Bomag BW 100 AD-4 Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Bomag Manuals
  4. Construction Equipment
  5. BW 100 AD-4
  6. Operating instructions manual

Bomag BW 100 AD-4 Operating Instructions Manual

Tandem vibratory roller, combination roller
Hide thumbs
Table of Contents

Advertisement

Quick Links

Operating instructions
Maintenance instructions
Original operating instructions
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 .... > / S/N 101 880 09 .... > / S/N 101 880 15 .... > / S/N 101 880 11 .... >
Tandem Vibratory Roller
Combination Roller
Catalogue No.
008 053 01
01/2012

Advertisement

Table of Contents
loading

Related Manuals for Bomag BW 100 AD-4

Summary of Contents for Bomag BW 100 AD-4

  • Page 1 Maintenance instructions Original operating instructions 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 ..>...

  • Page 3: Foreword

    BOMAG dealer against the serial number of your machine. Compliance with the maintenance instructions will Your BOMAG dealer will also supply you with in- enhance the reliability of the machine on con- formation about the correct use of our machines in struction sites, soil and asphalt construction.

  • Page 4: Bomag Bw 100/120/125 Ad-4/Ac

    Supplement the above data together with the com- missioning protocol. During commissioning our organisation will in- struct you in the operation and maintenance of the machine. Please observe strictly the safety regulations and all notes on risks and dangers! Fig. 2 Fig. 3 BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 5: Table Of Contents

    Fuels and lubricants Table of fuels and lubricants Running-in instructions Maintenance table Every 10 operating hours Check the engine oil level Checking the fuel level Check the hydraulic oil level Checking the hydraulic oil filter element BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 6 6.36 Cleaning the water sprinkler system 6.37 Draining the water sprinkler system, maintenance in case of frost 6.38 Filling the provision tank for the windscreen washer system 6.39 Tightening torques for screws with metric unified thread 6.40 Engine conservation BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 7 Table of Contents Trouble shooting General notes Engine Disposal Final shut-down of machine BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 8 Table of Contents BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 9: Technical Data

    2 Technical Data BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 10 Technical Data Fig. 4 Dimensions in mm 1728 1076 1800 2475 2475 1000 BW 100 AD-4 1728 1276 1800 2475 2475 1200 BW 120 AD-4 1728 1276 1800 2475 2475 1200 BW 125 AD-4 BW 100 AD-4 BW 120 AD-4...
  • Page 11 Technical Data BW 100 AD-4 BW 120 AD-4 BW 125 AD-4 Travel characteristics Working speed with vibration km/h 0 – 6.5 0 – 6.5 0 – 6.5 Travel speed km/h 0 – 12 0 – 12 0 – 12 Max. gradability without/with vibration...
  • Page 12 Axle load, drum (CECE) 1150 1240 1600 Axle load, wheels (CECE) 1100 1160 1350 Static linear load (CECE) kg/cm 11.5 10.3 13.5 Wheel load (CECE) Max. operating weight 2600 2800 3250 Dimensions Inner track radius 2720 2620 2620 BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 13 40 approx. 40 Water tank capacity approx. 220 approx. 220 approx. 220 Emulsion approx. 20 approx. 20 approx. 20 Hydraulic oil approx. 28 approx. 28 approx. 28 Engine oil approx. 6,5 approx. 6,5 approx. 6,5 BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 14 Technical Data Subject to technical alterations. BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 15 Vibration of the entire body (driver’s seat) The weighted effective acceleration value determined according to ISO 7096 is ≤ 0.5 m/s Hand-arm vibration values The weighted effective acceleration value determined according to ISO 5349 is ≤ 2.5 m/s BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 16 Technical Data BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 17: Safety Regulations

