Bomag BW 151 AC-5 Operating Instruction
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Bomag BW 151 AC-5 Operating Instruction

Bomag BW 151 AC-5 Operating Instruction

Combination roller
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Operating Instruction
Maintenance Instruction
Original Operating Instructions
BW 151 AC-5
S/N 101 921 06 1001>
Combination roller
008 200 25 EN
© 04/2015

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Summary of Contents for Bomag BW 151 AC-5

  • Page 1 Operating Instruction Maintenance Instruction Original Operating Instructions BW 151 AC-5 S/N 101 921 06 1001> Combination roller 008 200 25 EN © 04/2015...

  • Page 3: Table Of Contents

    35 3.4.3 Safety regulations and environmental protection regulations for handling oil.................. 37 3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil..............38 3.4.5 Safety regulations and environmental protection regulations for handling coolants................ 40 BW 151 AC-5...
  • Page 4 3.11.6 Working on wheels and tires............. 61 3.11.7 Cleaning work................62 3.11.8 After maintenance work............. 62 3.12 Repair..................63 3.13 Information and safety stickers/decals on the machine..64 Display and control elements............. 69 4.1 Operator’s stand................70 4.1.1 Overview..................70 BW 151 AC-5...
  • Page 5 4.2.7 12 V Universal socket..............89 4.3 ROPS..................... 90 4.3.1 Rotary switch for ROPS working head lights....... 90 4.3.2 Rotary switch for drum edge illumination........90 4.3.3 12 V DIN socket................90 4.3.4 12 V Universal socket..............91 4.4 Engine compartment..............92 BW 151 AC-5...
  • Page 6 6.3.1 Preliminary remarks and safety notes........119 6.3.2 Driving the machine..............120 6.3.3 Apply the parking brake............. 121 6.3.4 Notes on travel operation............121 6.4 Working with vibration............... 122 6.4.1 Preliminary remarks and safety notes........122 6.4.2 Vibration in manual mode............123 BW 151 AC-5...
  • Page 7 Maintenance..................165 8.1 Preliminary remarks and safety notes........166 8.2 Preparations / concluding work..........168 8.2.1 Open the engine hood............... 168 8.2.2 Engaging / releasing the articulation lock........169 8.2.3 Lifting the machine with a jack..........170 BW 151 AC-5...
  • Page 8 8.9.5 Check the hydraulic lines............203 8.9.6 Servicing the battery, checking the main battery switch.... 204 8.9.7 Checking the oil level in the exciter housing......205 8.9.8 Service the air conditioning............206 8.10 Every 1000 operating hours............ 209 BW 151 AC-5...
  • Page 9 8.13.5 Filling the provision tank for the windscreen washer system. . 240 8.13.6 Measures before longer downtimes of the machine....241 Trouble shooting................245 9.1 Preliminary remarks..............246 9.2 Starting the engine with jump leads......... 247 9.3 Fuse assignment................ 249 BW 151 AC-5...
  • Page 10 9.3.1 Notes on safety................. 249 9.3.2 Central electrics................. 249 9.3.3 Main fuses................. 251 9.3.4 Fuse, cabin................252 9.3.5 Fuses ROPS................253 9.4 Engine faults................254 10 Waste disposal.................. 257 10.1 Final shut-down of machine............ 258 11 List of special tools................259 BW 151 AC-5...

  • Page 11: Introduction

    Introduction Introduction BW 151 AC-5...

  • Page 12: Foreword

    Introduction – Foreword Foreword BOMAG manufactures machines for earth, asphalt and refuse compaction, stabilizers/ recyclers as well as milling machines and pavers. BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all impor-...
  • Page 13 Ä Chapter 8 ‘Mainte- chapter "Maintenance" nance’ on page 165. For your own personal safety you should only use original spare 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 14 Introduction – Foreword The above notes do not constitute an extension of the warranty and liability conditions specified in the general sales and delivery conditions of BOMAG GmbH. We wish you successful work with your BOMAG machine. BW 151 AC-5...

  • Page 15: 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 151 AC-5...
  • Page 16 Introduction – Machine type plate and engine type plate BW 151 AC-5...

  • Page 17: Technical Data

    Technical data Technical data BW 151 AC-5...
  • Page 18 (29) (43) (88) (118) (9.8) (173) (3.2) (0.6) (66) Dimensions in millimetre (Dimensions in inch) Weights Max. operating weight 8500 (18739) (lbs) Operating weight with ROPS-cabin (CECE) 7500 (16535) (lbs) Axle load, drum (CECE) 3900 (8598) (lbs) BW 151 AC-5...
  • Page 19 (mph) Max. gradability without/with vibration (soil 40/30 dependent) Drive Engine manufacturer Kubota Type V 3307 CR-T Cooling Water Number of cylinders Rated power ISO 14396 55.4 Rated power SAE J 1995 Rated speed 2400 Electric system Voltage BW 151 AC-5...
  • Page 20 +/- 6 ° Inner track radius 4390 (172.8) (in) Crabwalk, lateral offsetting of drum right/left (6.7) (in) Exciter system Vibrating drum front Frequency (1/2) 45/55 (2700/3300) (vpm) Amplitude (1/2) 0.68/0.27 (0,027/0,011) (in) Centrifugal force (1/2) 69/41 (15512/9217) (lbf) BW 151 AC-5...

  • Page 21: Noise And Vibration Data

    = 106 dB(A), determined acc. to ISO 3744 power level and EN 500 2.1.2 Vibration data Vibration of the entire The weighted effective acceleration value body (driver’s seat) determined according to ISO 7096 is ≤ 0.5 m/ BW 151 AC-5...
  • Page 22 Technical data – Noise and vibration data Hand-arm vibration The weighted effective acceleration value determined according to EN 500/ISO 5349 is ≤ 2.5 m/s BW 151 AC-5...

  • Page 23: Concerning Your Safety

    Concerning your safety Concerning your safety BW 151 AC-5...

  • Page 24: General Prerequisites

    Concerning your safety – General prerequisites General prerequisites 3.1.1 General This BOMAG machine has been built in compli- ance 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:...

  • Page 25: Explanations To Signal Words Used

    Danger of material damage if failing to comply! Sections marked like this highlight possible dangers for machines or com- ponents. Sections marked like this provide tech- nical information or notes on using the machine or its components. BW 151 AC-5...

  • Page 26: Personal Protective Outfit

    Safety goggles To protect the eyes against airborne particles and fluid squirts. Face protection To protect the face against airborne particles and fluid squirts. BW 151 AC-5...

  • Page 27: Intended Use

    Examples for unintended 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. driving on subsoils with too low load bearing capacity BW 151 AC-5...
  • Page 28 (danger of turning over) unauthorized use of public roads 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 151 AC-5...

  • Page 29: Terminological Definition Of The 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 BW 151 AC-5...

  • Page 30: Driver / Operating Personnel

    Persons under the influence of alcohol, medi- cine 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 151 AC-5...

