkling sys...

Страница 34: ...cluster Note i With the ignition switch in position I all gauges and instruments are switched on for a moment a yel low Warning light for seat contact moni toring while machine is travelling warning b...

Страница 35: ...light Lights when the parking brake is ap plied h Operating hour meter Counts the operating hours while the engine is running Maintenance work is to be carried out in accordance with the indicated op...

Страница 36: ...arning lights in switch and indicator control light in the instrument cluster start flashing Fig 27 No 7 Rotary switch for vibration manual or automatic3 Position left Pre selection for vibration acti...

Страница 37: ...n for warning horn Fig 30 No 10 Rotary switch for direction indica tors1 Position mid dle Direction indicators disabled Position left or right Front and rear direction indica tors on the corresponding...

Страница 38: ...gine solenoid 3 10A F04 Gauges 4 10A F119 Engine 5 10A F30 Seat heating1 6 10A F45 Edge cutter1 7 10A F23 Warning horn 8 10A F48 pre heating system Fuse box B 1 15A F11 Head lights left1 2 15A F12 hea...

Страница 39: ...The starter switch is designed with a re start lock For a new starting attempt the ignition key must first be turned back to position 0 Position III Turn further against spring pressure the engine sta...

Страница 40: ...avel without vibra tion Position III Max forward reverse travel with vibration Fig 40 No 18 Throttle lever Position MAX II Full load position 2500 rpm operating position for driving and vibration Posi...

Страница 41: ...on release Sprinkler system switched off Fig 44 Foot switch for flow divider1 only AD press flow divider switched on release flow divider switched off Fig 45 No 22 Rotary switch button for windscreen...

Страница 42: ...Towing Position I Brake applied Position II Brake released Note i Release the brake by turning the steering wheel in clockwise direction Fig 47 No 24 Main battery switch1 Note i The main battery swit...

Страница 43: ...on chip spreader Fig 49 No 26 Adjustment lever for chip quantity1 to the left lower chip quantity towards the right higher chip quantity Fig 50 No 27 Lever to slide the chip spreader2 to the left The...

Страница 44: ...Indicators and Controls BOMAG 44 BW 100 120 125 AD 4 AC 4...

Страница 45: ...BOMAG 45 BW 100 120 125 AD 4 AC 4 5 Operation...

Страница 46: ...hine on ground as level as possi ble Check l fuel tank and fuel lines for leaks l Screw connections l function of steering l function of emergency stop l function of parking brake l machine for cleanl...

Страница 47: ...ectronic immobilizer is now disarmed and the engine can be started within the next 15 minutes 5 4 Adjusting the operator s seat Danger Danger of accident Do not adjust the seat while driving Fig 52 l...

Страница 48: ...perator s seat Caution In this chapter it is assumed that the operator is fully acquainted with the function of the dif ferent control elements on the machine Fig 53 l Fasten your seat belt Fig 53 Fig...

Страница 49: ...switch is designed with a re start lock For a new starting attempt the ignition key must first be turned back to position 0 Fig 59 l Turn the ignition key Fig 59 through position II to position III t...

Страница 50: ...nus pole of the current supplying battery and then to engine or chassis ground as far away from the battery as possible Fig 61 l Start as described under Starting the engine l Once the engine is runni...

Страница 51: ...s e g curbstones embankments trench es potholes when driving over these edges Do not drive without wearing your seat belt Always give way to loaded transport vehicles Before starting to drive make sur...

Страница 52: ...he warning light for the seat contact switch a Fig 65 lights up together with the parking brake warning light g when the driver s seat is not occupied The machine cannot drive Note i When moving the t...

Страница 53: ...ydro static drive and the parking brake is applied Fig 67 The parking brake warning light g in the instru ment cluster Fig 67 lights up 5 9 Shutting down the engine Fig 68 l Shift the travel lever Fig...

Страница 54: ...isible sign 5 10 Switching the vibration on and off Danger Risk of damage When compacting with vibration you must check the effect of nearby buildings and un derground supply lines gas water sewage el...

Страница 55: ...automatic mode Fig 73 anti clockwise to the symbol Manual Switching the vibration on Fig 74 l Set the throttle lever Fig 74 to position Max I or MAX II Fig 75 l Actuate the vibration push button Fig...

Страница 56: ...g 77 l Set the throttle lever Fig 77 to position Max I or MAX II Fig 78 l Pull the travel lever Fig 78 out of zero posi tion braking position and shift it slowly to the desired travel direction forwar...