    3 Safety regulations BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 18 General Examples for unintended use are: work with vibration on hard concrete, cured bi- This BOMAG machine has been built in com- tumen layers or extremely frozen ground pliance with the latest technical standard and complies with the applicable regulations and cleaning the drums while driving or changing technical rules.
  • Page 19 Danger or a damaged or in its functionality impaired lifting Paragraphs marked like this highlight possible belt must not be used. dangers for persons. Optional equipment Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 20 Optional equipment Wear your personal protective outfit (hard hat, Optional equipment safety boots, etc.). Wear ear defenders. Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 21 Change the travel direction only at standstill. closed rooms and trenches Do not use the machine to transport persons. Exhaust gases are highly dangerous! Always en- sure an adequate supply of fresh air when starting and operating in closed rooms and trenches! BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 22 Refuel only with the engine stopped and the auxil- dents. iary heater switched off. Always use access steps. BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 23 Pull the key out of the ignition switch. Do not mix up hoses by mistake. Lock the articulated joint with the articulation lock. damage or deformation of the fitting, which im- pairs the function and strength of the hose/ hose connection. Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 24 Safety regulations Only genuine BOMAG hydraulic hoses ensure Working on the fuel system that the correct type of hose (pressure range) is Do not inhale fuel fumes. used at the right place. No open fire, do not smoke, do not spill any fuel.
  • Page 25 Information and safety stickers/decals on the machine Keep safety stickers in good and legible condition (see parts manual) and comply with their meaning. Replace damaged and illegible stickers/decals. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 26 14 Prohibition sticker - High pressure cleaner Operation sticker - Travel lever 15 Information sticker - Hydraulic oil Operation sticker - Water sprinkling system 16 Information sticker - Low sulphur fuel 17 Information sticker - Diesel only BW 100 AD-4 BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 27 Operation sticker - Travel lever 16 Information sticker - Hydraulic oil Operation sticker - Water sprinkling system 17 Information sticker - Low sulphur fuel Information sticker - Water 18 Information sticker - Diesel only BW 100 AC-4 BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 28 Warning sticker - Foldable ROPS Information sticker - Main battery switch S_0005 Fig. 11 Fig. 14 Instruction sticker - Always wear your seat belt Information sticker - Biodegradable hydraulic oil Optional equipment Optional equipment Optional equipment Optional equipment Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 29 Operation sticker "Chip spreader" Fig. 16 Fig. 19 Operation sticker - Edge cutter Warning sticker "Chipping temperature" 880122 Fig. 17 Information sticker - Ball valve, vibration 3-stages (only AD) Optional equipment Optional equipment Optional equipment Optional equipment Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 30 Safety regulations BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 31: Indicators And Controls

    4 Indicators and Controls BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 32 Indicators and Controls Fig. 20 BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 33 20 Water level gauge 10 Rotary switch for direction indicators 21 Foot switch for rubber tire sprinkling system 11 Rotary switch for gravity feed sprinkling sys- (only AC) or foot switch for flow divider (only Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 34: General Notes

    Preheating for starting at low temper- atures c red = Engine oil pressure warning light flashes when the engine oil pressure is too low, the warning buzzer sounds, the engine is shut down after 10 seconds. BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 35 Position Right = Seat heating on Fig. 22 No. 2 = Rotary switch for lighting Position "left" = Light off Position "mid- dle" = Side light on, with ignition switch in position "I" Optional equipment Optional equipment Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 36 Position "right" = Hazard light system switched on. Warning lights in switch and indicator control light in Fig. 28 the instrument cluster start No. 8 = Emergency stop push button flashing. Optional equipment Optional equipment Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 37 Position "left" = Gravity sprinkling system No. 9 = Push button for warning horn switched off Position "right" = Gravity sprinkling system switched on Fig. 30 No. 10 = Rotary switch for direction indica- tors Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 38 Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fuse box A (1) 20A = (F68) Potential 30 (2) 30A = (F139) Engine solenoid (3) 10A = (F04) Gauges Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 39 "I" once the engine has started. Fig. 37 Ball valve, vibration 3-stages (only AD) Position up- ward = Vibration of front drum only Position horizon- = Vibration of both drums Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 40 = Edge cutter stops at the pres- ently reached position Position "III" = Max. forward/reverse travel with vibration Position "left" = Edged cutter is raised. Position "right" = Edged cutter is lowered. Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 41 = Sprinkler system switched off Position "left" = The windscreen wiper is switched on Position "mid- dle" = The windscreen wiper is switched off Position "right" (button) = The windscreen wiper/washer is switched on Optional equipment Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 42 = Operating position, engine can Position "II" = Brake released be started. Note Release the brake by turning the steering wheel in clockwise direction. Fig. 48 No. 25 = Ball valve for chip spreader Optional equipment Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 43 Fig. 50 No. 27 = Lever to slide the chip spreader to the left = The chip spreader slides to the left to the right = The chip spreader slides to the right Optional equipment Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 44 Indicators and Controls BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 45: Operation

