Fayat BOMAG BW 100 ADM-5 Operating Instruction
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Fayat BOMAG BW 100 ADM-5 Operating Instruction

Tandem vibratory roller
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Operating Instruction
Maintenance Instruction
Original Operating Instructions
BW 100 ADM-5
S/N 101 462 12 1553>
Tandem vibratory roller
008 206 66 EN
© 01/2021

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Summary of Contents for Fayat BOMAG BW 100 ADM-5

  • Page 1 Operating Instruction Maintenance Instruction Original Operating Instructions BW 100 ADM-5 S/N 101 462 12 1553> Tandem vibratory roller 008 206 66 EN © 01/2021...
  • Page 2 WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system.

  • Page 3: Table Of Contents

    Table of contents Table of contents Introduction.................... 9 1.1 Foreword..................10 1.2 Machine type plate and engine type plate......... 12 Technical data..................13 2.1 Noise and vibration data.............. 17 2.1.1 Noise data................... 17 2.1.2 Vibration data................17 Concerning your safety..............19 3.1 Basic prerequisites..............
  • Page 4 Table of contents 3.4.5 Safety regulations and environmental protection regulations for handling coolants................ 35 3.4.6 Safety regulations and environmental protection regulations for handling battery acid..............37 3.5 Loading/transporting the machine..........39 3.6 Starting up the machine.............. 41 3.6.1 Prior to commissioning..............41 3.6.2 Starting the engine..............
  • Page 5 Table of contents 4.1.3 Rotary switch for lighting............. 67 4.1.4 Rotary switch for hazard light system.......... 68 4.1.5 Rotary switch for flashing beacon..........68 4.1.6 Rotary switch for the hydraulic hammer........68 4.1.7 Rotary switch for drum pre-selection........... 69 4.1.8 Rotary switch for vibration pre-selection........69 4.1.9 Emergency stop switch...............
  • Page 6 Table of contents Operation....................97 6.1 Setting up the workplace............. 98 6.2 Electronic immobilizer..............99 6.3 Starting the engine..............100 6.4 Travel mode................103 6.4.1 Preliminary remarks and safety notes........103 6.4.2 Driving the machine..............104 6.4.3 Stopping the machine, applying the parking brake....105 6.5 Driving the machine in public traffic........
  • Page 7 Table of contents Maintenance..................139 8.1 Preliminary remarks and safety notes........140 8.2 Preparations/concluding work..........142 8.2.1 Engine hood................142 8.2.2 Maintenance flap............... 143 8.2.3 Articulation lock................. 143 8.3 Fuels and lubricants..............145 8.3.1 Engine oil................... 145 8.3.2 Fuel................... 146 8.3.3 Coolant..................
  • Page 8 Table of contents 8.10.2 Checking the engine mounts........... 172 8.10.3 Checking the travel lever control..........173 8.10.4 Checking the ROPS..............173 8.11 Every 2000 operating hours............ 174 8.11.1 Changing the hydraulic oil............174 8.11.2 Replacing the hydraulic oil filter..........177 8.11.3 Changing the coolant...............

  • Page 9: Introduction

    Introduction Introduction BW 100 ADM-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 Introduction – Foreword A description of all necessary maintenance work, maintenance intervals as well as informa- tion on fuels and lubricants can be found in the chapter “Maintenance” Ä Chapter 8 ‘Mainte- nance’ on page 139. Do not service or repair your machine by your- self to avoid harming persons or damaging material or environment.

  • Page 12: Machine Type Plate And Engine Type Plate

    Introduction – 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.

  • Page 13: Technical Data

    Technical data Technical data BW 100 ADM-5...
  • Page 14 Technical data Dimensions B-462-0005 Fig. 3 1483 1056 1627 2304 2194 1000 (58) (42) (17.0) (22.8) (64) (91) (10.0) (86) (1.1) (0.5) (39) Dimensions in millimetres (Dimensions in inches) Weights Max. operating weight 1900 (4189) (lbs) Operating weight 1700 (3748) (lbs) Average static linear load kg/cm...
  • Page 15 Technical data Travel characteristics Travel speed 0 - 10 km/h (mph) (0 - 6.2) Working speed with vibration 0 - 10 km/h (mph) (0 - 6.2) Max. gradeability without/with vibration (soil 40/30 and weather dependent) Drive Engine manufacturer Kubota Type D902 Cooling Water...
  • Page 16 Technical data Steering Type of steering Oscill.-articul. Steering operation hydrostatic Steering angle +/- 33 ° Oscillation angle +/- 8 ° Inner track radius 1980 (78.0) (in) Crabwalk, lateral offsetting of drum to the right/ 0 - 50 left (0 - 2.0) (in) Exciter system Vibrating drum...

  • Page 17: Noise And Vibration Data

    Technical data – Noise and vibration data Noise and vibration data The following noise and vibration data were determined in accordance with the following guidelines under equipment specific conditions and by using harmonized standards: EU Machine Directive edition 2006/42/EU Noise Emission Directive 2000/14/EU, Noise Protection Directive 2003/10/EU Vibration Protection Directive 2002/44/EU During operation these values may vary...
  • Page 18 Technical data – Noise and vibration data BW 100 ADM-5...

  • Page 19: Concerning Your Safety

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

  • Page 20: Basic Prerequisites

    Concerning your safety – Basic prerequisites Basic prerequisites 3.1.1 General This machine has been built in compliance with the latest technical standard and complies with the applicable regulations and technical rules. However, dangers for persons and property may arise from this machine, if: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel,...

  • Page 21: Explanation Of Signal Words Used

    Concerning your safety – Basic prerequisites 3.1.2 Explanation of signal words used: DANGER! Danger to life if failing to comply! Sections marked accordingly indi- cate an extremely dangerous situa- tion that could lead to fatal or severe injuries, if this warning is dis- regarded.

  • Page 22: Personal Protective Equipment

    Concerning your safety – Basic prerequisites Sections marked accordingly indi- cate technical information or notes on using the machine or its compo- nents. ENVIRONMENT! Environmental damage if failing to comply! Paragraphs marked accordingly indicate practices for safe and envi- ronment-friendly disposal of fuels and lubricants as well as replace- ment parts.

  • Page 23: Intended Use

    Concerning your safety – Basic prerequisites Face protection To protect the face against airborne par- ticles and squirting fluids. Hard hat To protect the head against falling parts and to protect against injuries. Hearing protection To protect hearing against excessive noise.

  • Page 24: Estimated Service Life Of The Machine

    Concerning your safety – Basic prerequisites Any hazard caused by improper use is the sole responsibility of the operating company or driver/operator; the manufacturer cannot be held liable. Examples of improper use are: Work with vibration on hard concrete, cured bitumen layers or extremely frozen ground cleaning the drums while driving or changing nozzles during travel...

  • Page 25: Definition Of Responsible Persons

    Concerning your safety – Definition of responsible persons Definition of responsible persons 3.2.1 Operating company The operating company is the natural or jurid- ical person who uses the machine or in who's name the machine is used. The operating company must make sure that the machine is only used for the purpose it is intended for and in strict compliance with the safety regulations mentioned in these operating...