Страница 57: ...ling system to the left the gravity feed sprin kling system is switched off 5 12 Switching the pressure sprinkling system1 on and off Fig 80 l Check the water level indicator on the water tank Fig 80...

Страница 58: ...testing position for interval position 11 Fig 83 l To switch off the pressure sprinkler system re turn the travel lever to the position brake closed Fig 83 Fig 84 Note i The parking brake warning lig...

Страница 59: ...tch immediate ly Start travel operation of the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated Caution Do not use as service brake The decelera...

Страница 60: ...emove the chip spreader when it is empty Mounting the chip spreader Fig 88 l Lift the chip spreader by the lifting points Fig 88 and hook it carefully into the fixing points on the machine Fig 89 l In...

Страница 61: ...electrically from the machine Fig 92 Fig 93 l Hook the chip spreader to the fastening points Fig 93 Fig 94 Danger Danger of accident Before pulling out the bolt Fig 94 make sure that the chip spreader...

Страница 62: ...not exceed 80 C as otherwise the shaft will be damaged Fig 95 l Fill the chippings container with no more than 200 litres of chippings Fig 95 specific weight of chippings 1 5 t m Emptying Danger Dang...

Страница 63: ...aution With the ball valve in horizontal position A Fig 98 follow the instructions for work with vibration see chapter Switching vibration on and off Fig 99 l Turn the ball valve for the chip spreader...

Страница 64: ...ans e g metal wheel chocks Use a towing vehicle with sufficient traction and braking power for the unbraked towed load Use a tow bar Using the machine as towing vehicle is not permitted The machine ca...

Страница 65: ...ning screw 1 Fig 106 l Switch the ball valve 2 over Position II Brake released l Turn the steering wheel slowly approx two turns in clockwise direction After towing Danger Danger of accident Before lo...

Страница 66: ...both screws Fig 107 to close the brake Fig 108 l Screw both plugs Fig 108 back in and tight en them with 20 Nm Fig 109 l Switch the ball valve 2 Fig 109 back to po sition I turn the locking screw back...

Страница 67: ...eye Secure the bolt with the cotter pin Fig 111 l Fold down the foldable ROPS2 for transport Loosen the eye bolts Fig 111 and adjust the clamping plates vertically l Fold the foldable ROPS back Loadin...

Страница 68: ...ad the lifting belt Use only safe lifting gear of sufficient load bearing capacity Minimum lifting capacity of lifting gear see operating weight in chapter Technical Data Do not lift or lower the mach...

Страница 69: ...aution Never attach the lashing gear to the chip spreader Fig 115 l Fold up the covers on front and rear frames l Lash the machine down so that it is secured against rolling sliding and turning over U...

Страница 70: ...7 l To fold up the foldable ROPS align the clamp ing plates on both sides vertically Fig 117 Fig 118 l Fold up the foldable ROPS Fig 118 l Turn the clamping plates to horizontal position and tighten t...

Страница 71: ...BOMAG 71 BW 100 120 125 AD 4 AC 4 6 Maintenance...

Страница 72: ...rums with inside zinc lining are not suitable to store fuel l When choosing the storage place for fuel make sure that spilled fuel will not harm the en vironment l Do not let the hose stir up the slur...

Страница 73: ...ality class Oils according to other comparable specifications may be used If low sulphur fuel 0 05 is used you must only use engine oils of API1 classification CF CF 4 CG 4 CH 4 and CI 4 For operation...

Страница 74: ...se diesel fuel no 2 D S500 or S15 with ambient temperatures be low 10 C the diesel fuel no 1 D S500 or S15 should be used fir no 1 D The fuel level should always be topped up in due time so that the f...

Страница 75: ...part 3 or hydraulic oils type HV ac cording to ISO 6743 3 The viscosity index VI should be at least 150 observe information of manufacturer Bio degradable hydraulic oil The hydraulic system can also b...

Страница 76: ...C to 40 C SAE 30 5 C to 30 C SAE 10 30 C to 5 C Fuel Diesel Winter diesel fuel down to 12 C approx 40 litres Coolant Mixture of water and anti freeze agent BOMAG PN 009 940 08 20 l approx 4 litres Hy...

Страница 77: ...eck the engine oil level twice every day Depending on the load the engine is subjected to the oil consumption will drop to the normal level after approx 100 to 250 operating hours Maintenance after 50...

