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8.1 Preliminary remarks and safety notes

DANGER!

Danger to life caused by an

operationally unsafe machine!

– The machine must only be serv-

iced by qualified and authorized

personnel.

– Follow the safety regulations for

maintenance work

Chapter

3.10 ‘Maintenance work’

on page 51

WARNING!

Health hazard caused by fuels

and lubricants!

– Safety regulations and environ-

mental protection regulations

must be followed when handling

fuels and lubricants

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

machine.
Perform maintenance work only with the

engine shut down.

Maintenance – Preliminary remarks and safety notes

BW 100 ADM-5

140

Содержание BOMAG BW 100 ADM-5

Страница 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...

Страница 2: ...ding 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...

Страница 3: ...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...

Страница 4: ...tion 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 Main...

Страница 5: ...ocket 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...

Страница 6: ...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 hydraul...

Страница 7: ...5 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 ai...

Страница 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...

Страница 9: ...1 Introduction Introduction BW 100 ADM 5 9...

Страница 10: ...ntenance 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...

Страница 11: ...d 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 maintena...

Страница 12: ...late 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 pla...

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

Страница 14: ...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...

Страница 15: ...0 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 Fix...

Страница 16: ...g 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 1...

Страница 17: ...ng 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 10...

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

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

Страница 20: ...y 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 preventi...

Страница 21: ...ions 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 accordi...

Страница 22: ...uip 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...

Страница 23: ...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 eart...

Страница 24: ...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 ex...

Страница 25: ...t 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...

Страница 26: ...y 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...

Страница 27: ...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 fai...

Страница 28: ...ective 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 o...

Страница 29: ...me 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...

Страница 30: ...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 Dang...

Страница 31: ...y 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 1...

Страница 32: ...sed 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...

Страница 33: ...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...

Страница 34: ...ding 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 accordi...

Страница 35: ...ed 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 spil...

Страница 36: ...ely 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...

Страница 37: ...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...

Страница 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...

Страница 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 th...

Страница 40: ...k 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 Lo...

Страница 41: ...ting 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 obst...

Страница 42: ...ilot 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 conta...

Страница 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...

Страница 44: ...nd 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 appeara...

Страница 45: ...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...

Страница 46: ...ildings 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 ag...

Страница 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 opera...

Страница 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 nec...

Страница 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 ba...

Страница 50: ...ans 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 rol...

Страница 51: ...lic 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...

Страница 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 sep...

Страница 53: ...ing 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 coo...

Страница 54: ...t both before and after shut down 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...

Страница 55: ...rning 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...

Страница 56: ...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...

Страница 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...

Страница 58: ...lant 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 y...

Страница 59: ...cker 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...

Страница 60: ...ker 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...

Страница 61: ...il 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...

Страница 62: ...rmation 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 03...

Страница 63: ...r 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...

Страница 64: ...s 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 a...

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

Страница 66: ...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...

Страница 67: ...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 P...

Страница 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 Hy...

Страница 69: ...y 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 of...

Страница 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...

Страница 71: ...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 shif...

Страница 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...

Страница 73: ...pment 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 sp...

Страница 74: ...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 st...

Страница 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 w...

Страница 76: ...el 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 Positio...

Страница 77: ...ent 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 eq...

Страница 78: ...rect 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 s...

Страница 79: ...e 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...

Страница 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 electri...

Страница 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...

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

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

Страница 84: ...and lubricants Safety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Chapter 3 4 Handling fuels and lubri cants on page 29 WARNING Danger of...

Страница 85: ...pen and secure the engine hood 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...

Страница 86: ...heck 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...

Страница 87: ...afety 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 The oil level must be between the MIN and...

Страница 88: ...ge 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 F...

Страница 89: ...n or even damage of the engine If necessary fill in fuel through a screen filter Use only fuel of the permitted specification Chapter 8 3 2 Fuel on page 146 Protective equip ment n Working clothes n S...

Страница 90: ...il of the permitted specification 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 Norma...

Страница 91: ...age 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 We...

Страница 92: ...he air filter 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 m...

Страница 93: ...e 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 Clos...

Страница 94: ...o 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 maint...

Страница 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 Should the p...

Страница 96: ...e 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 mai...

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

Страница 98: ...ace 1 Park the machine safely Chapter 6 9 Parking the machine in secured condition on page 117 2 If necessary adjust the driver s seat Chapter 4 2 4 Driver s seat on page 78 Operation Setting up the w...

Страница 99: ...mobilizer armed the light emitting diode a flashes slowly 1 Slowly enter the six digit user code When entering the code the light emit ting diode 6 lights up with every digit 2 Press the diamond butto...

Страница 100: ...requisites 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 loc...

Страница 101: ...nition 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...

Страница 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...

Страница 103: ...he 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 towa...

Страница 104: ...r 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...