  • Page 26: Driver / Operator

    Concerning your safety – Definition of responsible persons This person is acquainted with the applicable governmental industrial safety regulations, accident prevention instructions, guidelines and generally acknowledged technical rules and regulations (standards, directives, technical rules of other member states of the European Union or other contractual states concerning the agreement about the European Economic Area) in as far as is necessary to be able to...

  • Page 27: Fundamentals For Safe Operation

    Concerning your safety – Fundamentals for safe operation Fundamentals for safe operation 3.3.1 Remaining dangers, remaining risks Despite careful work and compliance with standards and regulations it cannot be ruled out that further dangers may arise when working with and handling the machine. Both the machine as well as all other system components comply with the currently valid safety regulations.

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

    Concerning your safety – Fundamentals for safe operation We wish to make explicitly clear that we have not tested or approved any parts or accesso- ries not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive safety.

  • Page 29: Handling Fuels And Lubricants

    Concerning your safety – Handling fuels and lubricants Handling fuels and lubricants 3.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the indi- vidual fuels and lubricants. Safety data sheets provide valuable informa- tion about the following characteristics: name of substance...

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

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.2 tions for handling diesel fuel WARNING! Danger of burning by ignited diesel fuel! – Do not allow diesel fuel to come into contact with hot compo- nents.
  • Page 31 Concerning your safety – Handling fuels and lubricants – 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 ADM-5...

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

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.3 tions for handling oil WARNING! Danger of burning by ignited oil! – Do not allow oil to come into con- tact with hot components. – Smoking and open fire is pro- hibited! –...

  • Page 33: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic Oil

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.4 tions for handling hydraulic oil WARNING! Danger of injury caused by escaping pressure fluid! – Always depressurize the hydraulic system before starting work in the hydraulic system. –...
  • Page 34 Concerning your safety – Handling fuels and lubricants CAUTION! Danger of slipping on spilled oil! – Immediately bind spilled oil with an oil-binding agent. ENVIRONMENT! Oil is an environmentally haz- ardous substance! – Always keep oil in proper con- tainers. –...

  • Page 35: Safety Regulations And Environmental Protection Regulations For Handling Coolants

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.5 tions for handling coolants WARNING! Danger of scalding by hot fluid! – Open the compensation tank only when the engine is cold. – Wear your personal protective equipment (protective gloves, protective clothing, goggles).
  • Page 36 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 ADM-5...

  • Page 37: Safety Regulations And Environmental Protection Regulations For Handling Battery Acid

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.6 tions for handling battery acid WARNING! Danger of cauterization with acid! – Wear your personal protective equipment (protective gloves, protective clothing, goggles). – Do not allow clothes, skin or eyes to come into contact with acid.
  • Page 38 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 ADM-5...

  • Page 39: Loading/Transporting The Machine

    Concerning your safety – Loading/transporting the machine Loading/transporting the machine Use only stable loading ramps of sufficient load bearing capacity. Loading ramps and transport vehicle must be free of grease, oil, snow and ice. The ramp inclination must be less than the gra- deability of the machine.
  • Page 40 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 ADM-5...

  • Page 41: Starting Up The Machine

    Concerning your safety – Starting up the machine Starting up the machine 3.6.1 Prior to commissioning Only use machines which have been serviced at regular intervals. Become acquainted with the equipment, the indicators and control elements, the working principle of the machine and the working area. Use your personal protective equipment (hard hat, safety boots, if necessary also goggles and ear protection).

  • Page 42: Starting The Engine

    Concerning your safety – Starting up the machine If the tests reveal damage or other defects, the machine must not be operated until these have been rectified. Do not operate the machine with defective indi- cators and control elements. 3.6.2 Starting the engine The machine must only be started and oper- ated from the driver’s seat.
  • Page 43 Concerning your safety – Starting up the machine Do not start the engine by shorting the electric terminals on the starter motor, because the machine may start to drive immediately. BW 100 ADM-5...

  • Page 44: Driving The Machine; Working Operation

    Concerning your safety – Driving the machine; working operation Driving the machine; working operation 3.7.1 Driving the machine Always wear the seat belt when driving. Only drive on load-bearing surfaces. Do not drive on ice and snow. Before driving in public traffic, disassemble the tool from the edge cutter (optional equipment).

  • Page 45: Driving Up And Down Slopes

    Concerning your safety – Driving the machine; working operation Always keep a sufficient distance when passing through subways, under bridges, tun- nels, electric power lines etc. Do not drive with the attached hydraulic hammer (optional equipment). Do not operate the rotary switch for the hydraulic hammer (optional equipment) while driving.

  • Page 46: Working With Vibration

    Concerning your safety – Driving the machine; working operation Driving across slopes should therefore be strictly avoided, because of the high risk of tip- ping over and the related risk of severe or even fatal accidents. For rollers with a drum width of 1 meter or less there is a considerable risk of tipping over near edges (e.g.
  • Page 47 Concerning your safety – Driving the machine; working operation 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 ADM-5...

  • Page 48: Refuelling

    Concerning your safety – Refuelling Refuelling Do not inhale any fuel fumes. Refuel only with the engine shut down. Do not refuel in closed rooms. No open fire, do not smoke. Static charges may be generated in the fuel as it passes through the filling system.

  • Page 49: Emergency Procedures

    Concerning your safety – Emergency procedures Emergency procedures 3.9.1 Actuating the emergency stop switch In events of emergency and in case of danger actuate the emergency stop switch immedi- ately. The machine is braked immediately, the engine is shut down. Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.
  • Page 50 Concerning your safety – Emergency procedures 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.

  • Page 51: Maintenance Work

    Concerning your safety – Maintenance work 3.10 Maintenance work 3.10.1 Preliminary remarks Always carry out the prescribed maintenance work and maintenance measures on time in order to maintain the safety, operational readi- ness and long service life of the machine. The machine must only be serviced by quali- fied personnel authorised by the operating company.

  • Page 52: Working On The Engine

    Concerning your safety – Maintenance work Hydraulic hoses must be visually inspected at regular intervals. Do not mix up hoses by mistake. Only genuine replacement hydraulic hoses ensure that the correct hose type (pressure range) is used at the right location. 3.10.3 Working on the engine Do not work on the fuel system while the engine is running - danger to life due to high...

  • Page 53: Maintenance Work On Electric Components And Battery

    Concerning your safety – Maintenance work 3.10.4 Maintenance work on electric components and battery Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material. Do not use fuses with higher ampere ratings and do not bridge fuses.

  • Page 54: Measures For Longer Shut-Down Periods

    Concerning your safety – Maintenance work 3.10.6 Measures for longer shut-down periods If the machine is taken out of operation for a longer period of time, various conditions must be met and maintenance work must be carried out both before and after shut-down Ä...