  • Page 31: Fundamentals For Safe Operation

    3.3.3 Changes and conversions 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 151 AC-5...

  • Page 32: Damage, Deficiencies, Misuse Of Safety Installations

    The ROPS must therefore also not be straight- ened or repaired if it is damaged. BW 151 AC-5...
  • Page 33 Concerning your safety – Fundamentals for safe operation A defect ROPS must generally be replaced with an original spare part in close coordination with the manufacturer. BW 151 AC-5...

  • Page 34: Handling Fuels And Lubricants

    Measures in case of accidental release Handling and storage Limitation and monitoring of exposure / 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 151 AC-5...

  • Page 35: Safety Regulations And Environmental Protection Regulations For Handling Diesel Fuel

    Danger of slipping on spilled diesel fuel! – Immediately bind spilled diesel fuel with an oil-binding agent. ENVIRONMENT! Diesel fuel is an environmentally hazardous substance – Always keep diesel fuel in proper containers. » Continued on the next page BW 151 AC-5...
  • Page 36 Concerning your safety – Handling fuels and lubricants – Immediately bind spilled diesel fuel with an oil-binding agent. – Dispose of diesel fuel and fuel filters according to regulations. BW 151 AC-5...

  • Page 37: Safety Regulations And Environmental Protection Regulations For Handling Oil

    – Immediately bind spilled oil with an oil-binding agent. ENVIRONMENT! Oil is an environmentally hazardous 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 151 AC-5...

  • Page 38: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic Oil

    – Wear your personal protective outfit (protective gloves, protective clothing). CAUTION! Health hazard caused by contact with hydraulic oil! – Wear your personal protective outfit (protective gloves, protective clothing). – Do not inhale any oil vapours. – Avoid contact. BW 151 AC-5...
  • Page 39 – Immediately bind spilled oil with an oil-binding agent. ENVIRONMENT! Oil is an environmentally hazardous 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 151 AC-5...

  • Page 40: 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 haz- ardous substance – Always keep coolant and coolant additives in proper containers. » Continued on the next page BW 151 AC-5...
  • Page 41 Concerning your safety – Handling fuels and lubricants – Immediately bind spilled coolant with an oil-binding agent and dis- pose of environmentally. – Dispose of coolant according to reg- ulations. BW 151 AC-5...

  • Page 42: 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, bra- celets, etc.) when working on the battery. – Wear your personal protective outfit (protective gloves, protective clothing, goggles). BW 151 AC-5...
  • Page 43 Concerning your safety – Handling fuels and lubricants ENVIRONMENT! Battery acid is an environmentally hazardous substance – Dispose of battery and battery acid according to regulations. BW 151 AC-5...

  • Page 44: Load/Transport The Machine

    Loads must only be attached and hoisted by an expert / capable person. Use only lifting gear and lifting tackle with suffi- cient load bearing capacity for the weight to be loaded. Fasten the lifting gear only at the specified lifting points. BW 151 AC-5...
  • Page 45 When lifting the machine avoid uncontrolled movements of the load. If necessary hold the load with guide ropes. After the transport loosen the articulation lock again, as otherwise the machine wouild not be steerable. BW 151 AC-5...

  • Page 46: Taking The Machine Into Service

    Do not use control levers or hoses as hand grips for accessing the machine. Before starting the machine check whether: the machine shows any obvious faults, all guards and safety elements are in place, steering, brakes, control elements, light system and warning horn work correctly BW 151 AC-5...

  • Page 47: Starting The Engine

    Starting the engine with jump leads Connect positive with positive and negative with negative (ground cable) – always connect the ground strap last and disconnect it first! A wrong connection will cause severe damage in the electric system. BW 151 AC-5...
  • Page 48 Concerning your safety – Taking the machine into service Do not start the engine by shorting the electric terminals on the starter motor, because the machine may start to drive immediately. BW 151 AC-5...

  • Page 49: Driving The Machine, Working Operation

    Operate the machine only from the operator’s stand. Keep the cabin doors closed. Do not adjust the driver’s seat while driving. Do not climb onto or off the machine while the machine is driving. Do not use the machine to transport persons. BW 151 AC-5...

  • Page 50: Driving On Inclinations And Slopes

    On slopes drive extremely careful and always directly up or down the slope. Change to a lower gear before starting to drive. Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes. Higher risk of accident! BW 151 AC-5...

  • Page 51: Cross Slope

    Pay attention to the maximum filling capacity, as otherwise the permissible total weight may be exceeded. Do not step between precision spreader and machine while the engine is running. Always empty the precision spreader before mounting or removing it. BW 151 AC-5...

  • Page 52: Parking The Machine

    Before leaving the machine: shift all control levers to "Neutral position", "Off" or "0", apply the parking brake, shut down the engine, pull off the ignition key, pull off the main battery switch, secure the machine against unintended use. BW 151 AC-5...
  • Page 53 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 151 AC-5...

  • Page 54: 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 151 AC-5...

  • Page 55: Regeneration Of Exhaust Gas Aftertreatment System

    When performing regeneration at standstill park the machine outdoors at a safe distance from any combustible or explosive materials and apply the parking brake. BW 151 AC-5...

  • Page 56: What To Do In Events Of Emergency

    Before releasing the parking brake apply suit- able measures to secure the machine against unintended rolling. Use a towing vehicle with sufficient traction and braking power for the unbraked towed load. You should generally use a tow bar. BW 151 AC-5...
  • Page 57 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 151 AC-5...

  • Page 58: Maintenance Work

    3.11.2 Work on hydraulic lines Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. Immediately call for medical advice when injured by hydraulic oil. BW 151 AC-5...

  • Page 59: Working On The Engine

    Hydraulic hoses must be visually inspected at regular intervals. Do not mix up hoses by mistake. Only genuine BOMAG replacement hydraulic hoses ensure that the correct hose type (pres- sure range) is used at the right location. 3.11.3 Working on the engine...

  • Page 60: Maintenance Work On Electric Components And Battery

    When injured by acid, flush off with clear water and seek medical advice. Metal objects (e.g. tools, rings, watch straps) must not come in contact with the battery poles – danger of short circuit and burning! BW 151 AC-5...

  • Page 61: Working On The Air Conditioning

    Do not drive with damaged tires or wheels. Install the tires only if are sufficiently experi- enced and with the right tools at hand. If neces- sary have the tires assembled in a qualified workshop. BW 151 AC-5...

  • Page 62: Cleaning Work

    Do not guide the water jet into the exhaust pipe and into the air filter. 3.11.8 After maintenance work Reassemble all guards and protections. Close all maintenance flaps and doors again. BW 151 AC-5...

  • Page 63: Repair

    Identify a defect 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 151 AC-5...

