Bomag BW 100 AD-5 Operating & Maintenance Instructions
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Bomag BW 100 AD-5 Operating & Maintenance Instructions

Bomag BW 100 AD-5 Operating & Maintenance Instructions

Tandem vibratory roller
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Operating Instruction
Maintenance Instruction
Original Operating Instructions
BW 100 AD-5
S/N 861 880 41 1180>
Tandem vibratory roller
008 202 52 EN
© 05/2018

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Summary of Contents for Bomag BW 100 AD-5

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

  • Page 3: Table Of Contents

    30 3.4.3 Safety regulations and environmental protection regulations for handling oil.................. 32 3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil..............34 3.4.5 Safety regulations and environmental protection regulations for handling coolants................ 36 BW 100 AD-5...
  • Page 4 3.11 Repair..................55 3.12 Signage..................56 Indicators and control elements............65 4.1 Driver’s stand................66 4.1.1 Operating console............... 68 4.1.2 Starter switch................75 4.1.3 12 V DIN socket................75 4.1.4 Travel lever.................. 76 4.1.5 Throttle lever................79 BW 100 AD-5...
  • Page 5 6.5.2 Preparing to work with vibration..........107 6.5.3 Manual vibration................ 107 6.5.4 Vibration in automatic mode............108 6.5.5 Stop working with vibration............109 6.5.6 ECONOMIZER................109 6.6 Water spraying system.............. 112 6.7 Parking the machine in secured condition......113 6.8 Emergency procedures.............. 115 BW 100 AD-5...
  • Page 6 8.7.2 Checking, cleaning the water separator........150 8.8 Every 250 operating hours............152 8.8.1 Change engine oil and oil filter cartridge........152 8.8.2 Checking, tensioning the V-belt..........153 8.8.3 Check the air intake lines............154 8.8.4 Checking radiator hoses and hose clamps....... 155 BW 100 AD-5...
  • Page 7 9.1 Manually adjusting the crabwalk..........190 9.2 Edge cutter – installing tool............192 9.3 Mounting / removing the chip spreader........193 9.3.1 Preliminary remarks and safety notes........193 9.3.2 Mounting the chip spreader............194 9.3.3 Removing the chip spreader............. 195 BW 100 AD-5...
  • Page 8 10.3 Fuse assignment..............200 10.3.1 Notes on safety............... 200 10.3.2 Fuses in engine compartment..........200 10.3.3 Central electrics............... 201 10.4 Engine faults................203 10.5 Trouble shooting ECONOMIZER..........206 11 Disposal....................209 11.1 Final shut-down of machine............ 210 BW 100 AD-5...

  • Page 9: Introduction

    Introduction Introduction BW 100 AD-5...

  • Page 10: Foreword

    Introduction – Foreword Foreword BOMAG manufactures machines for earth, asphalt and refuse compaction, stabilizers/ recyclers as well as planers and pavers. BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all impor- tant components and highest quality demands guarantee maximum reliability of your machine.
  • Page 11 For your own personal safety you should only use original parts from BOMAG. For your machine we offer service kits to make maintenance easier. In the course of technical development we reserve the right for technical modifications without prior notification.

  • Page 12: Machine Type Plate And Engine Type Plate

    Machine type plate and engine type plate Please enter here: Machine type (1): Serial number (2): Fig. 1: Machine type plate (example) Please enter here: Engine type (Fig. 1) Engine number (2): Fig. 2: Engine type plate (example) BW 100 AD-5...

  • Page 13: Technical Data

    Technical data Technical data BW 100 AD-5...
  • Page 14 (69) (42) (20.6) (27.6) (71) (101) Dimensions in millimetres (Dimensions in inch) 2529 1000 (10.0) (100) (1.4) (0.5) (39) Dimensions in millimetres (Dimensions in inch) Height with protective roof and flashing beacon 2890 (optional equipment) (114) (in) BW 100 AD-5...
  • Page 15 Type D 1703-M-E3B Cooling Water Number of cylinders Rated power ISO 14396 24.3 Rated power SAE J 1995 32.6 Rated speed 2600 Fixed engine speed (1) 2500 Fixed engine speed (2) 2600 Driven drum front + rear BW 100 AD-5...
  • Page 16 +/- 10 ° Inner track radius 2550 (100) (in) Crabwalk, lateral offsetting of drum right/left (2.0) (in) Exciter system Vibrating drum front + rear Frequency (1/2) 63/67 (3780/4020) (vpm) Amplitude (0.02) (in) Centrifugal force (1/2) 30/34 (6744/7644) (lbf) BW 100 AD-5...

  • Page 17: Noise And Vibration Data

    EN 500. WARNING! Loss of hearing caused by too high noise burdens! – Wear your personal protective equipment (ear protection). Guaranteed sound = 106 dB(A), determined acc. to ISO 3744 power level and EN 500 BW 100 AD-5...

  • Page 18: Vibration Data

    Vibration of the entire The weighted effective acceleration value body (driver’s seat) determined according to ISO 7096 is ≤ 0.5 Hand-arm vibration The weighted effective acceleration value determined according to EN 500/ISO 5349 is ≤ 2.5 m/s BW 100 AD-5...

  • Page 19: Concerning Your Safety

    Concerning your safety Concerning your safety BW 100 AD-5...

  • Page 20: Basic Prerequisites

    This also applies for local regula- tions and regulations concerning different types of handling activities. Should the recommenda- tions in these instructions be different from the regulations valid in your country, you must comply with the safety regulations valid in your country. BW 100 AD-5...

  • Page 21: Explanation Of Signal Words Used

    NOTICE! Danger of material damage if failing to comply! Sections marked accordingly indi- cate possible dangers for machines or components. BW 100 AD-5...

  • Page 22: Personal Protective Equipment

    Protective gloves To protect the hands against excoria- tion, punctures or deep injuries, against irritating and caustic substances as well as against burns. Safety goggles To protect the eyes against airborne particles and squirting fluids. BW 100 AD-5...

  • Page 23: Intended Use

    Intended use also includes compliance with the specified operating, maintenance and repair measures. 3.1.5 Improper use Dangers may arise from the machine when it is used for purposes other than the one it is intended for. BW 100 AD-5...
  • Page 24 Using the machine for towing transporting persons, except the machine driver, is prohibited. starting and operation of the machine in explo- sive environments and in underground mining is prohibited. BW 100 AD-5...

  • Page 25: Definition Of Responsible Persons

    3.2.2 Expert / qualified person An expert / qualified person is a person who, based on his/her professional education and experience, has profound knowledge in the field of construction equipment and the machine in question in particular. BW 100 AD-5...