  • Page 55: Repair

    Concerning your safety – Repair 3.11 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 ADM-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 ADM-5...
  • Page 57 Concerning your safety – Signage WARNING California Proposition 65 Warning This product contains chemicals that cause cancer + chemicals that are reproductive toxicants B-462-0013 Fig. 10 BW 100 ADM-5...
  • Page 58 Concerning your safety – Signage Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) Nm 50-80 ft.lb. 37-60 8 kg ~ 80 Nm 17 kg ~ 50 Nm Hydraulic Oil B-462-0014 Fig. 11 Warning sticker - Danger of tipping over B-DEC-0206 Fig.
  • 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 Warning sticker – California Proposition 65 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer + chemicals that are reproductive toxicants...
  • Page 60 Concerning your safety – Signage Prohibition sticker - High pressure cleaning Fig. 17 Instruction sticker - Always wear your seat belt Fig. 18 Information sticker - Lifting point Fig. 19 Information sticker - Lashing point Fig. 20 BW 100 ADM-5...
  • Page 61 Concerning your safety – Signage Information sticker - Filler opening for hydraulic Hydraulic Oil B-DEC-0214 Fig. 21 Information sticker - Engine oil drain B-DEC-0211 Fig. 22 Information sticker - Disconnecting the battery B-DEC-0219 Fig. 23 Information sticker - Ultra-low sulphur fuel Fig.
  • Page 62 Concerning your safety – Signage Information sticker - Guaranteed sound capacity level Fig. 25 Information sticker - Low ash engine oil Fig. 26 Information sticker - Coolant Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) B-DEC-0221 Fig.
  • Page 63 Concerning your safety – Signage Operation sticker - Throttle lever B-DEC-0236 Fig. 29 Information sticker -for the operation of the foldable ROPS Nm 50-80 ft.lb. 37-60 8 kg ~ 80 Nm 17 kg ~ 50 Nm B-DEC-0007 Fig. 30 Machine type plate (example) Fig.

  • Page 64: Danger Zones

    Concerning your safety – Danger zones 3.13 Danger zones B-880-0243 Fig. 32 The area around the machine is a danger zone. Before starting the machine and during opera- tion, the driver / operator must ensure that nobody is in the danger zone. Give warning signals, if necessary.

  • Page 65: Indicators And Control Elements

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

  • Page 66: Operating Console

    Indicators and control elements – Operating console Operating console B-462-0006 Fig. 33: Overview of operating console 1 Rotary switch for direction indicators (optional equipment) 2 Rotary switch for working lights 3 Rotary switch for lighting (optional equipment) 4 Rotary switch for 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...

  • Page 67: Rotary Switch For Direction Indicators

    Indicators and control elements – Operating console 4.1.1 Rotary switch for direction indicators Position Direction indicators off “Middle” Position “left or Front and rear direction indi- right” cators on the corresponding side are flashing Optional equipment Fig. 34 4.1.2 Rotary switch for working lights Position "Left"...

  • Page 68: Rotary Switch For Hazard Light System

    Indicators and control elements – Operating console 4.1.4 Rotary switch for hazard light system Position "Left" Hazard light system off Position "Right" Hazard light system on Optional equipment Fig. 37 4.1.5 Rotary switch for flashing beacon Position “Left” Flashing beacon off Position “Right”...

  • Page 69: Rotary Switch For Drum Pre-Selection

    Indicators and control elements – Operating console 4.1.7 Rotary switch for drum pre-selection 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- vated, if the vibration has been B-SWI-1488 switched off beforehand.

  • Page 70: Emergency Stop Switch

    Indicators and control elements – Operating console 4.1.9 Emergency stop switch press In events of emergency and in case of danger actuate the emergency stop switch immediately by pressing it fully down. It automatically locks in end position. The machine will be braked immediately.

  • Page 71: Instrument Cluster

    Indicators and control elements – Operating console 4.1.10 Instrument cluster 1/ 2 3/ 4 1/ 4 100 120 140 160 °C 140 176 212 248 284 320 °F B-DIS-0516 Fig. 43 1 Control and warning lights 2 Fuel level indicator (optional equipment) 3 Display field 4 [F1] button (not assigned) 5 [F2] button...
  • Page 72 Indicators and control elements – Operating console Designation Note Engine oil pressure Lights up if the engine oil pressure is too low. warning light Warning buzzer sounds. The engine will be shut down after a short while. Check the engine oil level; if necessary, repair the engine.

  • Page 73: Economizer Display

    Indicators and control elements – Operating console 4.1.11 ECONOMIZER display The ECONOMIZER shows the compaction status of the road substructure or the asphalt layer. Description of display possibilities Ä Chapter 6.6.6 ‘ECONOMIZER’ on page 111. Optional equipment Fig. 45 4.1.12 Rotary switch for seat heating Position “left”...

  • Page 74: Driver's Stand

    Indicators and control elements – Driver’s stand Driver’s stand 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 BW 100 ADM-5...

  • Page 75: Starter Switch

    Indicators and control elements – Driver’s stand 4.2.1 Starter switch Position "P"/"0" Ignition off Ignition key can be removed Position "I" Ignition on All control and warning lamps light up for a moment (test function). Position "II" Under low temperatures the Fig.

  • Page 76: Travel Lever

    Indicators and control elements – Driver’s stand 4.2.3 Travel lever B-ELE-0261 Fig. 51 On machines with double travel lever (optional equipment), the two travel levers are mechanically con- nected to each other. Function Note Shift forward Forward travel Position I: up to approx. 5 km/h (3 mph) Position II: up to approx.
  • Page 77 Indicators and control elements – Driver’s stand 4.2.3.1 Push button assignment on travel lever The push button assignment depends on the machine’s equip- ment. B-ELE-0303 Vibration on/off Warning horn Lift edge cutter on right hand side (optional equipment) Lower edge cutter on right hand side (optional equipment) BW 100 ADM-5...

  • Page 78: Driver's Seat

    Indicators and control elements – Driver’s stand 4.2.4 Driver’s seat B-SEA-0023 Fig. 52 Pos. Control element Setting Description Driver’s weight Press down the handle 50 kg until the correct driver’s weight has been set. 130 kg Press down the handle against the end stop, the weight adjustment automatically switches...

  • Page 79: Throttle Lever

    Indicators and control elements – Driver’s stand 4.2.5 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. 53 BW 100 ADM-5...

  • Page 80: Outside Of Machine

    Indicators and control elements – Outside of machine Outside of machine 4.3.1 Water level gauge To check the filling level of the water spraying system. B-462-0022 Fig. 54 4.3.2 Fuel level gauge For checking the filling level of the fuel tank. B-462-0023 Fig.

  • Page 81: Warning Indicator For Seat Belt

    Indicators and control elements – Outside of machine 4.3.4 Warning indicator for seat belt Seat belt fastened Warning indicator for seat belt on Seat belt not fas- Warning indicator for tened seat belt off Optional equipment B-880-0222 Fig. 57 BW 100 ADM-5...
  • Page 82 Indicators and control elements – Outside of machine BW 100 ADM-5...