  • Page 64: Information And Safety Stickers/Decals On The Machine

    Concerning your safety – Information and safety stickers/decals on the machine 3.13 Information and safety stickers/decals on the machine Keep stickers and decals in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or decals immediately. BW 151 AC-5...
  • Page 65 5 Warning sticker - Danger of crushing 6 Operation sticker - Articulation lock 7 Information sticker - Guaranteed sound capacity level 8 Information sticker - Water 9 Information sticker - Diesel 10 Information sticker - Ultra-low sulphur fuel BW 151 AC-5...
  • Page 66 1 Operation sticker - Regeneration 2 Operation sticker - Travel lever 3 Prohibition sticker - High pressure cleaning 4 Information sticker - Main battery switch plus side 5 Information sticker - Hydraulic oil 6 Information sticker - Low ash engine oil BW 151 AC-5...
  • Page 67 Concerning your safety – Information and safety stickers/decals on the machine Fig. 12 1 Warning sticker - Load precision spreader 2 Warning sticker - Danger of crushing 3 Warning sticker - Shut down precision spreader Instruction sticker - Always wear your seat belt Fig. 13 BW 151 AC-5...
  • Page 68 Concerning your safety – Information and safety stickers/decals on the machine BW 151 AC-5...

  • Page 69: Display And Control Elements

    Display and control elements Display and control elements BW 151 AC-5...

  • Page 70: Operator's Stand

    5 Rotary switch for water pumps 6 Rotary switch for water spraying system pre-selection (optional equip- ment) 7 Rotary switch for emulsion spraying system 8 Rotary switch for working lights 9 Rotary switch for regeneration 10 Rotary switch for engine speed BW 151 AC-5...

  • Page 71: Instrument Cluster

    Instrument cluster Fig. 15 1 Control and warning lamps 2 INFO 3 display field 3 INFO 2 display field 4 INFO 1 display field 5 RPM-meter 6 not used 7 Fuel level gauge 8 Water level gauge BW 151 AC-5...
  • Page 72 Engine oil pressure Lights up if the engine oil pressure is too low. warning lamp The engine is shut down after a short while. Check the engine oil level; if necessary, repair the engine. BW 151 AC-5...
  • Page 73 Water level warning Lights up when the water tank is almost empty. lamp Parking brake Lights up when the parking brake is applied. warning lamp Crabwalk control Lights up when the crabwalk is extended. lamp Indicator control lamp BW 151 AC-5...
  • Page 74 Travel speed Asphalt temperature (optional equipment) Economizer (optional equipment) Fig. 16 Impacts per feet (optional equipment for the USA) Economizer and travel speed (optional equipment) Economizer and asphalt temperature (optional equipment)) Travel speed and asphalt temperature (optional equipment)) BW 151 AC-5...

  • Page 75: Economizer

    The maximum dis- play value (10) is not always reached. In case of jump operation of the drum the display (a) flashes. Fig. 18: INFO-2 display field in instrument cluster BW 151 AC-5...
  • Page 76 Tandem rollers of the same type show identical measuring values when used on the same soil. The measuring values achieved with different BOMAG tandem rollers can be made comparable by calibration to a reference value. BW 151 AC-5...

  • Page 77: Start Switch

    Position "Left" Push button assignment in travel lever for vibration and edge cutter Position Push button assignment in "Middle" travel lever for precision spreader Position "Right" Push button assignment in travel lever for vibration and Fig. 20 service BW 151 AC-5...

  • Page 78: Travel Lever

    Back of travel lever a + b not used Momentary contact push button for crabwalk, left Momentary contact push button for crabwalk, right Fig. 22 Front side of travel lever Push button vibration Push button to lift the edge cutter BW 151 AC-5...
  • Page 79 Fig. 23 Momentary contact push button for crabwalk, right Front side of travel lever Push button for precision spreader Push button to increase the chip quantity Push button to reduce the chip quantity Push button for warning horn BW 151 AC-5...

  • Page 80: Toggle Switch For Seat Heating

    Front side of travel lever Push button vibration d + e not used Push button for warning horn 4.1.8 Toggle switch for seat heating Position "0" Seat heating off Position "I" Seat heating on Optional equipment Fig. 25 BW 151 AC-5...

  • Page 81: Rotary Switch For Water Pumps

    Position "Right" Edge cutter Optional equipment Fig. 27 4.1.11 Rotary switch for emulsion spraying system Position "Left" Interval spraying (7 seconds on / 7 seconds off) Position Spraying off "Middle" actuate to the Spraying on right Fig. 28 BW 151 AC-5...

  • Page 82: Rotary Switch For Water Spraying System

    Fig. 31 in the rotary switch will also flash. If the control light does not flash, one of the indicators on the vehicle or on the precision chip spreader is defective. BW 151 AC-5...

  • Page 83: Rotary Switch For Hazard Light System

    Regeneration is automati- cally executed, if required. Turn clockwise To activate regeneration at for 3 seconds standstill Fig. 34 Description of the operating sequences and operating possibilities Ä Chapter 6.9 ‘Regeneration of exhaust gas aftertreatment system’ on page 132. BW 151 AC-5...

  • Page 84: Rotary Switch For Engine Speed

    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 151 AC-5...

  • Page 85: Rotary Switch For Travel Ranges

    4.1.22 Rotary switch for vibration, amplitude selection Position "Left" low amplitude, high fre- quency Position Vibration off "Middle" Position "Right" high amplitude, low fre- quency Fig. 39 BW 151 AC-5...

  • Page 86: Cabin

    Push button for drum edge illumi- Optional equipment nation not used not used not used not used not used Push button for side lights/addi- Optional equipment tional illumination right Push button for rear windscreen Interval/on/off wiper BW 151 AC-5...

  • Page 87: Rotary Switch For Air Distribution

    Push button for front windscreen washer Push button for front windscreen Interval/on/off wiper 4.2.2 Rotary switch for air distribution Position "Top" Air flow to windscreen Position Air flow to body "Middle" Position Air flow to body and footwell "Bottom" Fig. 41 BW 151 AC-5...

  • Page 88: Rotary Switch For Cabin Temperature

    Rotary switch for air conditioning system Position "Top" Air conditioning on Position Air conditioning off "Bottom" Optional equipment Fig. 44 The air conditioning system only works when the engine is running and the fan is switched on. BW 151 AC-5...

  • Page 89: Din Socket

    Display and control elements – Cabin 4.2.6 12 V DIN socket Permanent current, loadable up to 20 A. Fig. 45 4.2.7 12 V Universal socket Permanent current, loadable up to 20 A. Fig. 46 BW 151 AC-5...

  • Page 90: Rops

    Drum edge illumination off Position "Right" Drum edge illumination on (with ignition switch in posi- tion "I") Drum edge illumination is optional equipment Fig. 48 4.3.3 12 V DIN socket Permanent current, loadable up to 20 A. Fig. 49 BW 151 AC-5...

  • Page 91: Universal Socket

    Display and control elements – ROPS 4.3.4 12 V Universal socket Permanent current, loadable up to 20 A. Fig. 50 BW 151 AC-5...

  • Page 92: Engine Compartment

    Fig. 51 the engine compartment as well as protection against unauthorized use. NOTICE! Danger of damage to the electronic system! – Use the main battery to shut down the engine only in events of emer- gency. BW 151 AC-5...