  • Page 26: Driver / Operator

    Persons under the influence of alcohol, medi- cation or drugs are not allowed to operate, service or repair the machine. Maintenance and repair work requires specific knowledge and must therefore only be per- formed by trained specialists. BW 100 AD-5...

  • Page 27: Fundamentals For Safe Operation

    3.3.3 Modifications and alterations to the machine Unauthorized changes to the machine are pro- hibited for safety reasons. Original parts and accessories have been spe- cially designed for this machine. BW 100 AD-5...

  • Page 28: Damage, Defects, Misuse Of Safety Devices

    The ROPS must therefore also not be straight- ened or repaired if it is damaged. A defect ROPS must generally be replaced with an original spare part in close coordination with the manufacturer. BW 100 AD-5...

  • Page 29: Handling Fuels And Lubricants

    / per- sonal protective equipment physical and chemical properties stability and reactivity toxicological data environmental data notes on waste disposal information on transport legislation other data BW 100 AD-5...

  • Page 30: Safety Regulations And Environmental Protection Regulations For Handling Diesel Fuel

    – Wear your personal protective equipment (protective gloves, protective clothing). – Do not inhale any fuel fumes. – Avoid contact. CAUTION! Danger of slipping on spilled diesel fuel! – Immediately bind spilled diesel fuel with an oil-binding agent. BW 100 AD-5...
  • Page 31 Diesel fuel is an environmentally hazardous substance! – Always keep diesel fuel in proper containers. – Immediately bind spilled diesel fuel with an oil-binding agent and dispose of properly. – Dispose of diesel fuel and fuel fil- ters according to regulations. BW 100 AD-5...

  • Page 32: Safety Regulations And Environmental Protection Regulations For Handling Oil

    Danger of slipping on spilled oil! – Immediately bind spilled oil with an oil-binding agent. ENVIRONMENT! Oil is an environmentally haz- ardous substance! – Always keep oil in proper con- tainers. » Continued on the next page BW 100 AD-5...
  • Page 33 Concerning your safety – Handling fuels and lubricants – Immediately bind spilled oil with an oil-binding agent. – Dispose of oil and oil filter according to regulations. BW 100 AD-5...

  • Page 34: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic Oil

    Danger of burning by ignited hydraulic oil! – Do not allow hydraulic oil to come into contact with hot com- ponents. – Smoking and open fire is pro- hibited! – Wear your personal protective equipment (protective gloves, protective clothing). BW 100 AD-5...
  • Page 35 ENVIRONMENT! Oil is an environmentally haz- ardous substance! – Always keep oil in proper con- tainers. – Immediately bind spilled oil with an oil-binding agent. – Dispose of oil and oil filter according to regulations. BW 100 AD-5...

  • Page 36: Safety Regulations And Environmental Protection Regulations For Handling Coolants

    Danger of slipping on spilled coolant! – Immediately bind spilled coolant with an oil-binding agent. ENVIRONMENT! Coolant is an environmentally hazardous substance! – Always keep coolant and coolant additives in proper containers. » Continued on the next page BW 100 AD-5...
  • Page 37 Concerning your safety – Handling fuels and lubricants – Immediately bind spilled coolant with an oil-binding agent and dis- pose of it according to regula- tions. – Dispose of coolant according to regulations. BW 100 AD-5...

  • Page 38: Safety Regulations And Environmental Protection Regulations For Handling Battery Acid

    – Do not lay any tools or other metal objects on the battery. – Do not wear jewellery (watch, bracelets, etc.) when working on the battery. – Wear your personal protective equipment (protective gloves, protective clothing, goggles). BW 100 AD-5...
  • Page 39 Concerning your safety – Handling fuels and lubricants ENVIRONMENT! Battery acid is an environmen- tally hazardous substance! – Dispose of battery and battery acid according to regulations. BW 100 AD-5...

  • Page 40: Loading / Transporting The Machine

    Fasten the lifting gear only at the specified lifting points. Danger to the life of persons if they step or stand under a suspended load. When lifting the machine, avoid uncontrolled movements of the load. If necessary, hold the load with guide ropes. BW 100 AD-5...
  • Page 41 Concerning your safety – Loading / transporting the machine After the transport loosen the articulation lock 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. BW 100 AD-5...

  • Page 42: Start-Up Procedure

    If the following tests reveal damages or other faults, the machine must not be operated, until these deficiencies have been corrected. Do not operate the machine with defective indi- cators and control elements. BW 100 AD-5...

  • Page 43: Starting The Engine

    A wrong connection will cause severe damage in the electric system. Do not start the engine by shorting the electric terminals on the starter motor, because the machine may start to drive immediately. BW 100 AD-5...

  • Page 44: Driving The Machine; Working Operation

    Do not climb onto or off the machine while the machine is driving. Do not use the machine to transport persons. In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected. BW 100 AD-5...

  • Page 45: Driving Up And Down Slopes

    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! BW 100 AD-5...

  • Page 46: Cross Slope

    (gas, water, sewage, electric power). If neces- sary stop compacting with vibration. Do not activate the vibration on hard (frozen, concrete) ground. Components may get dam- aged. 3.7.6 Parking the machine Park the machine on horizontal, level, firm ground. BW 100 AD-5...
  • Page 47 Do not jump off the machine, but use hand grips and access steps. Mark machines, which could be in the way, with a clearly visible sign. When parking on ascents or descents use appropriate means to secure the machine against rolling. BW 100 AD-5...

  • Page 48: Refuelling

    Wipe off spilled fuel. Keep dirt and water away from the fuel. A leaking fuel tank can cause an explosion. Ensure tight fit of the fuel tank cover, if neces- sary replace immediately. BW 100 AD-5...

  • Page 49: Emergency Procedures

    Before releasing the parking brake apply suit- able measures to secure the machine against unintended rolling. Use a tractor vehicle with sufficient traction and braking power for the unbraked towed load. You should generally use a tow bar. BW 100 AD-5...
  • Page 50 Before starting towing operations make sure that the fastening means are able to withstand the load and are fastened at the points pro- vided for this purpose. Before removing the towing facility apply appropriate measures to secure the machine against unintended rolling. BW 100 AD-5...

  • Page 51: Maintenance Work

    Do not change the setting of pressure relief valves. Drain the hydraulic oil at operating temperature – danger of scalding! Any hydraulic oil must be collected and dis- posed of in an environmentally friendly way. Always collect and dispose of hydraulic oils separately. BW 100 AD-5...

  • Page 52: Working On The Engine

    The settings for idle speed and highest speed must not be changed, since this would affect the exhaust gas values and cause damage to engine and power train. BW 100 AD-5...