  • Page 83: Checks Prior To Start Up

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

  • Page 84: Notes On Safety

    Checks prior to start up – Notes on safety Notes on safety If the following tests reveal damages or other defects, the machine must not be operated, until these deficiencies have been corrected. Do not operate the machine with defective indi- cators and control elements.
  • Page 85 Checks prior to start up – Notes on safety Open and secure the engine hood Ä Chapter 8.2.1.1 ‘Open and secure the engine hood’ on page 142. Close the engine hood again after work is com- pleted. BW 100 ADM-5...

  • Page 86: Visual Inspections And Function Tests

    Checks prior to start up – Visual inspections and function tests Visual inspections and function tests 1. Check the hydraulic oil tank and lines for condition and leaks. 2. Check the fuel tank and lines for condition and leaks. 3. Check the cooling system for contamina- tion, damage and leaks.

  • Page 87: Daily Maintenance

    Checks prior to start up – Daily maintenance Daily maintenance 5.3.1 Checking the engine oil level NOTICE! Danger of engine damage! – If the engine is warm, shut it down and check the oil level after five minutes. With a cold engine the oil level can be checked immediately.

  • Page 88: Checking The Fuel Level; Topping Up Fuel

    Checks prior to start up – Daily maintenance 5.3.2 Checking the fuel level; topping up fuel 5.3.2.1 Checking the fuel level Fuel level gauge 1. Check the filling level on the fuel gauge. B-462-0023 Fig. 59 Instrument cluster 2. Check the filling level at the fuel level indi- 1/ 2 cator (optional equipment) in the instru- ment cluster.
  • Page 89 Checks prior to start up – Daily maintenance 5.3.2.2 Refuelling NOTICE! Danger of engine damage! – Never run the fuel tank empty, as otherwise the fuel system needs to be bled. – Monitor the entire refuelling process. – Contaminated fuel can cause malfunction or even damage of the engine.

  • Page 90: Checking The Hydraulic Oil Level

    Checks prior to start up – Daily maintenance 5.3.3 Checking the hydraulic oil level NOTICE! Components may get damaged! – Check the hydraulic oil level at room temperature (approx. 20 °C (68 °F)). – If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components...

  • Page 91: Checking The Coolant Level

    Checks prior to start up – Daily maintenance 5.3.4 Checking the coolant level NOTICE! Danger of engine damage! – If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks. –...

  • Page 92: Checking The Air Filter

    Checks prior to start up – Daily maintenance 5.3.5 Checking the air filter Protective equip- Working clothes ment: Safety shoes Protective gloves 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...
  • Page 93 Checks prior to start up – Daily maintenance 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 gauge, fill up if necessary. B-462-0022 Fig.

  • Page 94: Checking And Cleaning The Scrapers

    Checks prior to start up – Daily maintenance 5.3.7 Checking and cleaning the scrapers Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Check the condition of the scrapers (1) on both drums, clean if necessary. 2. Replace worn scrapers. B-880-0056 Fig.
  • Page 95 Checks prior to start up – Daily maintenance 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-ELE-0263 Fig.
  • Page 96 Checks prior to start up – Daily maintenance NOTICE! Danger of engine damage! – Do not shut down the engine all of a sudden from full load speed, but let it idle for about two minutes. B-ELE-0069 Turn the ignition key to position “0”. Fig.

  • Page 97: Operation

    Operation Operation BW 100 ADM-5...

  • Page 98: Setting Up The Workplace

    Operation – Setting up the workplace Setting up the workplace 1. Park the machine safely Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117. 2. If necessary, adjust the driver's seat Ä Chapter 4.2.4 ‘Driver’s seat’ on page 78. BW 100 ADM-5...

  • Page 99: Electronic Immobilizer

    Operation – Electronic immobilizer Electronic immobilizer Optional equipment Before starting the engine the anti-theft protec- tion* must be disarmed by entering a code. With the electronic immobilizer armed, the light emitting diode (a) flashes slowly. 1. Slowly enter the six-digit user code. ð...

  • Page 100: Starting The Engine

    Operation – Starting the engine Starting the engine WARNING! Loss of hearing caused by too high noise burdens! – Wear your personal protective equipment (ear protection). Protective equip- Hearing protection ment: Prerequisites: Main battery switch (if present) switched on Emergency stop switch is unlocked Travel lever in parking brake position When closing the dashboard cover, the emergency stop switch will lock...
  • Page 101 Operation – Starting the engine 2. Turn the ignition key to position “I”. ð All control and warning lights in the instrument cluster light up for a moment. B-ELE-0070 Fig. 74 3. With cold ambient temperatures hold the ignition key up to 10 seconds in position “II”.
  • Page 102 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 ADM-5...

  • Page 103: Travel Mode

    Operation – Travel mode Travel mode 6.4.1 Preliminary remarks and safety notes Before starting to drive make sure that the driving area is absolutely safe. DANGER! Danger to life caused by the machine turning over! – Never drive across a slope. –...

  • Page 104: Driving The Machine

    Operation – Travel mode 6.4.2 Driving the machine 1. Fasten your seat belt. 2. If necessary, set the rotary switch for the hydraulic hammer (optional equipment) to the "Left" position. B-SWI-0695 Fig. 78 3. Set the throttle lever to position “MAX I” or “MAX II”.

  • Page 105: Stopping The Machine, Applying The Parking Brake

    Operation – Travel mode 6.4.3 Stopping the machine, applying the parking brake 1. 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.

  • Page 106: Driving The Machine In Public Traffic

    Operation – Driving the machine in public traffic Driving the machine in public traffic The machine must be equipped for driving in public traffic. Driving in public traffic is not permitted without additional equipment (e.g. lighting, first aid kit, warning triangle). Observe national regulations! 1.
  • Page 107 Operation – Driving the machine in public traffic 7. Set the throttle lever to position “MAX I”. B-880-0160 Fig. 84 8. Before starting to drive make sure that the driving area is absolutely safe. 9. Disengage the travel lever to the left out of parking brake position and move it slowly to the required travel direction.

  • Page 108: Working With Vibration

    Operation – Working with vibration Working with vibration 6.6.1 Preliminary remarks and safety notes NOTICE! Possible damage to neigh- bouring buildings! – When compacting with vibration you must always check the effect of the vibration on nearby build- ings and underground supply lines (gas, water, sewage, elec- tric power).

  • Page 109: Preparing To Work With Vibration

    Operation – Working with vibration 6.6.2 Preparing to work with vibration 1. Use the rotary switch for drum pre-selec- tion to pre-select the desired drum(s). Drum pre-selection is only acti- vated, if the vibration has been switched off beforehand. B-SWI-1488 Fig.

  • Page 110: Vibration In Automatic Mode

    Operation – Working with vibration NOTICE! Vibration at standstill causes transverse marks! – Do not switch on vibration with the machine at stand- still. B-ELE-0264 Shift the travel lever slowly in the desired Fig. 89 travel direction. 3. Press the travel lever push button on the left or right.