  • Page 93: Precision Spreader

    Display and control elements – Precision spreader Precision spreader 4.5.1 Inclination indicator for precision spreader Position "0" Low chip quantity Position "6" High chip quantity In position "1" the precision spreader is hanging straight. Optional equipment Fig. 52 BW 151 AC-5...

  • Page 94: Fire Extinguisher

    The fire extinguisher can be subsequently mounted at the indicated positions: Installation position on machines with cabin Installation position on machines with ROPS For further information about the installation of a fire extinguisher you should contact our cus- tomer service department. BW 151 AC-5...

  • Page 95: Tests Before Commissioning

    Tests before commissioning Tests before commissioning BW 151 AC-5...

  • Page 96: Notes On Safety

    – Always secure an opened engine hood. Park the machine in secured condition Ä Chapter 6.7 ‘Park the machine in secured condition.’ on page 129. Ä Chapter Open and secure the engine hood 8.2.1 ‘Open the engine hood’ on page 168. BW 151 AC-5...
  • Page 97 Tests before commissioning – Notes on safety Close the engine hood again after work is com- pleted. BW 151 AC-5...

  • Page 98: Visual Inspections And Function Tests

    5. Check engine and exhaust system for leaks. 6. Check the belt drive for damage. 7. Check machine for contamination and damage. 8. Check function of steering. 9. Check function of brakes. 10. Check function of emergency stop. BW 151 AC-5...

  • Page 99: Checking The Engine Oil Level

    2. Pull the dipstick out again. 3. The oil level must always be between the "MIN"- and "MAX"-marks. If the oil level is too low, top up oil to the "MAX" mark immediately. Fig. 54 BW 151 AC-5...

  • Page 100: Checking The Fuel Level, Topping Up Fuel

    – Contaminated fuel can cause mal- function or even damage of the engine. If necessary, fill in fuel through a funnel with screen. – Use only fuel of the permitted speci- Ä Chapter 8.3.2 ‘Fuel’ fication on page 173. BW 151 AC-5...
  • Page 101 NOTICE! The fuel tank may get damaged! – Do not step on the fuel tank and do not place any heavy objects on it. Clean the area around the filler opening. Fig. 56 2. Fill in fuel. BW 151 AC-5...

  • Page 102: Checking The Hydraulic Oil Level

    1. Check the oil level in the inspection glass. Normal level approx. 3 cm (1.2 in) below the top edge of the inspection glass Minimum level approx. height of inspection glass 2. If necessary fill in hydraulic oil through the Fig. 57 filler neck. BW 151 AC-5...

  • Page 103: Check The Coolant Level

    Fig. 59 – Wear your personal protective outfit (protective gloves, protective clothing, goggles). 2. To top up unscrew the filler cap and fill in coolant up to the middle of the inspection glass. BW 151 AC-5...

  • Page 104: Checking The Water Level, Topping Up

    Ä Chapter 8.13.3 ‘Water spraying system, maintenance in case of frost’ on page 235. NOTICE! Dirty or contaminated water can block the water spraying system! – Fill only with clean water. – Use a filling screen. BW 151 AC-5...
  • Page 105 1. Unscrew the filler cap (1) and fill in clear water through the strainer (2). 2. Make sure that the ventilation bores in the filler cap are free. 3. Screw the cap back on again. Fig. 62 BW 151 AC-5...

  • Page 106: Checking The Emulsion Level, Topping Up

    1. Check the emulsion level in the inspection glass. 2. For filling up remove the locking cap and fill in emulsion. 3. Close the filler cap again tightly. Fig. 63 BW 151 AC-5...

  • Page 107: Checking, Adjusting The Scrapers

    Danger to life caused by machine movements! – Never step in front of or behind the drums/wheels while the engine is running. 1. Check the condition of the scrapers (two each per drum), clean if necessary. 2. Replace worn scrapers. Fig. 64 BW 151 AC-5...

  • Page 108: Rubber Tire Scraper

    1. Check the condition of the scrapers, clean if necessary. 2. Replace worn scrapers. 3. Check the gap between scrapers and rubber tires. Nominal value approx. 2 mm (0.08 in) 4. Equalize the gap, if necessary. Fig. 65 BW 151 AC-5...

  • Page 109: Checking The Condition Of And The Air Pressure In The Rubber Tires

    (safety shoes, gloves, goggles, hard hat). – When checking the tire pressure stand in the extension of the tyre tread. – Use an air hose with a length of min. 6 meters. – Never exceed the permitted air pressure. BW 151 AC-5...
  • Page 110 2. Have damaged tires replaced by author- ized service personnel. 3. Check the air pressure in the tires on the valve. Nominal value 2 bar (29 psi) Fig. 66 Ensure equal pressure in all rubber tires. 4. Correct the air pressure if necessary. BW 151 AC-5...

  • Page 111: Checking, Cleaning The Precision Spreader

    2. Check hydraulic lines for leak tightness. 3. Check hydraulic and electric connections for tight fit. Fig. 68 4. Check the fastening screws right and left for tight fit, tightening torque: 10 Nm (7.4 ft·lbf). Fig. 69 BW 151 AC-5...
  • Page 112 Tests before commissioning – Checking, cleaning the precision spreader BW 151 AC-5...

  • Page 113: Operation

    Operation Operation BW 151 AC-5...

  • Page 114: Set-Up The Work Place

    Inclination of the back- rest 4. To adjust the seat height lift up the seat, until it locks at the appropriate height. When lifting the seat completely it will sink down to lowest position. Fig. 71 BW 151 AC-5...

  • Page 115: Sliding The Driver's Seat Sideways

    2. Pull the lever up and swivel the seat to the desired position. The driver's seat can be swivelled by 15° to the left and 75° to the right. 3. Lock the seat securely in one of the locking positions. Fig. 73 BW 151 AC-5...

  • Page 116: Start The Engine

    2. Turn the rotary switch for vibration, ampli- tude pre-selection to position "Middle". Fig. 75 3. Turn the ignition key to position "I". ð All control and warning lamps in the instrument cluster light up for a moment. Fig. 76 BW 151 AC-5...
  • Page 117 Turn the ignition key through position "II" to position "III". ð The starter cranks the engine. NOTICE! Danger of engine damage! – Run the engine warm for a short while before starting work. Do not operate the engine immediately under full load. BW 151 AC-5...
  • Page 118 Operation – Start the engine NOTICE! Low exhaust gas temperatures result in increased soot loads in the DPF! – Short engine running times, low engine loads or excessively long engine idle times should be avoided. BW 151 AC-5...

  • Page 119: Travel Operation

    If the engine speed drops when driving up extreme inclinations, move the ravel lever slightly back, if necessary change to the lower speed range (select at least speed range 3-4). BW 151 AC-5...

  • Page 120: Driving The Machine

    5. Set the travel lever to "Middle" position to stop the machine. Fig. 81 ð The machine decelerates to standstill. 6. Always apply the parking brake to stop on inclinations or slopes. BW 151 AC-5...

  • Page 121: Apply The Parking Brake

    The parking brake is closed. 1. Occupy the driver's seat to start travel again from standstill. ð The driver's seat warning lamp goes out. 2. Shift the travel lever again to the desired travel direction through the parking brake position. BW 151 AC-5...