Страница 105: ...Middle position and engage it in parking brake position The machine will decelerate down to a standstill and the parking brake will be applied after approx 2 seconds The parking brake warning light li...

Страница 106: ...hine 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 Chapte...

Страница 107: ...tion 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 m...

Страница 108: ...ion 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...

Страница 109: ...n 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...

Страница 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...

Страница 111: ...e 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 start...

Страница 112: ...the vibration motor has reached its nominal frequency n flashes if the drum is in jump operation n lights in case of faults Chapter 10 5 Trouble shooting ECONOMIZER on page 210 In order to achieve the...

Страница 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...

Страница 114: ...he 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...

Страница 115: ...el 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...

Страница 116: ...1 Turn the ignition key to position 0 2 Start the engine 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...

Страница 117: ...er 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 fu...

Страница 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...

Страница 119: ...button on the right travel lever The edge cutter is lowered 2 Press the top push button on the right travel lever The edge cutter is raised If the water spraying system is switched on the edge cutter...

Страница 120: ...on 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 hydrau...

Страница 121: ...age 100 6 Turn the rotary switch for hydraulic hammer to the Right position 7 Set the throttle lever to position MAX II The hydraulic breaker can now be used B 462 0033 Fig 107 B SWI 0696 Fig 108 MIN...

Страница 122: ...he 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 Disconnec...

Страница 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 maintenanc...

Страница 124: ...nly 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...

Страница 125: ...owing 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...

Страница 126: ...nt 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 ma...

Страница 127: ...lease 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...

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

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

Страница 130: ...cutter optional equipment and remove the star handle screw 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...

Страница 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...

Страница 132: ...ified 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 ma...

Страница 133: ...ing 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 movem...

Страница 134: ...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...

Страница 135: ...age 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...

Страница 136: ...t 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 foldabl...

Страница 137: ...S 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...

Страница 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...

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

Страница 140: ...fety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Chapter 3 4 Handling fuels and lubri cants on page 29 CAUTION Danger of being injured by...

Страница 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 a...

Страница 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 positi...

Страница 143: ...ap 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 t...

Страница 144: ...iculation 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...

Страница 145: ...scosity 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...

Страница 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...

Страница 147: ...nly 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 suitabl...

Страница 148: ...ypes 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 proce...

Страница 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 Th...

Страница 150: ...op 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 manu...

Страница 151: ...ter 8 3 2 Fuel on page 146 Coolant Mixture of water and anti freeze agent Specification 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 Spec...

Страница 152: ...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 ho...

Страница 153: ...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...

Страница 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 r...

Страница 155: ...e 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 per...

Страница 156: ...sparent 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 fo...

Страница 157: ...ersonal 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 oi...

Страница 158: ...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 th...

Страница 159: ...king clothes n Protective gloves 1 Park the machine in secured condition Chapter 6 9 Parking the machine in secured condition on page 117 2 Allow the engine to cool down 3 Check the entire circumferen...

Страница 160: ...in secured condition 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...

Страница 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 conditi...

Страница 162: ...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 wit...

Страница 163: ...rong 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...

Страница 164: ...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 batte...

Страница 165: ...ug 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 environ...

Страница 166: ...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 engin...

Страница 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 men...

Страница 168: ...ne in secured condition 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 conc...

Страница 169: ...ion 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 stren...

Страница 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 shoe...

Страница 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...

Страница 172: ...in secured condition 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...

Страница 173: ...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 ope...

Страница 174: ...hydraulic 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...

Страница 175: ...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 Unscr...

Страница 176: ...nest 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...

Страница 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 ele...

Страница 178: ...ermine 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 o...

Страница 179: ...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...

Страница 180: ...engine damage Use only coolant of the permitted specification Chapter 8 3 3 Coolant on page 148 Do not mix different coolants and additives of any other kind Filling quantity Chapter 8 4 List of fuels...

Страница 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 ru...

Страница 182: ...rsonnel 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...

Страница 183: ...2 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 1...

Страница 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 Pr...

Страница 185: ...n 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 ai...

Страница 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...

Страница 187: ...hine 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...

Страница 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...

Страница 189: ...g 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 1...

Страница 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...

Страница 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 equi...

Страница 192: ...lways 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 o...

Страница 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 Maintenan...

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

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

Страница 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 machin...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 203: ...ngine or chassis ground as far away from the bat tery as possible 3 Start the engine Chapter 6 3 Starting the engine on page 100 NOTICE Danger of damage to the elec tronic system If no powerful consum...

Страница 204: ...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 Opt...

Страница 205: ...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 F0...

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

Страница 207: ...ty 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 ti...

Страница 208: ...o 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 free...

Страница 209: ...oo 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 be...

Страница 210: ...n 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 measu...

Страница 211: ...ews 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 c...

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

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

Страница 214: ...hazard caused by fuels and lubricants Safety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Chapter 3 4 Handling fuels and lubri cants on pag...

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