  • Page 53: Maintenance Work On Electric Components And Battery

    Never use gasoline or other easily inflammable substances for cleaning. When cleaning with a high pressure cleaner, do not subject electrical parts and insulation mate- rial to the direct jet of water, or cover them beforehand. BW 100 AD-5...

  • Page 54: After Maintenance Work

    Concerning your safety – Maintenance work Do not guide the water jet into the exhaust pipe and into the air filter. 3.10.6 After maintenance work Reassemble all guards and protective devices. Close all maintenance flaps and maintenance doors again. BW 100 AD-5...

  • Page 55: Repair

    Identify a defective machine with a warning sign. Only operate the machine after it has been repaired. Repairs must only be performed by an expert/ qualified person. When replacing safety relevant components, only original spare parts must be used. BW 100 AD-5...

  • Page 56: Signage

    Concerning your safety – Signage 3.12 Signage Keep stickers and signage in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or sig- nage immediately. BW 100 AD-5...
  • Page 57 Concerning your safety – Signage Nm 75-200 Nm 75-200 ft.lb. 55-147 ft.lb. 55-147 20 kg 20 kg ~ 200 Nm ~ 200 Nm 25 kg 25 kg ~ 75 Nm ~ 75 Nm Hydraulic Oil B-880-0149 Fig. 10 BW 100 AD-5...
  • Page 58 Concerning your safety – Signage B-880-0150 Fig. 11 Warning sticker - Danger of tipping over B-DEC-0206 Fig. 12 BW 100 AD-5...
  • Page 59 Concerning your safety – Signage Warning sticker - Follow operating instructions Fig. 13 Warning sticker - Danger of crushing Fig. 14 Warning sticker - Foldable ROPS B-DEC-0207 Fig. 15 Prohibition sticker - High pressure cleaning Fig. 16 BW 100 AD-5...
  • Page 60 Concerning your safety – Signage Instruction sticker - Always wear your seat belt Fig. 17 Information sticker - Lifting point Fig. 18 Information sticker - Lashing point Fig. 19 Information sticker - Filler opening for hydraulic Hydraulic Oil B-DEC-0214 Fig. 20 BW 100 AD-5...
  • Page 61 Concerning your safety – Signage Information sticker - Engine oil drain B-DEC-0211 Fig. 21 Information sticker - Hydraulic oil drain B-DEC-0210 Fig. 22 Information sticker - Coolant drain B-DEC-0212 Fig. 23 Information sticker - Disconnecting the battery B-DEC-0219 Fig. 24 BW 100 AD-5...
  • Page 62 Concerning your safety – Signage Information sticker - Main battery switch plus side Fig. 25 Operation sticker - Throttle lever B-DEC-0236 Fig. 26 Information sticker - Low sulphur fuel Fig. 27 Information sticker - Guaranteed sound capacity level Fig. 28 BW 100 AD-5...
  • Page 63 Concerning your safety – Signage Information sticker - Foldable ROPS operation Nm 75-200 ft.lb. 55-147 20 kg ~ 200 Nm 25 kg ~ 75 Nm B-DEC-0208 Fig. 29 Machine type plate (example) Fig. 30 BW 100 AD-5...
  • Page 64 Concerning your safety – Signage BW 100 AD-5...

  • Page 65: Indicators And Control Elements

    Indicators and control elements Indicators and control elements BW 100 AD-5...

  • Page 66: Driver's Stand

    Indicators and control elements – Driver’s stand Driver’s stand B-880-0161 Fig. 31: Overview of driver’s stand 1 Operating console 2 Starter switch 3 12 V DIN socket 4 Travel lever, right 5 Travel lever, left (optional equipment) 6 Throttle lever BW 100 AD-5...
  • Page 67 6 Rotary switch for drum pre-selection 7 Rotary switch for vibration pre-selection 8 Emergency stop switch 9 Instrument cluster 10 ECONOMIZER display (optional equipment) 11 Rotary switch for seat heating (optional equipment) 12 Rotary switch for water spraying system BW 100 AD-5...

  • Page 68: Operating Console

    Rotary switch for working lights Position "Left" Working lights off Position "Right" Working light on Fig. 34 4.1.1.3 Rotary switch for lighting Position "Left" Light off Position Side light on “Middle” Position "Right" Travel light on Optional equipment Fig. 35 BW 100 AD-5...
  • Page 69 Position “left” Vibration of front drum Position Vibration of front and rear “middle” drums Position “right” Vibration of rear drum Drum pre-selection is only acti- B-SWI-1488 vated, if the vibration has been switched off beforehand. Fig. 38 BW 100 AD-5...
  • Page 70 Position Vibration off “middle” B-SWI-1485 Position “right” Pre-selection vibration in Fig. 39 automatic mode Vibration is automatically switched on or off when the travel speed exceeds or falls below a certain value. BW 100 AD-5...
  • Page 71 Turn the Emergency Stop unlock switch clockwise and let it NOTICE! In case of frequent use the wear on the multi-discs brakes will be very high. – Do not use the emergency stop switch as service brake! BW 100 AD-5...
  • Page 72 2 seconds. If the travel lever is shifted to any travel direc- tion, the engine is shut down. If the engine stops, occupy the driver’s seat and restart the engine. Pre-heating control Lights up during pre-heating. light BW 100 AD-5...
  • Page 73 Each actuation of the function key [F2] switches between: Operating hours Asphalt temperature in °C (optional equip- 100 120 140 160 °C 140 176 212 248 284 320 °F ment) Asphalt temperature in °F (optional equip- ment) B-DIS-0519 Fig. 42 BW 100 AD-5...
  • Page 74 Seat heating on The control light in the switch lights up. Optional equipment Fig. 44 4.1.1.12 Rotary switch for water spraying system Position “0” Spraying off Position “1” to Interval spraying “4” Position “MAX” Permanent spraying B-SWI-1493 Fig. 45 BW 100 AD-5...

  • Page 75: Starter Switch

    The starter switch is designed with a re-start lock. The ignition key must first be turned back to position “0” before a new starting attempt can be made. 4.1.3 12 V DIN socket Permanent current, loadable up to 10 A. Fig. 47 BW 100 AD-5...

  • Page 76: Travel Lever

    Indicators and control elements – Driver’s stand 4.1.4 Travel lever B-ELE-0163 Fig. 48 R Travel lever, right L Travel lever, left (optional equipment) On machines with double travel lever, the two travel levers are mechanically connected to each other. BW 100 AD-5...
  • Page 77 Position I: up to approx. 5 km/h (3 mph) Position II: up to approx. 10 km/h (6 mph) Position “middle” Service brake position Position “middle right” (travel lever Parking brake position right) Position “middle left” (travel lever left) BW 100 AD-5...
  • Page 78 Lift edge cutter on left hand side Optional equipment Extend crabwalk The front drum is extended to the right Optional equipment Lower edge cutter on left hand Optional equipment side Retract crabwalk The front drum is retracted Optional equipment BW 100 AD-5...