  • Page 122: 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 151 AC-5...

  • Page 123: Vibration In Manual Mode

    4. Press the vibration push button on the travel lever. ð Vibration is switched on. 5. Press the vibration push button on the travel lever once again to switch off vibra- tion. Fig. 86 ð Vibration is switched off. BW 151 AC-5...

  • Page 124: Vibration In Automatic Mode

    Rotary switch for engine speed in position "Middle" (ECO-mode) 1. Turn the rotary switch for vibration in manual/auto mode to position "Right". Fig. 88 2. Preselect the desired amplitude with the rotary switch for vibration, amplitude pre- selection. Fig. 89 BW 151 AC-5...
  • Page 125 "Middle" position. ð The vibration switches off when falling below a certain slow travel speed. Fig. 90 5. After the end of work switch the rotary switch for vibration amplitude pre-selection to position "Middle". Fig. 91 BW 151 AC-5...

  • Page 126: Operating The Crabwalk

    (a') or the push button for crabwalk right (b') on the travel lever to offset to the left or right. Fig. 92 ð The crabwalk operates immediately, also in standstill. The crabwalk control lamp lights up. Fig. 93 BW 151 AC-5...

  • Page 127: Water Spraying System

    ("MAX"). Fig. 96 With the travel lever in neutral, spraying will continue for a short while. BW 151 AC-5...
  • Page 128 ð If the water tank is empty, the water level warning lamp lights up and the warning buzzer sounds. Fig. 98 5. After the end of work switch the rotary switch for the water pumps to position "Middle". Fig. 99 BW 151 AC-5...

  • Page 129: Park The Machine In Secured Condition

    3. Turn the ignition key to position "0" and pull it out. 4. Open and secure the engine hood Ä Chapter 8.2.1 ‘Open the engine hood’ on page 168. Fig. 101 5. Turn the main battery switch counter-clock- wise and pull it out. Fig. 102 BW 151 AC-5...

  • Page 130: Operating The Heating/Air Conditioning System

    3. Switch on the fan 4. Regulate the cabin temperature. Cooling the interior 1. Close all windows completely. 2. Adjust the desired air distribution. 3. Switch on the fan 4. Switch the air conditioning on. 5. Regulate the cabin temperature. BW 151 AC-5...
  • Page 131 The following settings are marked on each rotary switch with the "wind- screen" symbol. 1. Direct the air distribution to the windscreen. 2. Switch the fan to stage "3". 3. Set the cabin temperature to "Max". 4. Switch the air conditioning on. BW 151 AC-5...

  • Page 132: Regeneration Of Exhaust Gas Aftertreatment System

    To make sure that the regeneration will be triggered automatically, the rotary switch for regeneration must be in "Middle" position " (AUTO). During the regeneration process the exhaust gas reaches very high temperatures and the exhaust gas quantity increases. BW 151 AC-5...
  • Page 133 Regeneration at standstill takes up to 30 minutes. If regeneration at standstill is not carried out or is interrupted and the soot load continues to increase, the engine power will be reduced (warning buzzer + information code 5153). BW 151 AC-5...

  • Page 134: Information Codes

    5153 The warning buzzer sounds, engine power is reduced. Perform regeneration at standstill immediately. 5154 The warning buzzer sounds, engine power is extremely reduced. Regeneration must be carried out by authorized Service Personnel. Inform our service department. BW 151 AC-5...

  • Page 135: Suppressing Regeneration

    ð Regeneration will be suppressed. NOTICE! Increasing soot load in DPF! – Switch the rotary switch for regener- Fig. 107 ation back to position "Middle" (AUTO) if there is no longer any danger caused by high exhaust gas temperatures and quantities. BW 151 AC-5...

  • Page 136: Running Regeneration At Standstill

    When the travel lever is disen- gaged out of parking brake posi- tion to the left, regeneration at standstill will be aborted. 3. Turn the rotary switch for engine speed to position "Middle" (ECO-mode). Fig. 110 BW 151 AC-5...
  • Page 137 Ä Fig. 112 and the information code 5161 go out. Once the exhaust gas temperature has dropped to its normal level, the exhaust gas temperature control lamp will also go out Ä Fig. 113. BW 151 AC-5...

  • Page 138: Edge Cutter

    4. Unscrew both screws (1) from the roller bracket. 5. Remove screws and adapter piece (2). 6. Take off the compression roller (3). Fig. 115 7. Fasten the compression roller on the front drum and tighten the screw. Fig. 116 BW 151 AC-5...

  • Page 139: Operating The Edge Cutter

    WARNING! Danger of crushing when low- ering the edge cutter! – Make sure that no persons are in the danger area. Fig. 119 Press push button (e) on the travel lever to lower the edge cutter. BW 151 AC-5...

  • Page 140: Precision Spreader

    – Do not step between precision spreader and machine while the engine is running. 6.11.1.2 Mounting the precision spreader 1. Stop the machine on level and firm ground and apply the parking brake. 2. Shut down the engine. BW 151 AC-5...
  • Page 141 Danger to life caused by sus- pended loads! – Do not step or stand under sus- pended loads. Lift the precision spreader with a forklift Fig. 123 truck or a crane and hook it carefully into the fixing points on the machine. BW 151 AC-5...
  • Page 142 Fig. 125 9. Loosen the counter nuts and screws (1) on the left and right support feet. 10. Push in the sliding sections. 11. Tighten the screws and lock these with the counter nuts. Fig. 126 BW 151 AC-5...
  • Page 143 4. Use push buttons (d) or (e) to incline the precision spreader, so that the inclination indicator on the precision spreader is in position "1". Fig. 128 ð The precision spreader is in vertical position. Fig. 129 BW 151 AC-5...
  • Page 144 9. Loosen the counter nuts and screws (1) on the left and right support feet. 10. Pull the sliding sections out against the stop. 11. Tighten the screws and lock these with the counter nuts. Fig. 133 BW 151 AC-5...
  • Page 145 – Do not step or stand under sus- pended loads. Use a forklift truck or crane to lift the preci- Fig. 136 sion spreader off the machine. 16. Put the precision spreader down on level and firm ground. BW 151 AC-5...

  • Page 146: Filling The Precision Spreader

    2. Use push buttons (d) or (e) to incline the precision spreader, so that the inclination indicator on the precision spreader is in position "1". Fig. 138 ð The precision spreader is in vertical position. Fig. 139 BW 151 AC-5...

  • Page 147: Emptying The Precision Spreader

    – The screen should not stand upright. Lay the screen correctly on the frame of Fig. 141 the precision spreader. 6.11.3 Emptying the precision spreader 1. Turn the rotary switch for travel lever button assignment to position "Middle". Fig. 142 BW 151 AC-5...