  • Page 111: Stop Working With Vibration

    Operation – Working with vibration 6.6.5 Stop working with vibration 1. Switch the vibration off. 2. Turn the rotary switch for vibration pre- selection to position “Middle”. B-SWI-1485 Fig. 92 6.6.6 ECONOMIZER The ECONOMIZER continuously informs the driver about the compaction status of the road subbase or the asphalt layer and enables the detection and selected re-compaction of weak spots.
  • Page 112 Operation – Working with vibration Measuring operation With the vibration switched on, the measuring value is displayed by the LED display (1-10). If the display value does not increase any fur- ther, no further compaction can be achieved with this machine. The maximum display value (10) is not always reached.
  • Page 113 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 ADM-5...

  • Page 114: Water Spraying System

    Operation – Water spraying system Water spraying system 1. Set the rotary switch for the water spraying system to the desired spraying interval. 2. Disengage the travel lever from parking brake position. ð Spraying will only become active after the travel lever is actuated in travel direction, or after the rotary switch for B-SWI-1765 the water spraying system has been set...

  • Page 115: Ecostop

    Operation – ECOSTOP ECOSTOP Optional equipment In order to reduce the idle speed times of the machine, the engine is, under certain condi- tions, automatically shut down after an idle time of 10 minutes. B-SYM-0139 Prerequisites for automatic shut-down of the Fig.
  • Page 116 Operation – ECOSTOP Starting the engine after ECOSTOP 1. Turn the ignition key to position “0”. 2. Start the engine Ä Chapter 6.3 ‘Starting the engine’ on page 100. B-ELE-0069 Fig. 97 BW 100 ADM-5...

  • Page 117: Parking The Machine In Secured Condition

    Operation – Parking the machine in secured condition Parking the machine in secured condition 1. Drive the machine onto level, firm ground. 2. 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.
  • Page 118 Operation – Parking the machine in secured condition 5. Turn the main battery switch (if present) anticlockwise and pull it out. B-SWI-0079 Fig. 102 BW 100 ADM-5...

  • Page 119: Lifting / Lowering The Edge Cutter

    Operation – Lifting / lowering the edge cutter 6.10 Lifting / lowering the edge cutter Optional equipment WARNING! Danger of crushing when low- ering the edge cutter! – Make sure that no persons are in the danger area. 1. Press the bottom push button on the right travel lever.

  • Page 120: Connecting/Disconnecting The Hydraulic Hammer

    Operation – Connecting/disconnecting the hydraulic hammer 6.11 Connecting/disconnecting the hydraulic hammer Optional equipment Connecting the hydraulic breaker 1. To stop the machine, you must return the travel lever to “middle” position and engage it to the right into parking brake position. B-ELE-0263 Fig.
  • Page 121 Operation – Connecting/disconnecting the hydraulic hammer 4. Connect the hydraulic breaker to the cou- plings. 5. Start the engine Ä Chapter 6.3 ‘Starting the engine’ on page 100. B-462-0033 Fig. 107 6. Turn the rotary switch for hydraulic hammer to the “Right” position. B-SWI-0696 Fig.
  • Page 122 Operation – Connecting/disconnecting the hydraulic hammer Disconnecting the hydraulic hammer 8. Shift the throttle lever to position “MIN” (idle speed). B-880-0159 Fig. 110 9. Turn the rotary switch for hydraulic hammer to the “Left” position. B-SWI-0695 Fig. 111 NOTICE! Danger of engine damage! –...

  • Page 123: Emergency Procedures

    Operation – Emergency procedures 6.12 Emergency procedures 6.12.1 Actuating the emergency stop switch 1. In events of emergency and in case of danger actuate the emergency stop switch immediately. ð The engine is shut down and the parking brake is closed. Fig.

  • Page 124: Towing The Machine

    Operation – Emergency procedures Main battery switch (optional equipment) 4. Turn the main battery switch anticlockwise and pull it out. B-SWI-0079 Fig. 115 6.12.3 Towing the machine 6.12.3.1 Preliminary remarks and safety notes Tow the machine only in case of emergency or to prevent an accident.
  • Page 125 Operation – Emergency procedures 6.12.3.2 Towing the machine Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Shut down the engine. 2. Fold the front or rear cover up. 3. Fasten the tow bar to the towing eye. WARNING! Danger of injury caused by uncontrolled machine movement! –...
  • Page 126 Operation – Emergency procedures 7. Screw both plugs back in, tightening torque: 50 Nm (37 ft·lbf). 8. Also release the brake on the second drum. ð The machine can now be towed. B-880-0014 Fig. 119 6.12.3.3 After towing Protective equip- Working clothes ment: Safety shoes...
  • Page 127 Operation – Emergency procedures 3. Completely release both screws to close the brake. Fig. 121 4. Screw both plugs back in, tightening torque: 50 Nm (37 ft·lbf). 5. Close also the brake on the second drum. B-880-0014 Fig. 122 BW 100 ADM-5...
  • Page 128 Operation – Emergency procedures BW 100 ADM-5...

  • Page 129: Loading / Transporting The Machine

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

  • Page 130: Preparation For Transport

    Loading / transporting the machine – Preparation for transport Preparation for transport 1. If necessary, dismantle the tool (pressure roller, cutting wheel) on the edge cutter (optional equipment) and remove the star handle screw Ä Chapter 9.2 ‘Edge cutter - mounting and removing tools’...

  • Page 131: Loading The Machine

    Loading / transporting the machine – Loading the machine Loading the machine Use only stable loading ramps of sufficient load bearing capacity. Loading ramps and transport vehicle must be free of grease, oil, snow and ice. The ramp inclination must be less than the gra- deability of the machine.

  • Page 132: Lashing The Machine To The Transport Vehicle

    Loading / transporting the machine – Lashing the machine to the transport vehicle Lashing the machine to the transport vehicle Do not use lashing points that are damaged or impaired in any way. Always use appropriate lashing tackle at the lashing points.

  • Page 133: Loading By Crane

    Loading / transporting the machine – Loading by crane Loading by crane Loads must only be attached and hoisted by an expert / capable person. Do not use damaged or in any other way impaired lashing points. Use only lifting gear and lifting tackle with suffi- cient load bearing capacity for the weight to be loaded.
  • Page 134 Loading / transporting the machine – Loading by crane 4. Swing the central lifting point up and fasten the lashing tackle. DANGER! Danger to life caused by sus- pended loads! – Do not step or stand under B-880-0261 suspended loads. Fig.

  • Page 135: After Transportation

    Loading / transporting the machine – After transportation After transportation 1. If necessary, erect the foldable ROPS back 2. Loosen the articulation lock Ä Chapter 8.2.3.2 ‘Disengaging the articulation lock’ on page 144. 3. Fasten your seat belt. 4. Set the throttle lever to position “MAX I”. DANGER! Danger to life caused by the machine slipping or turning over!