    5 Operation BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 46: General

    Coolant level, top up if necessary Dry air filter service indicator Water level, top up if necessary. Emulsion level, top up if necessary Air pressure in tires Checking the chip spreader and cleaning the spreading beam Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 47: Electronic Immobilizer

    This lock can be released by pressing the 15 minutes. lever down against the end stop. Then adjust the operator's weight by sliding the lever downwards. Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 48: Starting The Engine

    Fasten your seat belt (Fig. 53). Check, whether the emergency stop switch (Fig. 56) is unlocked. Fig. 54 Shift the travel lever (Fig. 54) to position "0". Fig. 57 Turn the ignition key (Fig. 57) to position "I". BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 49 For a new starting attempt the ignition key must first be turned back to position "0". Fig. 59 Turn the ignition key (Fig. 59) through position "II" to position "III", the starter will crank the en- gine. BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 50: Starting With Jump Wires

    Then connect the ground cable first to the mi- nus pole of the current supplying battery and then to engine or chassis ground, as far away from the battery as possible (Fig. 61). Start as described under 'Starting the engine'. BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 51: Driving The Machine

    Fig. 62 Fig. 64 Set the throttle lever (Fig. 62) to full load posi- The parking brake warning light (g) (Fig. 64) in the tion "Max I" or "MAX II". instrument cluster goes out. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 52 Danger of accident! If the seat is not occupied when the machine is driving, the warning buzzer will sound, the en- gine will be shut down after 4 seconds and the parking brake will close. Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 53: Stopping The Machine, Operating The Parking Brake

    Fig. 69 The parking brake warning light (g) (Fig. 69) in the Fig. 67 instrument cluster lights up. The parking brake warning light (g) in the instru- ment cluster (Fig. 67) lights up. BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 54: Switching The Vibration On And Off

    Turn the start switch (Fig. 71) to position "0" and pull out the ignition key. Danger Danger of accident! Secure the machine against unauthorized use, pull the ignition key out. Mark machines, which could be in the way, with a clearly visible sign. BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 55 Turn the rotary switch for vibration in manual or automatic mode (Fig. 73) anti-clockwise to Switching the vibration off the symbol "Manual". Caution Always switch the vibration off before stop- ping the machine. Press the vibration push button again. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 56 Shift the travel lever slowly to position 0. The machine is decelerated and the vibration will automatically switch off at a low travel speed. Fig. 77 Set the throttle lever (Fig. 77) to position "Max I" or "MAX II". BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 57: Switching The Gravity Sprinkling System On And Off

    Switch the interval switch for pressure sprin- kling (Fig. 81) to the desired flow interval. Position "0" = Sprinkler system switched off Position "1" to "10" = Interval sprinkling pre-selected Position "11" = Permanent sprinkling pre-se- lected Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 58 To switch off the pressure sprinkling system switch the interval switch for pressure sprinkling Fig. 83 (Fig. 85) to position "0". To switch off the pressure sprinkler system re- turn the travel lever to the position "brake closed" (Fig. 83). BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 59: Switching The Tire Sprinkling System On And Off (Only Ac)

    (Fig. 87) completely down, it automatically locks in fully pressed position. Note Shuts the engine down and closes the brake. Turn the button clockwise to unlock the emer- gency stop switch. Start the engine again, see chapter "Starting the engine". BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 60: Mounting/Removing The Chip Spreader

    88) and hook it carefully into the fixing points on the machine. Empty the chip spreader, see section "Filling/ emptying the chip spreader". Danger Danger of accident! Always stand the chip spreader on level and firm ground. Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 61 Fig. 92 Disconnect the chip spreader hydraulically and electrically from the machine (Fig. 92). Fig. 93 Hook the chip spreader to the fastening points (Fig. 93). BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 62: Filling/Emptying The Chip Spreader

    1.5 t/m³). trickle out. Clean the spreading screed. Emptying Danger Danger of injury! Never enter the spreader shaft area while the spreader shaft is running. Empty the hopper only with the engine off. Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 63: Operating The Chip Spreader