  • Page 148: Operating The Precision Spreader

    (50cm (20 in)) and two shorter (25cm (10 in)) brushes . 1. Park the machine in secured condition Ä Chapter 6.7 ‘Park the machine in secured condition.’ on page 129. 2. Lift or lower the brushes to adjust the spreading width. Fig. 144 BW 151 AC-5...
  • Page 149 4. Use the adjusting screw (2) to adjust the desired gap dimension. 5. Tighten the fastening screws. 6. Assemble the brushes again. Fig. 146 6.11.4.3 Operation via travel lever 1. Turn the rotary switch for travel lever button assignment to position "Middle". Fig. 147 BW 151 AC-5...
  • Page 150 (e) Ä Fig. 148. ð Read the adjusted spreader inclination on the inclination indicator. Fig. 150 4. Move the slidable precision spreader hydraulically to left or right using push but- tons (a) or (b) . Fig. 151 BW 151 AC-5...

  • Page 151: What To Do In Events Of Emergency

    You should generally use a tow bar. The machine cannot be steered. BW 151 AC-5...
  • Page 152 6. Fasten the towing eye with the bolt (1) to the front left or right lashing point. Fig. 155 7. The recess (3) must point up. 8. Secure the bolt (1) with the clip pin (2). Fig. 156 BW 151 AC-5...
  • Page 153 1. Unscrew the pump lever extension. Fig. 158 WARNING! Danger of burning on hot com- ponents! – Wear your personal protective outfit (protective gloves, protec- tive clothing). Press the emergency operation button Fig. 159 completely down. BW 151 AC-5...

  • Page 154: After Towing

    2. Pull the emergency operation button up against the stop to activate the parking brake. After starting the engine the emer- gency operation button is pushed out by hydraulic pressure. Fig. 161 BW 151 AC-5...
  • Page 155 Remove tow bar and towing eye (3). 4. Fasten the towing eye (3) in the bracket, using bolt (1). 5. Secure the bolt with clip pin (2). Fig. 163 6. Screw on the pump lever extension. Fig. 164 BW 151 AC-5...
  • Page 156 Operation – What to do in events of emergency BW 151 AC-5...

  • Page 157: Loading / Transporting The Machine

    Loading / transporting the machine Loading / transporting the machine BW 151 AC-5...

  • Page 158: Prepare For Transport

    3. Push the sliding sections on the support feet of the precision spreader completely 4. Close all doors, windows and flaps. 5. Remove all loose objects from the machine or from the operator's stand or fasten them reliably. BW 151 AC-5...

  • Page 159: Loading The Machine

    – Make sure that no persons are Fig. 166 in the danger area. – Do not drive with crabwalk onto the transport vehicle. Drive the machine carefully on the trans- port vehicle. 4. Move the steering to middle position. BW 151 AC-5...
  • Page 160 5. Swing the precision spreader back, do not lower it down onto the transport vehicle. 6. Shut down the engine, pull off the ignition key. Ä Chapter 7. Engage the articulation lock 8.2.2.1 ‘Engaging the articulation lock’ on page 169. BW 151 AC-5...

  • Page 161: Lashing The Machine To The Transport Vehicle

    Never attach the lashing gear to the precision spreader. 1. Fasten the lashing tackle at the four marked lashing points. Fig. 167 2. Lash the machine securely to the transport vehicle. Fig. 168 BW 151 AC-5...

  • Page 162: Loading By Crane

    1. Shut down the engine. Ä Chapter 2. Engage the articulation lock 8.2.2.1 ‘Engaging the articulation lock’ on page 169. 3. Fasten the lifting tackle at the four marked lifting points. Fig. 169 BW 151 AC-5...
  • Page 163 Fig. 170 DANGER! Danger to life caused by sus- pended loads! – Do not step or stand under sus- pended loads. Lift the machine carefully and lower it again at the intended location. BW 151 AC-5...

  • Page 164: After Transport

    Loading / transporting the machine – After transport After transport 1. After transportation loosen the articulation Ä Chapter 8.2.2.2 ‘Disengaging lock again the articulation lock’ on page 170. BW 151 AC-5...

  • Page 165: Maintenance

    Maintenance Maintenance BW 151 AC-5...

  • Page 166: Preliminary Remarks And Safety Notes

    1. Always clean machine and engine thor- oughly before starting maintenance work. 2. For all maintenance work park the machine Ä Chapter 6.7 ‘Park is secured condition the machine in secured condition.’ on page 129. BW 151 AC-5...
  • Page 167 8. Relieve hydraulic pressures before working on hydraulic lines. 9. Before working on electric parts disconnect the battery and cover it with insulation material. 10. After all maintenance work is completed reinstall all guards and safety installations. BW 151 AC-5...

  • Page 168: Preparations / Concluding Work

    Open the engine hood 1. Unlock the engine hood. 2. Press in the knob on the engine hood handle. 3. Push the engine hood up. Fig. 171 4. Secure the opened engine hood with the locking bolt. Fig. 172 BW 151 AC-5...

  • Page 169: Engaging / Releasing The Articulation Lock

    Fig. 173 1. Make sure that no persons are in the artic- ulation area. 2. Start the engine. 3. Turn the steering to right or left.. 4. Shut down the engine, pull off the ignition BW 151 AC-5...

  • Page 170: Lifting The Machine With A Jack

    1. Pull out the locking bolt (1) and turn the lever in direction of arrow. 2. Securely engage the bolt in the bore (3) to avoid accidental locking of the articulation lock during operation. Fig. 174 8.2.3 Lifting the machine with a jack Fig. 175 BW 151 AC-5...
  • Page 171 – Do not place the jack under the floor plate. Place the jack under the edges (2) on the rear frame and lift the machine. 2. Perform the required maintenance work. 3. Lower the machine to the ground. BW 151 AC-5...

  • Page 172: Fuels And Lubricants

    Oil viscosity ture 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 BW 151 AC-5...

  • Page 173: Fuel

    -20 °C (-4 °F) and when working at altitudes of 1500 m (4921 ft) and more. 8.3.2.2 Winter fuel For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separa- tion. BW 151 AC-5...

  • Page 174: Coolant

    1:1. Under particularly extreme temperature condi- tions you should consult our customer service concerning the anti-freeze agent to be used. There are various types of anti-freeze agents available. For this engine you should use eth- ylene glycol. BW 151 AC-5...
  • Page 175 If this mixes with cleaning agent it may cause the development of sludge, which could damage the cooling system. Anti-freeze concen- Freezing point tration 50 % -37 °C (-35 °F) BW 151 AC-5...

  • Page 176: Hydraulic Oil

    Synth.46 always use the same oil to top up. When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrica- tion oil service of the oil manufacturer, or our customer service for details. BW 151 AC-5...

  • Page 177: Exciter System

    API GL5-class with a minimum viscosity of 20 mm /s at 100 °C (212 °F). This is a hypoid lubricant of highest quality class for transmissions under extreme strain. The additives in this oil ensure low wear lubri- cation under all operating conditions. BW 151 AC-5...