  • Page 136: Folding Down And Erecting The Foldable Rops

    Loading / transporting the machine – Folding down and erecting the foldable ROPS Folding down and erecting the foldable ROPS The transport height of the machine can be reduced by folding down the foldable ROPS. 7.6.1 Folding down the foldable ROPS Protective equip- Working clothes ment:...

  • Page 137: Erecting The Foldable Rops

    Loading / transporting the machine – Folding down and erecting the foldable ROPS 3. Fold the foldable ROPS back. B-462-0041 Fig. 129 7.6.2 Erecting the foldable ROPS Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Erect the clamping plates on both sides vertically.
  • Page 138 Loading / transporting the machine – Folding down and erecting the foldable ROPS CAUTION! Danger of crushing when erecting the foldable ROPS! – Do not reach with your hands into the slewing area of the foldable ROPS. Fold up the foldable ROPS. B-462-0042 Fig.

  • Page 139: Maintenance

    Maintenance Maintenance BW 100 ADM-5...

  • Page 140: Preliminary Remarks And Safety Notes

    Maintenance – Preliminary remarks and safety notes 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 Ä...
  • Page 141 Maintenance – Preliminary remarks and safety notes Make sure that the engine cannot be acciden- tally started during maintenance work. Do not touch hot components. Thoroughly clean the 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.

  • Page 142: Preparations/Concluding Work

    Maintenance – Preparations/concluding work Preparations/concluding work Certain maintenance tasks require prepara- tions and concluding activities. This includes e.g. opening and closing mainte- nance flaps and maintenance doors as well as securing certain components. After this work close all maintenance flaps and doors again and return all components to their operating condition.

  • Page 143: Maintenance Flap

    Maintenance – Preparations/concluding work 8.2.2 Maintenance flap 8.2.2.1 Opening the maintenance flap 1. Remove the bottle holder. 2. Swing the maintenance flap upwards by the handle. B-462-0051 Fig. 136 8.2.2.2 Closing the maintenance flap 1. Swing the maintenance flap downwards by the handle.
  • Page 144 Maintenance – Preparations/concluding work WARNING! Danger of crushing by the articulating machine! – Do not step into the articula- tion area of the machine while the engine is running. B-880-0262 Swing the articulation lock up and secure it Fig. 138 with screws.

  • Page 145: Fuels And Lubricants

    Maintenance – Fuels and lubricants Fuels and lubricants 8.3.1 Engine oil 8.3.1.1 Oil quality The following engine oil specifications are per- mitted: Engine oils as per API-classification CF, CF-4, CG-4, CH-4 and CI-4 For operation of an engine with high sulphur fuels we recommended to use an engine oil of API-classification CF or higher with a total base number of at least 10.

  • Page 146: Fuel

    Maintenance – Fuels and lubricants Ambient temperature Oil viscosity higher than 25 °C SAE 30 (77 °F) SAE 10W-30 SAE 15W-40 -10 °C to 25 °C (14 °F SAE 10W-30 to 77 °F) SAE 15W-40 below - 10 °C (14 °F) SAE 10W-30 8.3.1.3 Oil change intervals...
  • Page 147 Maintenance – Fuels and lubricants (EPA: United States Environmental Protection Agency) The recommended Cetan index number is 45. A Cetan index number higher than 50 should preferably be used, especially at ambient tem- peratures below -20 °C (-4 °F) and when working at altitudes of more than 1500 m (4921 ft).

  • Page 148: Coolant

    Maintenance – Fuels and lubricants Zinc and lead coatings in refuelling systems and fuel lines are not permitted. Copper containing materials (copper lines, brass items) should be avoided, because they can cause catalytic reactions in the fuel with subsequent depositing in the injection system. 8.3.3 Coolant Always use a mixture of anti-freeze agent and...

  • Page 149: Hydraulic Oil

    Maintenance – Fuels and lubricants Add anti-freeze agent: If the coolant level drops because of evapo- ration,only clean water is to be used for top- ping up. In case of leakages you must always fill in anti-freeze agents of the same brand and the same mixing ratio.
  • Page 150 Maintenance – Fuels and lubricants 8.3.4.2 Bio-degradable hydraulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil. The biodegradable hydraulic oil Panolin HLP Synth. 46 or Plantohyd 46 S meets all the requirements of a mineral oil based hydraulic oil according to DIN 51524.

  • Page 151: List Of Fuels And Lubricants

    Maintenance – List of fuels and lubricants List of fuels and lubricants Assembly Fuel or lubricant Spare Filling group parts quantity number Summer Winter Observe the level mark! Engine oil SAE 10W-40 009 920 06 3.9 l Specification: 20 l (1.0 gal us) Ä...

  • Page 152: Running-In Instructions

    Maintenance – Running-in instructions Running-in instructions 8.5.1 General The following maintenance work must be per- formed when running in new machines or over- hauled engines. NOTICE! Danger of engine damage! – Up to approx. 250 operating hours check the engine oil level twice every day.

  • Page 153: Maintenance Table

    Maintenance – Maintenance Table Maintenance Table Maintenance works Page Daily maintenance 5.3.1 Checking the engine oil level 5.3.2 Checking the fuel level; topping up fuel 5.3.3 Checking the hydraulic oil level 5.3.4 Checking the coolant level 5.3.5 Checking the air filter 5.3.6 Checking the water level, topping up 5.3.7...
  • Page 154 Maintenance – Maintenance Table Maintenance works Page 8.10.2 Checking the engine mounts 8.10.3 Checking the travel lever control 8.10.4 Checking the ROPS Every 2000 operating hours 8.11.1 Changing the hydraulic oil 8.11.2 Replacing the hydraulic oil filter 8.11.3 Changing the coolant 8.11.4 Replacing hoses 8.11.5...

  • Page 155: Every 50 Operating Hours

    Maintenance – Every 50 operating hours Every 50 operating hours 8.7.1 Checking radiator hoses and hose clamps Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117. 2.
  • Page 156 Maintenance – Every 50 operating hours Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine safely Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117. 2. Place the transparent container under the drain plug. 3.

  • Page 157: Every 250 Operating Hours

    Maintenance – Every 250 operating hours Every 250 operating hours 8.8.1 Change engine oil and oil filter cartridge Perform this maintenance work at the latest after one year. WARNING! Danger of burning on hot compo- nents! – Wear your personal protective equipment (protective gloves, protective clothing).
  • Page 158 Maintenance – Every 250 operating hours Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine safely Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117. 2. Unscrew the cover. B-462-0048 Fig. 141 3. Unscrew the drain plug and collect any oil running out.

  • Page 159: Checking, Tensioning The V-Belt

    Maintenance – Every 250 operating hours 10. Fill with new engine oil. 11. After a short test run check the oil level on the oil dipstick, if necessary top up to the “MAX” mark. 12. Check the oil filter cartridge and drain plug for leaks.

  • Page 160: Check The Air Intake Lines

    Maintenance – Every 250 operating hours 8.8.2.2 Tightening the V-belt Protective equip- Working clothes ment: Protective gloves 1. Loosen the tensioning screw (1) and the screw (2) on the generator. 2. Press the generator towards the outside using a lever, until the correct V-belt ten- sion is reached.