Страница 78: ...ation indica tor X 6 10 Check the coolant level X 6 11 Check the water separator X 6 12 Check the water level Water level gauge X 6 13 Check the emulsion level only AC machines X 6 14 Check the chip s...

Страница 79: ...st every 2 years X 6 33 Check the injection valves X 6 34 Check the fuel injection pump X 6 35 Check the tire pressure only AC machines X 6 36 Clean the water sprinkler system X 6 37 Drain the water s...

Страница 80: ...Maintenance BOMAG 80 BW 100 120 125 AD 4 AC 4...

Страница 81: ...l If the oil level is too low top up oil immediately l If the oil level is too high determine the cause and drain the oil off 6 7 Checking the fuel level Caution Do not drive the fuel tank dry as othe...

Страница 82: ...vel the hydraulic oil level is found to have dropped check all lines hoses and compo nents for leaks In hydraulic systems filled with Panolin HLP Synth 46 always use the same oil to top up With other...

Страница 83: ...sary press the pin in Pin remains pressed in Hydraulic oil filter element o k Pin pops out Replace the hydraulic oil filter element 6 10 Check the coolant level Danger Danger of scalding Open the cap...

Страница 84: ...ater Environment Any fuel must be caught and disposed of in an environmentally friendly manner Fig 125 l Slacken the drain plug Fig 125 for a few turns and catch running out fuel water l Tighten the d...

Страница 85: ...anufactur er Fig 128 l Unscrew the cover Fig 128 and check the emulsion level fill up if necessary Caution Make sure that the ventilation bore in the filler cap is free 6 14 Checking the chip spread e...

Страница 86: ...Every 10 operating hours BOMAG 86 BW 100 120 125 AD 4 AC 4 Fig 131 Caution When cleaning with a steam cleaner do not di rect the water jet into the sealing elements of the slide profiles Fig 131...

Страница 87: ...ng lines or hose clamps the fuel system needs to be bled Disassembled or new fuel lines must be closed with clean cloths on both ends to make sure that no dirt will enter into the fuel system Dirt par...

Страница 88: ...Every 50 operating hours BOMAG 88 BW 100 120 125 AD 4 AC 4...

Страница 89: ...els with a sulphur content high er than 0 5 the oil change intervals must be halved Drain the engine oil only when the engine is warm For quality and quantity of oil refer to the table of fuels and lu...

Страница 90: ...ridge Fig 136 l Turn the new filter cartridge on by hand until the seal contacts l Tighten the filter element for another half turn Fig 137 l Fill in new engine oil Fig 137 l Tighten the oil filler ca...

Страница 91: ...ting hours Each cleaning interval must be marked with a cross on the cover of the filter element Cleaning does not make sense if the air filter element is covered with a sooty deposit Use a new filter...

Страница 92: ...impair effective sealing l Check the old main filter element The old main filter element can be of help to dis cover foreign particles on the sealing face which could lead to leaks A dust strip on th...

Страница 93: ...must point vertically downwards Dry cleaning of the main filter element Danger Eye injury Wear protective clothing goggles gloves Fig 145 Note i For cleaning purposes fit a tube to the compressed air...

Страница 94: ...of the service work l Remove the housing cover and pull the main filter element off Fig 146 l Pull the safety element Fig 146 out by turn ing it lightly l Push in a new safety filter element l Reassem...

Страница 95: ...ar cooling fan cylinder or en gine oil cooler and subsequently clean the cooling fins Cleaning with compressed air Fig 147 l Blow the cooling air passages out with com pressed air from the air dischar...

Страница 96: ...using a lever until the correct V belt tension is reached l Retighten all fastening screws and check the V belt tension once again Changing the V belt l Slightly slacken the fastening screws 2 l Pres...

Страница 97: ...Scrapers 2 per drum must be replaced when worn Fig 151 l Open the flap check the scrapers replace if ncessary Fig 151 Wheels AC machines Fig 152 l Open the rear flap check the scrapers re place if nce...

Страница 98: ...Every 250 operating hours BOMAG 98 BW 100 120 125 AD 4 AC 4...

Страница 99: ...ignition light in side light radio l Check open circuit voltage of the battery at regular intervals At least once per month Reference values 12 6 V fully charged 12 3 V 50 discharged l Recharge the b...

Страница 100: ...mps Fig 155 l Pull the fuel filter out of the hoses l Install the new fuel pre filter and observe the flow direction arrow l Fasten the hose clamps Replacing the fuel filter cartridge Fig 156 l Slacke...