  • Page 178: Table Of Fuels And Lubricants

    Ä Chapter 8.3.4.2 Specification: ‘Bio-degradable hydraulic oil’ on page 176 Exciter housing SAE 75W-90, API GL-5 009 925 05 3.6 l each Ä Chapter 8.3.5 Specification: 20 l (1 gal us) ‘Exciter system’ on page 177 BW 151 AC-5...
  • Page 179 Water spraying Water Anti-freeze 600 l system mixture (159 gal Emulsion Emulsion 45 l spraying system (12 gal us) Air conditioning Refrigerant R134a 1300 g (2.9 lbs) Exciter housing SAE 15W-40 0.2 l of precision (0.05 gal spreader BW 151 AC-5...

  • Page 180: Running-In Instructions

    3. Oil and filter change diesel engine Ä Chapter 8.9.1 ‘Change engine oil and oil filter cartridge’ on page 194. Ä Chapter 8.10.8 4. Exciter unit oil change ‘Change the oil in the exciter housing’ on page 216. BW 151 AC-5...

  • Page 181: After 500 Operating Hours

    ‘Changing the oil in the travel gear’ on page 214 8.5.4 After 500 operating hours 1. Oil change in travel gear. 8.5.5 After 1000 operating hours 1. Exciter unit oil change. 2. Oil change in travel gear. BW 151 AC-5...

  • Page 182: Maintenance Table

    Service the air conditioning Every 1000 operating hours 8.10.1 Adjusting the valve clearance 8.10.2 Drain the fuel tank sludge 8.10.3 Checking the lines on the diesel engine 8.10.4 Checking the exhaust manifold 8.10.5 Check the engine mounts BW 151 AC-5...
  • Page 183 Cleaning water tank and water filter 8.13.3 Water spraying system, maintenance in case of frost 8.13.4 Cleaning the emulsion filter 8.13.5 Filling the provision tank for the windscreen washer system 8.13.6 Measures before longer downtimes of the machine BW 151 AC-5...
  • Page 184 Maintenance – Maintenance table BW 151 AC-5...

  • Page 185: Every 50 Operating Hours

    After taking the engine into operation you should check the filter bowl for signs of water and dirt initially every day, later as required. If a too high quantity is drained off, the filter needs to be bled. BW 151 AC-5...
  • Page 186 ð Once the water separator is empty the warning lamp for water in fuel must go out. 9. Slightly loosen the fastening screws (1) and push the bracket carefully up. 10. Tighten the fastening screws. 11. Dispose of the fluid environmentally. Fig. 179 BW 151 AC-5...

  • Page 187: Every 250 Operating Hours

    Service the belt drive 8.8.3.1 Checking the condition of the V-belt 1. Park the machine in secured condition Ä Chapter 6.7 ‘Park the machine in secured condition.’ on page 129. 2. Allow the engine to cool down. BW 151 AC-5...
  • Page 188 Belt tension tester 1. Press the indicator arm (a) of the tester into the gap of the measuring scale. 2. Place the meter in the middle between the V-belt pulleys on the back of the belt. Fig. 182 BW 151 AC-5...
  • Page 189 6. Tighten the belt, if necessary. 8.8.3.3 Tensioning the generator V-belt 1. Loosen the tensioning screw (1) and the screw (2) on the generator. 2. Tension the belt to the specified value. 3. Retighten clamping screw (1) and screw (2). Fig. 185 BW 151 AC-5...

  • Page 190: Cleaning The Radiator Module

    – Do not clean with high pressure. 1. Park the machine in secured condition Ä Chapter 6.7 ‘Park the machine in secured condition.’ on page 129. 2. Allow the engine to cool down. 3. Remove the covering sheets from the cooler. Fig. 187 BW 151 AC-5...
  • Page 191 Fig. 188 2. Blow the cooler out with compressed air from the air supply side. Fig. 189 Cleaning with cold Heat will cause extreme overpressure, which cleansing agent could cause damage or explosion of the system. BW 151 AC-5...

  • Page 192: Checking The Oil Level In The Travel Gear

    The travel gear is located on the right hand side of the drum. NOTICE! Components may get damaged! – Drain gear oil only at operating tem- perature. – Use only gear oil of the permitted Ä Chapter 8.3.6 ‘Gear specification oil’ on page 177. BW 151 AC-5...
  • Page 193 3. Clean and unscrew oil level inspection plug (horizontal). 4. The oil level must reach the bottom edge of Fig. 190 the bore, top up oil through the filler opening (vertically upwards) if necessary. 5. Turn the level inspection plug tightly back BW 151 AC-5...

  • Page 194: Every 500 Operating Hours

    – Change the oil only with the engine at operating temperature. – Use only oil of the permitted specifi- Ä Chapter 8.3.1 ‘Engine oil’ cation on page 172. Ä Chapter 8.4 – Filling quantity: ‘Table of fuels and lubricants’ on page 178 BW 151 AC-5...
  • Page 195 A Bottom view the cover plate. 6. Open and secure the engine hood Ä Chapter 8.2.1 ‘Open the engine hood’ on page 168. 7. Unscrew the fastening screws (1) and put the filter bracket to the side. Fig. 192 BW 151 AC-5...
  • Page 196 Fig. 193 12. Spin on the new fuel filter cartridge and tighten it hand tight. 13. Reassemble the filter bracket with new fas- tening screws (1). Fig. 194 14. Fill in new engine oil. Fig. 195 BW 151 AC-5...

  • Page 197: Changing The Fuel Filter, Bleeding The Fuel System

    5 minute test run in idle speed or low load is mandatory. Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.7 ‘Park the machine in secured condition.’ on page 129. BW 151 AC-5...
  • Page 198 6. Unscrew the drain plug (1) and catch run- ning out fuel. 7. Open the quick lock (2) and take off the fuel pre-filter (3). Fig. 199 8. Clean the sealing face on the filter carrier from any dirt. BW 151 AC-5...
  • Page 199 – Never fill filters beforehand, to avoid the entry of dirt into the clean side. Slightly oil the rubber seal on the new fuel Fig. 202 filter. 17. Attach the fuel filter (1) with the quick lock and ensure correct coding. BW 151 AC-5...
  • Page 200 21. Open the shut-off valve (handle across the flow direction). 22. Dispose of fuel and filter environmentally. Fig. 204 8.9.2.3 Bleed the fuel system 1. Open the bleeding screw (1) on the fuel filter for one turn. Fig. 205 BW 151 AC-5...

  • Page 201: Replacing The V-Belt

    2. Allow the engine to cool down. 3. Remove the cover. Fig. 207 4. Loosen the tensioning screw (2) and the screw (1) on the air conditioning com- pressor. 5. Relieve and remove the V-belt. Fig. 208 BW 151 AC-5...

  • Page 202: Check The Anti-Freeze Concentration And 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 ‘Change the coolant’ on page 225. Fig. 211 6. Screw the cover back on again. BW 151 AC-5...

  • Page 203: Check The Hydraulic Lines

    (no detec- tion of identifications or cracks), shelf life and utilization period exceeded. 3. Replace damaged hydraulic hoses immedi- ately, fasten these properly and avoid chafing. 4. Only operate the machine after the travel control has been repaired. BW 151 AC-5...