  • Page 161: Cleaning The Radiator Module

    Maintenance – Every 250 operating hours 3. Check the condition and tight fit of all radi- ator hoses and hose clamps. 4. If a radiator hose is swollen, hardened or cracked, both hose and hose clamp must be replaced immediately. 8.8.5 Cleaning the radiator module NOTICE!
  • Page 162 Maintenance – Every 250 operating hours Cleaning with com- Protective equip- Working clothes pressed air ment: Protective gloves Safety goggles CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protec- tive working clothes, goggles). 1.

  • Page 163: Battery Service

    Maintenance – Every 250 operating hours Cleaning with cold Protective equip- Working clothes cleansing agent ment: Protective gloves NOTICE! Electric components can be dam- aged by water entering into the system! – Protect electrical equipment such as generator, regulator and starter against the direct water jet.
  • Page 164 Maintenance – Every 250 operating hours Protective equip- Working clothes ment: Safety shoes Protective gloves Safety goggles 1. Park the machine safely Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117. 2. Remove the battery and clean the battery compartment.

  • Page 165: Every 500 Operating Hours

    Maintenance – Every 500 operating hours Every 500 operating hours 8.9.1 Draining the fuel tank sludge Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine safely Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117. 2.
  • Page 166 Maintenance – Every 500 operating hours Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine safely Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117. 2. Unscrew the hose clamps on the fuel pre- filter.

  • Page 167: Replacing The V-Belt

    Maintenance – Every 500 operating hours 9. Check the drain plug, tighten if necessary. 10. Open the bleeding screw on the fuel filter for one turn. B-462-0057 Fig. 154 11. Turn the ignition key to position “I”. 12. Retighten the bleeding screw as soon as pure fuel comes out of the bleeding screw.

  • Page 168: Checking The Anti-Freeze Concentration And The Condition Of The Coolant

    Maintenance – Every 500 operating hours 3. Loosen the tensioning screw (1) and the screw (2) on the generator. 4. Relieve and remove the V-belt. 5. Assemble a new V-belt at the generator. 6. Tension the V-belt to the specified value Ä...
  • Page 169 Maintenance – Every 500 operating hours 1. Park the machine in secured condition Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117. 2. Check all hydraulic lines. Hydraulic hoses must be immediately replaced if: the outer layer is damaged down to the inlay (e.g.

  • Page 170: Every 1000 Operating Hours

    Maintenance – Every 1000 operating hours 8.10 Every 1000 operating hours 8.10.1 Checking, adjusting the valve clearance NOTICE! Danger of engine damage! We recommend to have this work carried out by trained personnel or our after sales service. – Before checking the valve clear- ance let the engine cool down for at least 30 minutes.
  • Page 171 Maintenance – Every 1000 operating hours 4. Set cylinder 1 to overlapping and check the valve clearance on the valves marked black, adjust if necessary. Cylinder 1 is on the cooling fan side. I E I E B-KUB-0007 Fig. 159 I Intake valve E Exhaust valve 5.

  • Page 172: Checking The Engine Mounts

    Maintenance – Every 1000 operating hours 1. Check valve clearance (A) between rocker arm and valve with a feeler gauge. The feeler gauge must fit through the gap with little resistance. 2. If the gap is too narrow or too wide for the feeler gauge, adjust the valve clearance.

  • Page 173: Checking The Travel Lever Control

    Maintenance – Every 1000 operating hours 8.10.3 Checking the travel lever control 1. Park the machine safely Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117. 2. Move the travel lever forwards, backwards and to braking position. Check the function, for ease of movement, clearance and damage.

  • Page 174: Every 2000 Operating Hours

    Maintenance – Every 2000 operating hours 8.11 Every 2000 operating hours 8.11.1 Changing the hydraulic oil Perform this maintenance work at the latest after two years. The hydraulic oil must also be changed after major repairs in the hydraulic system. Always replace the hydraulic oil filter after each hydraulic oil change.
  • Page 175 Maintenance – Every 2000 operating hours Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine safely Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117. 2. Clean the area around the hydraulic oil tank, filling port and cover.
  • Page 176 Maintenance – Every 2000 operating hours 6. Loosen tightening strap and seal ring take off the cover with the seal ring to clean the hydraulic oil tank from inside. NOTICE! This will contaminate the hydraulic oil! B-462-0060 – Never use detergents. Fig.

  • Page 177: Replacing The Hydraulic Oil Filter

    Maintenance – Every 2000 operating hours 13. Dispose of the hydraulic oil and cover in line with environmental regulations. 8.11.2 Replacing the hydraulic oil filter Perform this maintenance work at the latest after two years. NOTICE! Components may get damaged! –...
  • Page 178 Maintenance – Every 2000 operating hours Hydraulic oil filter Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Unscrew the filter housing (3). NOTICE! Negligence may cause destruc- tion to the entire hydraulic system! – Visible dirt may be an early sign B-HYD-0013 for the failure of system compo- Fig.

  • Page 179: Changing The Coolant

    Maintenance – Every 2000 operating hours High pressure filter Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Clean the area around the high pressure filter. 2. Disconnect the high pressure oil lines from the high pressure filter. 3. Remove the high pressure filter and install the new high pressure filter while paying attention to the flow direction (arrow).
  • Page 180 Maintenance – Every 2000 operating hours If oil has entered, you must add a cleansing agent in order to remove any residues from the system. Follow the instructions of the manufac- turer! If in doubt, consult your Customer Service or the engine manufacturer. When changing the coolant without any signs of contamination, cleaning of the cooling system is not necessary.
  • Page 181 Maintenance – Every 2000 operating hours 4. Remove the cap from the compensation tank. B-462-0066 Fig. 172 5. Loosen the hose clamp (2) and pull off the hose. 6. Open the drain valve (1). 7. Drain off the coolant completely and collect 8.

  • Page 182: Replacing Hoses

    Maintenance – Every 2000 operating hours 16. Dispose of coolant in line with environ- mental regulations. 8.11.4 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, hoses in connection with the oil separator.

  • Page 183: Every 3000 Operating Hours

    Maintenance – Every 3000 operating hours 8.12 Every 3000 operating hours 8.12.1 Checking the exhaust gas recirculation system This work must only be performed by authorized service personnel. BW 100 ADM-5...

  • Page 184: As Required

    Maintenance – As required 8.13 As required 8.13.1 Air filter maintenance NOTICE! Danger of engine damage! – Do not start the engine after having removed the air filter. – If necessary, the air filter may be cleaned up to six times. –...
  • Page 185 Maintenance – As required 3. Release the snap bow and take off the cover. 4. Clean the cover and dust discharge valve. B-462-0076 Fig. 177 5. Pull out the air filter with light turning move- ments. 6. Thoroughly clean the filter housing and sealing faces.
  • Page 186 Maintenance – As required 9. Examine the air filter with a torch for cracks and holes in the paper bellows. 10. Replace the air filter if it is damaged. Fig. 180 11. Slide the air filter carefully into the housing. NOTICE! Danger of engine damage! –...