  • Page 79: Throttle Lever

    Indicators and control elements – Driver’s stand 4.1.5 Throttle lever Position “MIN” Idle speed position Position “MAX Full load position I I” Position “MAX Full load position II II” B-880-0159 Fig. 50 BW 100 AD-5...

  • Page 80: Engine Compartment

    B-880-0033 the engine compartment as Fig. 51 well as protection against unauthorized use. Individual control units may still be connected to the board electrics despite the main battery switch being pulled out. Optional equipment BW 100 AD-5...

  • Page 81: Checks Prior To Start Up

    Checks prior to start up Checks prior to start up BW 100 AD-5...

  • Page 82: Notes On Safety

    CAUTION! Danger of being injured by the engine hood dropping down! – Always secure an opened engine hood. Ä Chapter 6.7 Park the machine safely „Parking the machine in secured condi- tion“ on page 113. BW 100 AD-5...
  • Page 83 Checks prior to start up – Notes on safety Ä Chapter Open and secure the engine hood 8.2.2.1 „Open and secure the engine hood“ on page 140. Close the engine hood again after work is com- pleted. BW 100 AD-5...

  • Page 84: Visual Inspections And Function Tests

    6. Check belt drive for damage. 7. Check machine for contamination and damage. 8. Check function of steering. 9. Check function of brake. 10. Check emergency stop function. 11. Check function of backup alarm system. 12. Check function of seat contact switch. BW 100 AD-5...

  • Page 85: Checking The Engine Oil Level

    3. For topping up, clean the area around the B-880-0083 filling port. Fig. 52 4. Unscrew the cap and fill with engine oil up 1 Oil dipstick to the “MAX” mark. 2 Oil filler opening 5. Push the dipstick in. 6. Close the cap. BW 100 AD-5...

  • Page 86: Checking The Fuel Level; Topping Up Fuel

    – Contaminated fuel can cause malfunction or even damage of the engine. If necessary, fill in fuel through a screen filter. – Use only fuel of the permitted Ä Chapter 8.3.2 specification „Fuel“ on page 142. BW 100 AD-5...
  • Page 87 Checks prior to start up – Checking the fuel level; topping up fuel Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Clean the area around the filling port. Diesel 2. Unscrew the cap and fill with fuel. 3. Close the cap. B-880-0187 Fig. 54 BW 100 AD-5...

  • Page 88: Checking The Hydraulic Oil Level

    2. Remove the cap and check the hydraulic oil level on the dipstick. 3. The hydraulic oil level must always be between the “MIN” and “MAX” marks. ð Top up hydraulic oil. B-880-0167 Fig. 55 4. Close the cap. BW 100 AD-5...

  • Page 89: Checking The Coolant Level

    (protective gloves, protective clothing, Fig. 56 goggles). Check the coolant level in the compensa- tion tank. 2. To refill remove the cover and fill up to the "MAX" mark with coolant. 3. Close the cap. BW 100 AD-5...

  • Page 90: Checking The Air Filter

    1. Check the air filter on the maintenance indicator. 2. If the yellow pin has reached the red area (1) conduct maintenance of the air filter Ä Chapter 8.13.1 „Air filter mainte- nance“ on page 178. B-880-0084 Fig. 57 BW 100 AD-5...

  • Page 91: Checking The Water Level, Topping Up

    186. NOTICE! Dirty or contaminated water can block the water spraying system! – Fill only with clean water. 1. Check the filling level on the water level Water gauge, fill up if necessary. B-880-0188 Fig. 58 BW 100 AD-5...
  • Page 92 Checks prior to start up – Checking the water level, topping up 2. Unscrew the cap (1) and fill in clean water Water through the strainer (2). 3. Make sure that the ventilation bore in the filler cap is free. 4. Close the cap. B-880-0189 Fig. 59 BW 100 AD-5...

  • Page 93: Checking, Adjusting The Scrapers

    Checks prior to start up – Checking, adjusting the scrapers Checking, adjusting the scrapers Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Check the condition of the scrapers (1) and clean them. 2. Replace worn scrapers. Fig. 60 BW 100 AD-5...

  • Page 94: Checking The Hydraulic Oil Filter

    3. Shift the travel lever to “Middle” position and engage it in parking brake position. ð The machine will decelerate down to a standstill and the parking brake will be applied after approx. 2 seconds. The parking brake warning light lights B-880-0012 Fig. 61 BW 100 AD-5...
  • Page 95 Danger of engine damage! – Do not shut down the engine all of a sudden from full load speed, but let it idle for about two minutes. B-ELE-0069 Turn the ignition key to position “0”. Fig. 64 BW 100 AD-5...
  • Page 96 Checks prior to start up – Checking the hydraulic oil filter BW 100 AD-5...

  • Page 97: Operation

    Operation Operation BW 100 AD-5...

  • Page 98: Setting-Up The Work Place

    The adjustment lever (a) is b Longitudinal adjustment locked in upwards direction. c Backrest adjustment To release the lock press the lever down against the end stop. Then adjust to the weight of the operator by sliding the lever down. BW 100 AD-5...

  • Page 99: Sliding The Driver's Seat Sideways

    Operation – Setting-up the work place 6.1.2 Sliding the driver’s seat sideways 1. Pull the lever up and slide the driver's seat sideways 2. Always lock the driver's seat safely in one of the locking positions. Fig. 66 BW 100 AD-5...

  • Page 100: Electronic Immobilizer

    ð When entering the code, the light emit- ting diode (6) lights up with every digit. 2. Press the diamond button. ð The electronic immobilizer is now dis- armed and the engine can be started within the next 15 minutes. Fig. 67 BW 100 AD-5...

  • Page 101: Starting The Engine

    Emergency stop switch is unlocked Travel lever in parking brake position When closing the dashboard cover, the emergency stop switch will lock automatically and must be unlocked before starting again. 1. Set the throttle lever to position “MIN”. B-880-0159 Fig. 68 BW 100 AD-5...
  • Page 102 – If the engine has not started after two attempts, determine the cause. Turn the ignition key through position “II” to position “III”. ð The starter cranks the engine. BW 100 AD-5...
  • Page 103 Operation – Starting the engine NOTICE! Danger of engine damage! – Warm up engine for a short while before starting work. Do not operate the engine immediately under full load. BW 100 AD-5...

  • Page 104: Travel Operation

    The warning buzzer sounds. After approx. 3 seconds, the machine brakes to Fig. 72 a standstill. Before being able to drive again, the travel lever must first be shifted to the right into the parking brake position. BW 100 AD-5...