    Operate the lever (Fig. 101) to slide the chip spreader to left or right to the desired speading position. Fig. 99 Turn the ball valve for the chip spreader to po- sition "II" (Fig. 99). Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 64: Towing

    Towing speed 1 km/h, max. towing distance 500 m. With the chip spreader attached the machine must not be towed backwards. Fig. 103 Tow the machine by the front or rear towing eye 1 (Fig. 103). Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 65 Tighten both screws alternately and in steps vated. with 35 Nm until they bottom. Always secure the ball valve of the brake re- leasing feature (only AC) with the locking screw. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 66 Screw both plugs (Fig. 108) back in and tight- en them with 20 Nm. 880112 Fig. 109 Switch the ball valve (2) (Fig. 109) back to po- sition "I", turn the locking screw back in and BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 67: Loading/Transport

    (Fig. 110) ing lifted. out of its receptacle and fasten it with the bolt Do not step or stand under suspended loads. to the eye. Secure the bolt with the cotter pin. Optional equipment Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 68 Lifting tackle must only be attached to loads 113). by expert personnel (qualified person). Do not overload the lifting belt. Use only safe lifting gear of sufficient load bearing capacity Minimum lifting capacity of Optional equipment Optional equipment Optional equipment Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 69 Caution Never attach the lashing gear to the chip spreader. Fig. 116 Pull the bolt out of the articulation locking bar and swing the locking bar back into its recep- tacle (Fig. 116). Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 70 (Fig. 117). Fig. 118 Fold up the foldable ROPS (Fig. 118). Turn the clamping plates to horizontal position and tighten the eye bolts with a tightening torque of 75 - 200 Nm. BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 71: Maintenance

    6 Maintenance BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 72: General Notes On Maintenance

    Perform maintenance work only with the motor (at higher altitudes) and under full load, you should switched off. consult the customer service of BOMAG or the customer service of the engine manufacturer. Relieve hydraulic pressures before working on hydraulic lines.

  • Page 73: Fuels And Lubricants

    Quality We recommend to use the BOMAG filling and Lubrication oils are classified according to their filtering unit with fine filter to fill the system. performance and quality class. Oils according to This ensures finest filtration of the hydraulic other comparable specifications may be used.
  • Page 74 2-D S500 or S15; with ambient temperatures be- Caution low -10 °C the diesel fuel no. 1-D S500 or S15 Do not mix different coolants and additives of should be used fir no. 1-D. any other kind. United States Environmental Protection Agency BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 75 Caution Check the filter more frequently after this change. Perform regular oil analyses for content of wa- ter and mineral oil. Replace the hydraulic oil filter element every 500 operating hours. BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 76: Table Of Fuels And Lubricants

    Engine oil API: CF, CF-4, CG-4, CH-4 or CI-4 approx. 6.5 litres SAE 10W-40 (-20 °C to +40 °C) (BOMAG PN 009 920 06; 20 l) SAE 10W-30 (-15 °C to +30 °C) SAE 15W-40 (-15 °C to + 40 °C) SAE 30 (+5 °C to +30 °C) SAE 10 (-30 °C to -5 °C)

  • Page 77: Running-In Instructions

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

  • Page 78: Maintenance Table

    6.19 Check the air intake lines 6.20 Cleaning radiator and hydraulic oil cooler 6.21 Check, tension, replace the V- belt 6.22 Check radiator hoses and hose clamps 6.23 Checking, adjusting the scrapers BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 79 6.38 Fill the provision tank for the windscreen washer system 6.39 Tightening torques 6.40 Engine conservation oil change after 50 and 250 operating hours, then every 250 operating hours Also after repairs in the hydraulic system. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 80 Maintenance BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 81: Every 10 Operating Hours

    Contaminated fuel can cause malfunction or even damage of the engine. If necessary, fill in fuel through a funnel with screen. Monitor the entire refuelling process. For quality and quantity of fuel refer to the "ta- ble of fuels and lubricants". BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 82: Check The Hydraulic Oil Level

    "MIN" and "MAX" marks (Fig. 122). If the oil level is too low top up hydraulic oil im- mediately. For quality and quantity of oil refer to the ”ta- ble of fuels and lubricants”. BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 83: Checking The Hydraulic Oil Filter Element