Страница 101: ...he fuel system do not use open fire do not smoke Do not spill any fuel Danger Health hazard Do not inhale any fuel fumes Environment Catch running out fuel do not let it seep into the ground Note i Wh...

Страница 102: ...Every 500 operating hours BOMAG 102 BW 100 120 125 AD 4 AC 4...

Страница 103: ...table Valve 2 black adjustable Fig 162 Crankshaft position 1 Fig 162 l Crank the engine with the starter or a spanner by the V belt pulley until both valves on cylin der 1 are overlapping Overlapping...

Страница 104: ...e adjust ed Note i Mark checked and adjusted valves with chalk l Install the cylinder head cover with a new gas ket Note i After a short test run check the engine for leaks 6 28 Check the engine mount...

Страница 105: ...clean the system Use only lint free cleaning cloths For quality and quantity of oil refer to the table of fuels and lubricants When changing from mineral oil based hydrau lic oil to an ester based bio...

Страница 106: ...changed together with the hydraulic oil the filter must only be changed after the oil change and after the test run Do not use the oil in the filter bowl again Visible dirt may be an early sign for t...

Страница 107: ...e the radiator cap when the en gine is still hot Always wear gloves when handling anti freeze agent Caution Always screw the radiator cap tightly back on second detent Always fill the engine cooling s...

Страница 108: ...ank l Check the condition of radiator hoses if nec essary replace all radiator hoses Fig 175 l Fill in coolant until the level reaches the bottom edge of the filler socket Fig 175 Fig 176 l Fill in co...

Страница 109: ...hazard Do not inhale any fuel fumes Caution For safety reasons this work should be per formed every two years Hoses consist of rubber or plastic material and age over the course of time Environment C...

Страница 110: ...Every 2000 operating hours BOMAG 110 BW 100 120 125 AD 4 AC 4...

Страница 111: ...Every 3000 operating hours BOMAG 111 BW 100 120 125 AD 4 AC 4 Every 3000 operating hours 6 34 Checking the fuel injection pump Note i This work must only be performed by authorized service personnel...

Страница 112: ...Every 3000 operating hours BOMAG 112 BW 100 120 125 AD 4 AC 4...

Страница 113: ...7 Nominal value approx 2 2 bar Note i Ensure equal pressure in all rubber tires 6 36 Cleaning the water sprinkler system Note i If there is a risk of frost observe the special service instructions und...

Страница 114: ...he plastic caps from the end of the sprinkler tube l Fill the water tank with clean water l Activate the sprinkler system for a short while so that all lines are flushed out l Screw the olastic caps b...

Страница 115: ...tank cover Fig 184 Fig 185 l Open the covering flap Fig 185 on the right hand side of the rear frame Fig 186 l Take out the drain hose Fig 186 open the drain tap and let all water run out Fig 187 l O...

Страница 116: ...orques for screws with metric unified thread Fig 189 Strength classes for screws with untreated non lubricated surface Screw quality designations are stamped on the screw heads 8 8 8G 10 9 10K 12 9 12...

Страница 117: ...zles with this conserving mixture and the new engine oil has been dis tributed to all parts l Now crank the engine several times without ignition to spray the combustion chambers l Take the V belts of...

Страница 118: ...As required BOMAG 118 BW 100 120 125 AD 4 AC 4...

Страница 119: ...BOMAG 119 BW 100 120 125 AD 4 AC 4 7 Trouble shooting...

Страница 120: ...nding section of these operat ing and maintenance instructions Malfunctions are frequently caused by incorrect operation of the machine or insufficient mainte nance Whenever a fault occurs you should...

Страница 121: ...s tighten them and cover them with acid free grease Especially during winter the use of too viscous engine oil Use engine oil suitable for the ambient temperature Insufficient fuel supply clogging of...

Страница 122: ...ooling air blow er Clean the cooling air duct V belt loose or broken Tension or replace the V belt Air filter cartridge dirty Clean change if necessary Engine oil pres sure too low shut down im mediat...

Страница 123: ...BOMAG 123 BW 100 120 125 AD 4 AC 4 8 Disposal...

Страница 124: ...oke The battery contains acid Do not let acid come in contact with skin or clothes Wear protective clothing l Remove the batteries and dispose of in com pliance with legal regulations Environment Catc...

Страница 125: ......

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