  • Page 105: Driving The Machine

    1. Shift the travel lever to “Middle” position and engage it in parking brake position. ð The machine will decelerate down to standstill and the parking brake will be applied after approx. 2 seconds. The parking brake warning lamp lights Fig. 75 BW 100 AD-5...

  • Page 106: Working With Vibration

    The vibration is automatically switched off when falling below this certain slow travel speed. This avoids the formation of transverse marks caused by vibration with the machine at stand- still. BW 100 AD-5...

  • Page 107: Preparing To Work With Vibration

    B-SWI-1488 Fig. 76 2. Set the throttle lever to position “MAX I” or “MAX II”. B-880-0160 Fig. 77 6.5.3 Manual vibration 1. Turn the rotary switch for vibration pre- selection to position “Left”. B-SWI-1486 Fig. 78 BW 100 AD-5...

  • Page 108: Vibration In Automatic Mode

    ð The vibration comes on at a low travel speed. 3. To switch off vibration, return the travel lever towards “Middle” position. ð The vibration switches off when falling B-880-0008 below a low travel speed. Fig. 81 BW 100 AD-5...

  • Page 109: Stop Working With Vibration

    The ECONOMIZER first of all runs an LED- test. The LEDs light up one after the other, starting with LED (1). Once all LEDs are on, the display goes out again in single steps. BW 100 AD-5...
  • Page 110 The reference measurement is used to deter- mine which display value of the ECONOMIZER corresponds with the measuring value for soil stiffness or asphalt density. Tandem vibratory rollers of the same type show identical measuring values when used on the same soil. BW 100 AD-5...
  • Page 111 Operation – Working with vibration The measuring values achieved with different tandem vibratory rollers can be made compa- rable by calibration to a reference value. BW 100 AD-5...

  • Page 112: Water Spraying System

    With the travel lever in neu- tral, spraying will continue for a short while. 3. After the end of work, turn the rotary switch for the water spraying system back to posi- tion “0”. B-SWI-1493 Fig. 85 BW 100 AD-5...

  • Page 113: Parking The Machine In Secured Condition

    – Do not shut down the engine all of a sudden from full load speed, but let it idle for about two minutes. B-ELE-0069 Turn the ignition key to position “0” and pull Fig. 88 it out. BW 100 AD-5...
  • Page 114 Operation – Parking the machine in secured condition 5. Turn the main battery switch (if present) anticlockwise and pull it out. B-SWI-0079 Fig. 89 BW 100 AD-5...

  • Page 115: Emergency Procedures

    Preliminary remarks and safety notes Tow the machine only in case of emergency or to prevent an accident. Always use a tow bar. Towing distance: only out of the direct danger zone, towing speed: 1 km/h (0.6 mph). BW 100 AD-5...
  • Page 116 The machine cannot be steered. BW 100 AD-5...
  • Page 117 Danger of burning on hot components! – Wear your personal protec- tive equipment (protective gloves, protective clothing). – Avoid touching hot compo- B-880-0050 nents. Fig. 93 Open the engine hood and remove the covering from the travel pump. BW 100 AD-5...
  • Page 118 B-880-0014 Remove two plugs. Fig. 95 10. Press both screws in against the springs. 11. Tighten both screws alternately and step by step against the end stop, tightening torque: 35 Nm (25 ft·lbf). Fig. 96 BW 100 AD-5...
  • Page 119 Danger of injury caused by uncontrolled machine movement! – Always secure the machine against unintended rolling. 1. After towing, park the machine in a safe place and secure it against accidentally rolling away. 2. Remove two plugs. B-880-0014 Fig. 98 BW 100 AD-5...
  • Page 120 7. Unscrew the socket head cap screws (1) against the end stop. 8. Tighten the counter nuts, tightening torque: 22 Nm (16 ft·lbf). B-HYD-0003 Fig. 101 9. Open the engine hood and assemble the covering on the travel pump. B-880-0050 Fig. 102 BW 100 AD-5...
  • Page 121 5. Repeat this process after a short break. 6. Pull off the ignition key. B-880-0159 Fig. 104 7. Open the engine hood and reconnect the plug (Y04) to the solenoid valve for the parking brake. 8. Close the engine hood. B-880-0049 Fig. 105 BW 100 AD-5...
  • Page 122 Operation – Emergency procedures 1 Plug (Y04) BW 100 AD-5...

  • Page 123: Loading / Transporting The Machine

    Loading / transporting the machine Loading / transporting the machine BW 100 AD-5...

  • Page 124: Prepare For Transport

    Loading / transporting the machine – Prepare for transport Prepare for transport 1. Close all flaps. 2. Remove all loose objects from the machine or from the operator's stand or fasten them reliably. BW 100 AD-5...

  • Page 125: Loading The Machine

    3. Shut down the engine, pull off the ignition key. WARNING! Danger of crushing by the articulating machine! – Do not step into the articula- tion area of the machine while the engine is running. Fig. 106 Attach and secure the articulation lock. BW 100 AD-5...

  • Page 126: Folding Down The Foldable Rops

    1. Loosen the eye bolts and adjust the clamping plates vertically. CAUTION! Head injuries caused by folding the foldable ROPS! – Do not step into the slewing B-650-0018 area of the foldable ROPS. Fig. 107 Fold the foldable ROPS back. BW 100 AD-5...

  • Page 127: Lashing The Machine To The Transport Vehicle

    Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Fasten the lifting and lashing tackle on the marked lashing points on front or rear frame. 2. Lash the machine securely to the transport vehicle. B-880-0081 Fig. 108 BW 100 AD-5...

  • Page 128: Loading By Crane

    Attach and secure the articulation lock. The foldable ROPS can be folded down to reduce the transport height. 3. Fold down the foldable ROPS, if necessary Ä Chapter 7.2.1 „Folding down the foldable ROPS“ on page 126. BW 100 AD-5...
  • Page 129 4. Attach the lifting tackle to the central lifting point. DANGER! Danger to life caused by sus- pended loads! – Do not step or stand under suspended loads. Fig. 110 Lift the machine carefully and lower it again at the intended location. BW 100 AD-5...

  • Page 130: Loading By Crane

    1. Shut down the engine. WARNING! Danger of crushing by the articulating machine! – Do not step into the articula- tion area of the machine while the engine is running. 650111 Fig. 111 Attach and secure the articulation lock. BW 100 AD-5...
  • Page 131 Attach the lifting tackle to the central lifting Fig. 112 point. 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. BW 100 AD-5...