    Pin pops out = Replace the hydraulic oil filter Check the coolant level in the compensation element tank (Fig. 124). To top up unscrew the filler cap and fill in cool- ant up to the MAX-mark. BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 84: Check The Water Separator

    If necessary fill in water through the filler turns and catch running out fuel / water. screen and close the cap again. Tighten the drain plug again and check for leaks, if necessary replace the seal ring. BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 85: Checking The Emulsion Level

    Caution Make sure that the ventilation bore in the filler cap is free. Fig. 130 Check hydraulic lines (Fig. 130) for leak tight- ness. Check hydraulic and electric connections for tight fit. only AC-machine Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 86 Every 10 operating hours 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). BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 87: Every 50 Operating Hours

    Dirt particles can destroy the injection pump. Fig. 132 Check the condition and tight fit of all fuel lines (2) (Fig. 132) and hose clamps (1). Optional equipment BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 88 Every 50 operating hours BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 89: Every 250 Operating Hours

    Fig. 135 Unscrew the filter cartridge (Fig. 135) using an appropriate filter wrench. Clean the sealing face on the filter carrier from any dirt. Fig. 133 Unscrew the oil filler plug (Fig. 133). BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 90 (MAX). Turn the new filter cartridge on by hand, until the seal contacts. Tighten the filter element for another half turn. Fig. 137 Fill in new engine oil (Fig. 137). Tighten the oil filler cap properly. BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 91: Checking, Cleaning, Replacing The Combustion Air Filter

    Under very dusty conditions you may have to check the filter service indicator every day. Fig. 140 Release the locking hook (Fig. 140) and take the filter hood off. Clean filter hood and dust discharge valve. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 92 Especially on the inside of the open end (sealing area). Do not install damaged Fig. 142 filter elements. Pull the main filter element (Fig. 142) carefully If necessary use safety elements. out of the housing. BOMAG BW 100/120/125 AD-4/AC-4...
  • Page 93 Dry cleaning of the main filter element Caution Do not continue to use a damaged main filter Danger element. If in doubt use a new main filter ele- ment. Eye injury! Wear protective clothing (goggles, gloves). BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 94: Check The Air Intake Lines

    Check the condition and tight fit of all air intake filter element off. lines and hose clamps. Fig. 146 Pull the safety element (Fig. 146) out by turn- ing it lightly. Push in a new safety filter element. Reassemble main filter element and cover. BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 95: Cleaning Radiator And Hydraulic Oil Cooler

    Run the engine warm for a while to avoid cor- rosion. Fig. 147 Blow the cooling air passages out with com- pressed air from the air discharge side (Fig. 147). BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 96: Checking, Tensioning, Replacing The V-Belt

    V-belt tension once again. Changing the V-belt Slightly slacken the fastening screws (2) . Press the generator completely against the engine. Remove the old V-belt. Fit the new V-belt to the V-belt pulleys. Tension the V-belt as previously described. BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 97: Checking, Adjusting The Scrapers

    Wheels (AC-machines) Fig. 152 Open the rear flap, check the scrapers, re- place if ncessary (Fig. 152). Adjust the scrapers with the screws to a uni- form distance of approx. 2 mm from the rubber tires. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 98 Every 250 operating hours BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 99: Every 500 Operating Hours

    After each charging process allow the battery Check the fastening of the battery. to rest for one hour before taking it into service. For resting periods of more than one month you should always disconnect the battery. Do BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 100: Change The Fuel Filter

    Pull the fuel filter out of the hoses. Install the new fuel pre-filter and observe the flow direction (arrow). Fasten the hose clamps. Fig. 157 Open the bleeding screw (Fig. 157) on the top of the injection pump. BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 101: Drain The Fuel Tank Sludge

    Fig. 159 Unscrew the plug (Fig. 159) from underneath the fuel tank and let the fuel run out. Once all fuel has run out screw the oil drain plug back in with a new seal ring. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 102 Every 500 operating hours BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 103: Every 1000 Operating Hours

    Perform the adjustment of the valve by follow- Fig. 161 ing the adjustment diagram "crankshaft posi- tion 2", black mark. Valve (1) (Fig. 161) white = not adjustable Valve (2) black = adjustable = Intake valve BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 104: Check The Engine Mounts

    Install the cylinder head cover with a new gas- ket. Note After a short test run check the engine for leaks. Fig. 166 Check the condition and tight fit of the engine pillow blocks (Fig. 166). BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 105: Every 2000 Operating Hours

    Note ice of the oil manufacturer for details. We recommend to use the BOMAG filling and fil- tering unit with fine filter to fill the system. This en- Environment sures finest filtration of the hydraulic oil, prolongs...