  • Page 187: Cleaning The Water Spraying System

    Maintenance – As required 8.13.2 Cleaning the water spraying system Perform this maintenance work at the latest after one year. Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine safely Ä Chapter 6.9 ‘Parking the machine in secured condition’ on page 117.

  • Page 188: Measures If There Is A Risk Of Frost

    Maintenance – As required 10. Clean the water filter and check for damage, replace if necessary. 11. Screw the drain cover back on with the water filter and a new seal. B-462-0079 Fig. 185 12. Unscrew all caps and nozzles and drain off all water.
  • Page 189 Maintenance – As required 3. Open the drain cover on the water tank and let all water run out. 4. Screw the drain cover back on. B-462-0078 Fig. 187 5. Open the line connection in the articulation area and let all water run out. 6.

  • Page 190: Measures Prior To Extended Shut-Down Period

    Maintenance – As required 15. Unscrew all nozzles and drain off all water. B-462-0069 Fig. 190 Before the next use 1. Reinstall all nozzles. 8.13.4 Measures prior to extended shut-down period 8.13.4.1 Measures before shutting down If the machine is shut down for a longer period of time, e.g.
  • Page 191 Maintenance – As required 9. Check the anti-freeze concentration and the coolant level. 10. Disconnect the ground strap from the bat- tery (this avoids self-discharge caused by closed-circuit consuming devices). 8.13.4.2 Battery service during prolonged machine downtimes WARNING! Danger of injury caused by exploding gas mixture! –...
  • Page 192 Maintenance – As required 3. Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform boost charging. ð The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge.
  • Page 193 Maintenance – As required 11. While the engine is running 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. BW 100 ADM-5...
  • Page 194 Maintenance – As required BW 100 ADM-5...

  • Page 195: Setting Up / Refitting

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

  • Page 196: Adjusting The Crabwalk

    Setting up / refitting – Adjusting the crabwalk Adjusting the crabwalk Loads may only be attached and hoisted by an expert/qualified person. Do not use lashing points that are damaged or impaired in any way. Use only lifting gear and lifting tackle with suffi- cient load bearing capacity for the loads to be lifted.
  • Page 197 Setting up / refitting – Adjusting the crabwalk 4. Swing the central lifting point up and fasten the lashing tackle. 5. Lift up the machine just above the ground. 6. Shift the rear frame to the desired position on the left or right. 7.

  • Page 198: Edge Cutter - Mounting And Removing Tools

    Setting up / refitting – Edge cutter - mounting and removing tools Edge cutter - mounting and removing tools Optional equipment Press rollers or cutting wheels are available tools for the edge cutter. The tools are directly mounted to the edge cutter or, if not used, are mounted to the holding fixture.
  • Page 199 Setting up / refitting – Edge cutter - mounting and removing tools 3. Use the star handle nut to mount the tools to or remove them from the holding fixture. B-462-0071 Fig. 195 BW 100 ADM-5...
  • Page 200 Setting up / refitting – Edge cutter - mounting and removing tools BW 100 ADM-5...

  • Page 201: Troubleshooting

    Troubleshooting Troubleshooting BW 100 ADM-5...

  • Page 202: Preliminary Remarks

    Troubleshooting – Preliminary remarks 10.1 Preliminary remarks Malfunctions are frequently caused by incorrect operation of the machine or insufficient mainte- nance. Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance. If you cannot locate the cause of a fault or rec- tify it yourself by following the trouble shooting chart, you should contact our customer service department.

  • Page 203: Starting The Engine With Jump Leads

    Troubleshooting – Starting the engine with jump leads 10.2 Starting the engine with jump leads NOTICE! A wrong connection will cause severe damage in the electric system. – Bridge the machine only with a 12 Volt auxiliary battery. 1. Connect the plus pole of the external bat- tery first with the plus pole of the vehicle battery using the first jump lead.

  • Page 204: Fuse Assignment

    Troubleshooting – Fuse assignment 10.3 Fuse assignment 10.3.1 Notes on safety WARNING! Danger of injury by fire in the machine! – Do not use fuses with higher ampere ratings and do not bridge fuses. 10.3.2 Central electrics The central electrics are located in the oper- ating console.

  • Page 205: Main Fuse

    Troubleshooting – Fuse assignment Fuse Amperage Designation 15 A Head lights, right F156 15 A Lighting 15 A Direction indicators and working head lights 15 A Hazard light system F103 10 A Potential 15 10 A Vibration F139 30 A Engine solenoid F275 Economizer...
  • Page 206 Troubleshooting – Fuse assignment Fuse Amperage Designation 80 A Main fuse BW 100 ADM-5...

  • Page 207: Engine Malfunctions

    Troubleshooting – Engine malfunctions 10.4 Engine malfunctions Fault Possible cause Remedy Engine does Fuel tank empty Refuel, bleed the fuel system not start Fuel filter gets clogged in Replace the fuel filter; use winter due to paraffin separa- winter fuel. tion Fuel lines leaking Check all line connections for...
  • Page 208 Troubleshooting – Engine malfunctions Fault Possible cause Remedy The exhaust Engine oil level too high Check; drain off if necessary emits a lot of Air filter contaminated Clean, replace if necessary smoke Insufficient fuel quality Use the specified fuel Poor compaction due to burnt Have examined by a spe- or broken compaction rings cialist.
  • Page 209 Troubleshooting – Engine malfunctions Fault Possible cause Remedy The engine oil Engine oil level too low Check, refill if necessary. pressure is too low (warning light for engine oil pressure) The charge Generator speed too low Check the tension of the gen- control light erator belt;...

  • Page 210: Trouble Shooting Economizer

    Troubleshooting – Trouble shooting ECONOMIZER 10.5 Trouble shooting ECONOMIZER Fig. 199: Economizer dis- play Fault Possible cause Remedy LED (a) Switching on: The LED (a) flashes flashes for approx 1 - 2 sec- onds after the vibration has been switched on. Jump operation of the drum on hard ground Acceleration sensor is not...
  • Page 211 Troubleshooting – Trouble shooting ECONOMIZER Fault Possible cause Remedy The displayed The acceleration sensor is Shut down the engine and measuring not fastened correctly. check the fastening screws of values are not the acceleration sensor. plausible. Weak spots in the road sub- In unfavourable cases, an base are also measured excessively varying material...
  • Page 212 Troubleshooting – Trouble shooting ECONOMIZER BW 100 ADM-5...

  • Page 213: Disposal

    Disposal Disposal BW 100 ADM-5...

  • Page 214: Final Shut-Down Of Machine

    Disposal – Final shut-down of machine 11.1 Final shut-down of machine After the machine has reached the end of its service life, the individual components of the machine must be disposed of properly. Observe national regulations! Carry out the following work and have the machine dismantled by a state-approved recy- cling company.

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