  • Page 132: After Transport

    8.2.1.2 „Disengaging the articulation lock“ on page 139 7.6.1 Erecting the foldable ROPS Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Erect the clamping plates on both sides vertically. B-650-0019 Fig. 113 BW 100 AD-5...
  • Page 133 ROPS. B-650-0039 Fold up the foldable ROPS. Fig. 114 3. Turn the clamping plates horizontally and tighten the eye bolts, tightening torque: 75 – 200 Nm (55 – 148 ft·lbf). BW 100 AD-5...
  • Page 134 Loading / transporting the machine – After transport BW 100 AD-5...

  • Page 135: Maintenance

    Maintenance Maintenance BW 100 AD-5...

  • Page 136: Preliminary Remarks And Safety Notes

    Thoroughly clean machine and engine before starting maintenance work. Before mounting the machine, check whether all access steps, grips and platforms are free of obstacles, grease, oils, fuel, dirt, snow and ice. BW 100 AD-5...
  • Page 137 After all maintenance work is completed rein- stall all guards and safety installations. Close all maintenance flaps and doors after maintenance work has been completed. The terms right/left are always in relation to the travel direction. BW 100 AD-5...

  • Page 138: Preparations/Concluding Work

    – Do not step into the articulation area of the machine while the engine is running. 1. Move the steering to middle position and stop the machine. 2. Switch off the engine and remove the igni- tion key. BW 100 AD-5...
  • Page 139 Danger of crushing by the articulating machine! – Do not step into the articula- tion area of the machine while the engine is running. 650112 Fig. 116 Loosen the articulation lock again and fasten it in the holding fixture. BW 100 AD-5...

  • Page 140: Engine Hood

    2. Push the hood to top position. ð The hood is raised supported by the gas springs. B-880-0192 Fig. 117 8.2.2.2 Closing the engine hood 1. Push the hood at the handle into initial position. 2. Lock the hood. B-880-0193 Fig. 118 BW 100 AD-5...

  • Page 141: Fuels And Lubricants

    This adversely affects the properties of the engine oil, especially under low ambient temperatures. Optimal operating conditions can be achieved by using the following oil viscosity chart as a reference: BW 100 AD-5...

  • Page 142: Fuel

    0.5 % to 1.0 % the oil change inter- vals must be halved. Fuels with a sulphur content of more than 1.0 % are not permitted. In order to fulfil national emission regulations one must strictly use the legally required fuels (e.g. sulphur content). BW 100 AD-5...
  • Page 143 (fuel additives) is not permitted. 8.3.2.3 Storage Even traces of zinc, lead and copper can cause deposits in the injection nozzles, especially in modern Common-Rail injection systems. Zinc and lead coatings in refuelling systems and fuel lines are not permitted. BW 100 AD-5...

  • Page 144: Coolant

    50% low mineral, clean water. Stir well before filling it into the radiator. The method of mixing water and anti-freeze depends on the brand of the anti-freeze agent (see standard SAE J1034 and also standard SAE J814c). BW 100 AD-5...

  • Page 145: Hydraulic Oil

    When refilling or changing oil, use only hydraulic oil type HVLP according to DIN 51524, part 3, or hydraulic oil type HV according to ISO 6743/4. The viscosity index must be at least 150 (observe information of manufacturer). BW 100 AD-5...

  • Page 146: List Of Fuels And Lubricants

    Hydraulic oil (ISO), HVLP 46 009 930 09 35 l system Ä Chapter 8.3.4.1 Specification: 20 l (9.2 gal us) „Mineral oil based hydraulic oil“ on page 145 Water spraying Water Anti-freeze 160 l system mixture (42 gal us) BW 100 AD-5...

  • Page 147: Running-In Instructions

    100 to 250 operating hours. 8.5.2 After 50 operating hours 1. Check the engine for leaks. 2. Tighten all bolted connections on air intake, exhaust, oil sump and engine mounts 3. Retighten the bolted connections on the machine. BW 100 AD-5...

  • Page 148: Maintenance Table

    Checking the engine mounts 8.10.3 Checking the ROPS 8.10.4 Checking the travel control 8.10.5 Replacing the hydraulic oil filter Every 2000 operating hours 8.11.1 Changing the hydraulic oil 8.11.2 Changing the coolant 8.11.3 Replacing hoses 8.11.4 Check the injection valves BW 100 AD-5...
  • Page 149 Every 3000 operating hours 8.12.1 Checking the fuel injection pump As required 8.13.1 Air filter maintenance 8.13.2 Checking the water spraying system 8.13.3 Cleaning the water spraying system 8.13.4 Measures if there is a risk of frost BW 100 AD-5...

  • Page 150: Every 50 Operating Hours

    After taking the engine into opera- tion you should check for signs of water and dirt initially every day. If a too high quantity is drained off, the filter needs to be bled. BW 100 AD-5...
  • Page 151 4. Drain the fuel off until there is no water left. 5. Turn the plug tightly back in. Check for leaks, if necessary use a new seal ring. Fig. 119 6. Dispose of collected fluid in an environ- mentally friendly way. BW 100 AD-5...

  • Page 152: Every 250 Operating Hours

    – Wear your personal protec- tive equipment (protective gloves, protective clothing). – Avoid touching hot compo- B-880-0180 nents. Fig. 120 Unscrew the drain plug and collect any oil running out. 3. Screw the drain plug back in tightly. BW 100 AD-5...

  • Page 153: Checking, Tensioning The V-Belt

    8.8.2.1 Checking the V-belt Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.7 „Parking the machine in secured condition“ on page 113. 2. Allow the engine to cool down. BW 100 AD-5...

  • Page 154: Check The Air Intake Lines

    2. Allow the engine to cool down. 3. Check the condition and tight fit of all air intake lines and hose clamps. 4. If fuel lines or hose clamps are found to be damaged, the corresponding parts must be immediately replaced. BW 100 AD-5...

  • Page 155: Checking Radiator Hoses And Hose Clamps

    – Do not bend or damage cooling fins. – Do not clean with high pressure. 1. Park the machine in secured condition Ä Chapter 6.7 „Parking the machine in secured condition“ on page 113. 2. Allow the engine to cool down. BW 100 AD-5...
  • Page 156 – 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. Fig. 125 2. Blow the cooler out with compressed air from the outside. Fig. 126 BW 100 AD-5...

  • Page 157: Battery Service

    Every battery has a self-discharge, which may, if not checked occasion- ally, even cause damage to the bat- tery as a result of exhaustive dis- charge. Exhausted batteries (batteries with formation of sulphate on the plates) are not covered under warranty! BW 100 AD-5...

  • Page 158: Check The Parking Brake

    Fig. 127 6. On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water. 8.8.7 Check the parking brake This work must only be performed by authorized service personnel. BW 100 AD-5...