  • Page 106: Changing The Hydraulic Oil Filter

    The breather filter for the hydraulic oil tank is inte- grated in the filler cap. You should therefore re- place the complete filler cap. Close the tank with a new cover. Fig. 171 Remove filter bowl (4) (Fig. 171) with filter ele- ment (3). BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 107: Changing The Coolant

    For coolant quality refer to the "table of fuels and lubricants". Environment Catch running out coolant and dispose of envi- ronmentally. Fig. 172 Remove the radiator cap (Fig. 172). Disassemble the left hand side plate from the front frame. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 108 Check the condition of radiator hoses, if nec- Let the engine cool down and check the cool- essary replace all radiator hoses. ant level again, if necessary top up in the com- pensation tank. BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 109: Replacing The Fuel Lines

    Hoses consist of rubber or plastic material and age over the course of time. Environment Catch running out fuel, do not let it seep into the ground. Replace all fuel hoses, including their hose clips. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 110 Every 2000 operating hours BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 111: Every 3000 Operating Hours

    Every 3000 operating hours Every 3000 operating hours 6.34 Checking the fuel injection pump Note This work must only be performed by authorized service personnel. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 112 Every 3000 operating hours BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 113: As Required

    Nominal value: approx.2.2 bar Remove the water tank cover (Fig. 178). Note Ensure equal pressure in all rubber tires! Fig. 179 Open the covering flap (Fig. 179) on the right hand side of the rear frame. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 114 Fill the water tank with clean water. Check the function of the sprinkler tubes, if necessary clean or replace the nozzles. Activate the sprinkler system for a short while so that all lines are flushed out. AC-machines BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 115: Draining The Water Sprinkler System, Maintenance In Case Of Frost

    Environment Fig. 185 After the frost period drain off the anti-freeze mixture and dispose of environmentally. Open the covering flap (Fig. 185) on the right hand side of the rear frame. BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 116: Filling The Provision Tank For The Windscreen Washer System

    μ total = 0,14. Compliance with the tightening torque is checked with torque wrenches. The specified tightening torques do not apply when using MoS lubricants. Note Self-locking nuts must always be replaced once they have been unscrewed. Optional equipment BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 117: Engine Conservation

    Anti-corrosion oils are those that comply with the specification MIL-L-21260 B or TL 9150- 037/2 or Nato Code C 640/642. A machine with a conserved engine must be marked by attaching a clearly visible warning tag. BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 118 As required BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 119: Trouble Shooting

    7 Trouble shooting BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 120: General Notes

    If you cannot locate the cause of a fault or rectify it yourself by following the trouble shooting chart, you should contact our customer service depart- ment. BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 121: Engine

    Poor compression due to burned or bro- Have compression rings and pistons ex- ken compression rings or incorrect valve amined by a specialist, adjust the valve clearance clearance Injection valve defective Have examined by a specialist BW 100/120/125 AD-4/AC-4 BOMAG...
  • Page 122 Engine oil of wrong SAE-class Change the engine oil. The charge con- The generator does not charge the bat- Have examined by a specialist trol light lights tery, because generator or regulator is de- during operation fective BOMAG BW 100/120/125 AD-4/AC-4...

  • Page 123: Disposal

    8 Disposal BW 100/120/125 AD-4/AC-4 BOMAG...

  • Page 124: Final Shut-Down Of Machine

    Drain the hydraulic oil tank. Drain coolant from engine and cooling system. Drain the lubrication oil from the engine. Danger Danger of explosion! Parts that previously contained combustible fluids must not be cut with a cutting torch. BOMAG BW 100/120/125 AD-4/AC-4...

This manual is also suitable for:

Bw 120 ad-4Bw 120 ac-4Bw 125 ac-4Bw 125 ad-4Bw 100 ac-4

Table of Contents