  • Page 159: Every 500 Operating Hours

    113. 2. Loosen the hose clamps (1) on the fuel pre-filter. 3. Pull the hoses off the fuel pre-filter. 4. Install the new fuel pre-filter and observe the flow direction (arrow). Fig. 128 BW 100 AD-5...

  • Page 160: Replacing The V-Belt

    10. Close the quick lock (2) so that is engages noticeably. 11. Screw in drain plug (3). 12. Dispose of fuel and fuel filter in an environ- mentally friendly manner. 8.9.2 Replacing the V-belt Perform this maintenance work at the latest after two years. BW 100 AD-5...

  • Page 161: Checking The Anti-Freeze Concentration And The Condition Of The Coolant

    4. Check the condition of the coolant. 5. Thoroughly flush the cooling system if the coolant is contaminated by corrosion resi- Ä Chapter dues or other suspended matter 8.11.2 „Changing the coolant“ on page 173. Fig. 132 6. Close the cover again. BW 100 AD-5...

  • Page 162: Checking The Hydraulic Lines

    (no detec- tion of identifications or cracks), shelf life and service life exceeded. 3. Replace damaged hydraulic hoses immedi- ately, fasten these properly and avoid chafing. 4. Only operate the machine after it has been repaired. BW 100 AD-5...

  • Page 163: Every 1000 Operating Hours

    Safety shoes Protective gloves Ä Chapter 6.7 1. Park the machine safely „Parking the machine in secured condi- tion“ on page 113. 2. Allow the engine to cool down. 3. Remove the valve cover. Fig. 133 BW 100 AD-5...
  • Page 164 6. Check the valve clearance on the valves marked black, adjust if necessary. Fig. 135 7. Install the cylinder head cover with a new seal. 8. After a short test run, check the engine for leaks. Fig. 136 Checking the valve clear- ance BW 100 AD-5...

  • Page 165: Checking The Engine Mounts

    6. Check condition and tight fit of engine pillow blocks. 8.10.3 Checking the ROPS All bolted connections must comply with the specifications and should be absolutely tight (observe the tightening torques). Screw and nuts must not be damaged, bent or deformed. BW 100 AD-5...

  • Page 166: Checking The Travel Control

    3. In case of malfunction perform trouble shooting and replace the corresponding parts. 4. Only operate the machine after it has been Fig. 138 repaired. 8.10.5 Replacing the hydraulic oil filter Perform this maintenance work at the latest after two years. BW 100 AD-5...
  • Page 167 Hydraulic oil filter Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Clean the area around the hydraulic oil filter. 2. Unscrew filter bowl (4) and take it off with filter element (3). B-880-0082 Fig. 139 BW 100 AD-5...
  • Page 168 2. Disconnect the hydraulic oil lines (1) from the high pressure filter (2). 3. Remove the high pressure filter and install the new high pressure filter while paying attention to the flow direction (arrow). B-880-0065 4. Connect and tighten the hydraulic lines. Fig. 140 BW 100 AD-5...
  • Page 169 1. After the test run, check the filters for leaks. 2. Check the hydraulic oil level, top up if nec- Ä Chapter 8.11.1 „Changing the essary. hydraulic oil“ on page 170 3. Dispose of the hydraulic oil and filter in line with environmental regulations. BW 100 AD-5...

  • Page 170: Every 2000 Operating Hours

    – Use only hydraulic oil of the per- Ä Chapter mitted specification 8.3.4 „Hydraulic oil“ on page 145. Ä Chapter 8.4 – Filling quantity: „List of fuels and lubri- cants“ on page 146. BW 100 AD-5...
  • Page 171 – Wear your personal protec- tive equipment (protective gloves, protective clothing). – Avoid touching hot compo- B-880-0182 nents. Fig. 142 Unscrew the drain plug and collect any hydraulic oil running out. 5. Screw the drain plug back in tightly. BW 100 AD-5...
  • Page 172 The breather filter for the hydraulic oil tank is integrated in the cap, you must therefore replace the complete cap. Close the tank with a new cap. 13. Dispose of hydraulic oil in line with environ- mental regulations. BW 100 AD-5...

  • Page 173: Changing The Coolant

    – Use only coolant of the permitted Ä Chapter 8.3.3 specification „Coolant“ on page 144. – Do not mix different coolants and additives of any other kind. Ä Chapter 8.4 – Filling quantity: „List of fuels and lubri- cants“ on page 146 BW 100 AD-5...
  • Page 174 12. Allow the engine to cool down to approx. 50 °C (122 °F). 13. Drain off all water. 14. If using a cleaning agent repeat the flushing process twice with clear water. 15. Reinstall the thermostat. BW 100 AD-5...

  • Page 175: Replacing Hoses

    8.11.3 Replacing hoses This work must only be performed by authorized service personnel. Perform this maintenance work at the latest after two years. The following hoses need to be renewed: fuel hoses, air intake hoses. BW 100 AD-5...

  • Page 176: Check The Injection Valves

    Maintenance – Every 2000 operating hours 8.11.4 Check the injection valves This work must only be performed by authorized service personnel. BW 100 AD-5...

  • Page 177: Every 3000 Operating Hours

    Maintenance – Every 3000 operating hours 8.12 Every 3000 operating hours 8.12.1 Checking the fuel injection pump This work must only be performed by authorized service personnel. BW 100 AD-5...

  • Page 178: As Required

    – If the air filter is damaged, the safety element must be replaced as well. – The safety element must not be cleaned. We generally recommend to renew the air filter. A new filter element is far less expensive than a possible engine damage. BW 100 AD-5...
  • Page 179 3. Loosen both locking hooks on the housing cover and take the cover off. 4. Clean housing cover and dust discharge valve. Fig. 150 5. Pull out the main filter element with light turning movements. Fig. 151 BW 100 AD-5...
  • Page 180 9. Slide the air filter carefully into the housing. NOTICE! Danger of engine damage! – The dust discharge valve must point vertically downwards. – Make sure that the cover locks engage correctly. Fig. 154 10. Reassemble the housing cover. BW 100 AD-5...
  • Page 181 1. Remove the housing cover and pull the air filter element off. 2. Pull the safety element out by turning it lightly. 3. Push in a new safety element. 4. Insert the air filter and reassemble the housing cover. Fig. 156 BW 100 AD-5...

  • Page 182: Checking The Water Spraying System

    – Always keep the water tank filled with a sufficient amount of water. B-880-0188 Fig. 157 Check the filling level on the water level gauge, fill up if necessary. 4. Turn the ignition key to position “I”. B-ELE-0070 Fig. 158 BW 100 AD-5...
  • Page 183 (1) for both drums. B-880-0070 Fig. 160 7. Turn the rotary switch for pressure spraying to “0” to switch the water spraying system off. 8. Turn the ignition key back to position “0” and pull it out. B-SWI-1493 Fig. 161 BW 100 AD-5...

  • Page 184: Cleaning The Water Spraying System

    Fig. 162 6. Open the drain cover on the water tank and let all water run out. 7. Flush the water tank out with a strong water jet. 8. Drain off all water and dirt. B-880-0067 Fig. 163 BW 100 AD-5...
  • Page 185 13. Switch off the water spraying system. B-880-0127 14. Turn the ignition key back to position “0” Fig. 165 and pull it out. 15. Reassemble the caps and nozzles on the spray tube. BW 100 AD-5...

  • Page 186: Measures If There Is A Risk Of Frost

    8. Switch on the water spraying system for a short while to drain the water from the pump. B-880-0069 9. Switch off the water spraying system. Fig. 168 10. Turn the ignition key back to position “0” and pull it out. BW 100 AD-5...
  • Page 187 12. Unscrew the caps (1) and all nozzles (2) from the spray tube and let the water run out. B-880-0127 Fig. 169 Before the next use 1. Reassemble the caps and nozzles on the spray tube. BW 100 AD-5...
  • Page 188 Maintenance – As required BW 100 AD-5...

  • Page 189: Setting Up / Refitting

    Setting up / refitting Setting up / refitting BW 100 AD-5...

  • Page 190: Manually Adjusting The Crabwalk

    „Parking the machine in secured condi- tion“ on page 113. 2. Slightly loosen the screws (1). Do not back out the screws too far. 3. Disengage the articulation lock (2) and fasten it in the holding fixture. B-880-0045 Fig. 170 BW 100 AD-5...
  • Page 191 5. Lift up the machine just above the ground. 6. Shift the rear frame to the desired position left or right. 7. Lower the machine to the ground. 650118 Fig. 171 8. Retighten screws (1). B-880-0072 Fig. 172 BW 100 AD-5...

  • Page 192: Edge Cutter - Installing Tool

    Ä Chapter 6.7 „Parking the machine in secured condition“ on page 113. 2. Mount the tool (2) using the star handle screw (1) on the edge cutter. Fig. 173 3. Mount the unused tool to the brackets (1). Fig. 174 BW 100 AD-5...

  • Page 193: Mounting / Removing The Chip Spreader

    Use lifting and lashing gear only in the pre- scribed direction of load application. Lifting tackle must not be damaged by compo- nents of the chip spreader. When lifting the machine, avoid uncontrolled movements of the load. If necessary, hold the load with guide ropes. BW 100 AD-5...

  • Page 194: Mounting The Chip Spreader

    4. Assemble the bolt (1) and secure it with the split pin (2). B-880-0135 Fig. 176 5. Connect the chip spreader hydraulically and electrically with the machine. B-880-0039 Fig. 177 BW 100 AD-5...

  • Page 195: Removing The Chip Spreader

    3. Empty the chip spreader. 4. Disconnect the chip spreader hydraulically and electrically from the machine. B-880-0039 Fig. 178 5. Fasten the lifting tackle at the lifting points (1). 6. Attach the chip spreader to the lifting tackle. B-880-0137 Fig. 179 BW 100 AD-5...
  • Page 196 – Do not step or stand under suspended loads. B-880-0135 Fig. 180 Lift the chip spreader and lift it carefully out of the fixing points on the machine. 9. Set the chip spreader safely down on level and firm ground. BW 100 AD-5...

  • Page 197: Troubleshooting

    Troubleshooting Troubleshooting BW 100 AD-5...

  • Page 198: Preliminary Remarks

    If you cannot locate the cause of a fault or rec- tify it yourself by following the trouble shooting chart, you should contact our customer service department. BW 100 AD-5...

  • Page 199: Starting The Engine With Jump Leads

    4. Once the engine is running switch on a powerful consumer (working light, etc.). 5. After starting disconnect the negative poles first and the positive poles after. 6. Switch off the consumer. BW 100 AD-5...

  • Page 200: Fuse Assignment

    Danger of injury by fire in the machine! – Do not use fuses with higher ampere ratings and do not bridge fuses. 10.3.2 Fuses in engine compartment Fig. 182 Pos. Fuse Amperage Designation 80 A Main battery fuse BW 100 AD-5...

  • Page 201: Central Electrics

    15 A Head lights, right 10 A Warning horn 10 A Potential 15 10 A Water pump 10 A Edge cutter 40 A Preheating system 10 A Potential 30 F103 10 A Potential 15 F119 10 A Engine BW 100 AD-5...
  • Page 202 F156 15 A Lighting F157 30 A Starter F241 15 A Optional headlights F274 10 A Chip spreader / hydraulic cutting tool F275 Economizer F276 10 A Emulsion pump Vibration also with travel lever in position “II” BW 100 AD-5...

  • Page 203: Engine Faults

    Check all line connections for separation during winter leaks and tighten the fittings, bleed the fuel system Use winter fuel in winter Engine oil with wrong SAE Change the engine oil viscosity class Air filter dirty Clean, replace if necessary BW 100 AD-5...
  • Page 204 Interior parts of radiator cor- Clean or replace the radiator roded Insufficient cooling air supply Remove any clogging from to the cooling fan the cooling air duct Fan, radiator or radiator cap Have examined by a spe- defective cialist BW 100 AD-5...
  • Page 205 The charge Generator speed too low Check the generator belt for control light tension, replace the belt if lights during necessary operation, the Generator or regulator defec- Have examined by a spe- warning tive cialist buzzer sounds BW 100 AD-5...

  • Page 206: Trouble Shooting Economizer

    “0” and then again to position “I”. Since this value is required for calculation the measuring If the LED (a) remains on, values, measuring operation inform our Customer Service is blocked. Department. BW 100 AD-5...
  • Page 207 On material which is too dry or moist, lower measuring values will be displayed. BW 100 AD-5...
  • Page 208 Troubleshooting – Trouble shooting ECONOMIZER BW 100 AD-5...

  • Page 209: Disposal

    Disposal Disposal BW 100 AD-5...

  • Page 210: Final Shut-Down Of Machine

    Safety goggles 1. Remove the batteries and dispose of in compliance with legal regulations. 2. Empty the fuel tank. 3. Drain the hydraulic oil tank. 4. Drain coolant from cooling system and engine. 5. Drain off engine oil. BW 100 AD-5...
  • Page 212 BOMA Equipment Hong Kong LTD BOMAG Italia Srl. FAYAT BOMAG Polska Sp. z.o.o. Room 1003, 10/F Charm Centre Via Roma 50 Ul. Szyszkowa 52 700, Castle Peak Road 48011 Alfonsine 02-285 Warzawa Kowloon, ITALY...

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