  • Page 204: Servicing The Battery, Checking The Main Battery Switch

    Protective equip- Working clothes ment: Protective gloves Safety goggles 1. Park the machine in secured condition Ä Chapter 6.7 ‘Park the machine in secured condition.’ on page 129. 2. Remove the battery cover. Fig. 212 BW 151 AC-5...

  • Page 205: Checking The Oil Level In The Exciter Housing

    Checking the oil level in the exciter housing The exciter housing is located on the left hand side of the drum. NOTICE! Components may get damaged! – Use only oil of the permitted specifi- Ä Chapter 8.3.5 ‘Exciter cation system’ on page 177. BW 151 AC-5...

  • Page 206: Service The Air Conditioning

    ð If the outflowing air is considerably Fig. 217 cooler, the air conditioning system is in good working order. a Adjust the air distribu- tion b Regulate the cabin tem- perature BW 151 AC-5...
  • Page 207 7. Check the white floating ball inside the inspection glass of the drier/collector unit. Ball floats right on The refrigerant level is correct Ball floats at bottom The refrigerant level is not correct Fig. 220 BW 151 AC-5...
  • Page 208 Maintenance – Every 500 operating hours 8. If the refrigerant level is too low, have the air conditioning system inspected by our customer service. BW 151 AC-5...

  • Page 209: Every 1000 Operating Hours

    (1) and on feed line (3) and pull the fuel line off the fuel tank. 7. Pull off sensor cable (2). 8. Loosen two fastening screws on the tank (4) and take off the tank. Fig. 222 BW 151 AC-5...

  • Page 210: Checking The Lines On The Diesel Engine

    18. Dispose of fuel environmentally. Fig. 225 8.10.3 Checking the lines on the diesel engine This work must only be performed by authorized service personnel. Perform this maintenance work at the latest after one year. BW 151 AC-5...

  • Page 211: Checking The Exhaust Manifold

    5. Check fastening screws on oil sump and engine mounts for tight fit. 6. Check condition and tight fit of engine pillow blocks. BW 151 AC-5...

  • Page 212: Replacing The Hydraulic Oil Filter

    Fig. 226 Protective equip- Working clothes ment: Protective gloves Preparations 1. Park the machine in secured condition Ä Chapter 6.7 ‘Park the machine in secured condition.’ on page 129. 2. Allow the engine to cool down. BW 151 AC-5...
  • Page 213 6. Take out the old filter element and clean the filter bowl. 7. Clean the thread on the filter bowl. 8. Reassemble the filter bowl with a new filter element and new loop rings (1, 2). BW 151 AC-5...

  • Page 214: Changing The Oil In The Travel Gear

    16. After the test run check the filters for leaks. 17. Dispose of hydraulic oil and filter environ- mentally. 8.10.7 Changing the oil in the travel gear The travel gear is located on the right hand side of the drum. BW 151 AC-5...
  • Page 215 3. Clean and unscrew the drain plug and oil level inspection plug (horizontal). Fig. 231 WARNING! Danger of burning on hot com- ponents! – Wear your personal protective outfit (protective gloves, protec- tive clothing). Drain and catch all oil. BW 151 AC-5...

  • Page 216: Change The Oil In The Exciter Housing

    – Drain exciter oil only at operating temperature. – Use only exciter oil of the permitted Ä Chapter 8.3.5 specification ‘Exciter system’ on page 177. Ä Chapter 8.4 – Filling quantity: ‘Table of fuels and lubricants’ on page 178. BW 151 AC-5...
  • Page 217 7. Fill in oil through the filler bore, until it starts to run out through the level inspection bore. 8. Turn the oil filler (1) and level plugs (2) back in with new seal rings. 9. Dispose of exciter oil in an environmentally friendly manner. Fig. 235 BW 151 AC-5...

  • Page 218: Checking The Rops

    2. Check the fastening screws for the cabin (ROPS) to the operator’s stand for tight fit. 3. Check the rubber buffers of the operator’s platform suspension for condition and tight fit. 4. Check the condition and fastening of the seat belts. BW 151 AC-5...

  • Page 219: Check The Travel Control

    5. Insert the filter and reassemble the cov- ering. Fig. 237 8.10.12 Changing the fresh air filter in the cabin 1. Park the machine in secured condition Ä Chapter 6.7 ‘Park the machine in secured condition.’ on page 129. BW 151 AC-5...
  • Page 220 6. Tilt the console towards the front screen and hold it. Fig. 240 7. Remove the filter. 8. Insert the new filter and fold the console down again. 9. Tighten the left and right fastening screws and reassemble the covers. Fig. 241 BW 151 AC-5...

  • Page 221: Changing The Oil In The Exciter Housing Of The Precision Spreader

    Danger of burning on hot com- ponents! – Wear your personal protective outfit (protective gloves, protec- tive clothing). Fig. 242 Drain off and catch old oil. 6. Turn the oil drain plug back in with a new seal ring. BW 151 AC-5...
  • Page 222 Components may get damaged! – Do not overfill the exciter housing. Measure exactly 0.2 l (0.05 gal us) of oil and fill it in. Fig. 243 8. Turn the filler plug back in with a new seal ring. BW 151 AC-5...

  • Page 223: Every 2000 Operating Hours

    – Perform the oil change when the hydraulic oil is warm. – Use only hydraulic oil of the per- Ä Chapter 8.3.4 mitted specification ‘Hydraulic oil’ on page 176. Ä Chapter 8.4 – Filling quantity: ‘Table of fuels and lubricants’ on page 178. BW 151 AC-5...
  • Page 224 This ensures finest filtration of the hydraulic oil, pro- longs the lifetime of the hydraulic oil filter and protects the hydraulic system. Fig. 246 Fill in new hydraulic oil. BW 151 AC-5...

  • Page 225: Change The Coolant

    Follow the instructions of the manufacturer. 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. BW 151 AC-5...
  • Page 226 Protective gloves Safety goggles 1. Park the machine in secured condition Ä Chapter 6.7 ‘Park the machine in secured condition.’ on page 129. 2. Allow the engine to cool down. 3. Unscrew the cap. Fig. 247 BW 151 AC-5...
  • Page 227 18. Start the engine and run it warm to oper- ating temperature. 19. Let the engine cool down and check the coolant level again, top up if necessary. Fig. 249 20. Dispose of the coolant in an environmen- tally friendly manner. BW 151 AC-5...

  • Page 228: Replacing The Oil Separator Element

    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. BW 151 AC-5...

  • Page 229: Every 3000 Operating Hours

    This work must only be performed by authorized service personnel. 8.12.2 Cleaning the DPF This work must only be performed by authorized service personnel. 8.12.3 Checking the exhaust gas recirculation system This work must only be performed by authorized service personnel. BW 151 AC-5...

  • Page 230: 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 151 AC-5...
  • Page 231 4. Loosen both locking hooks on the housing cover and take the cover off. 5. Clean housing cover and dust discharge valve. Fig. 252 6. Pull out the main filter element with light turning movements. Fig. 253 BW 151 AC-5...
  • Page 232 10. 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. 256 11. Reassemble the housing cover. BW 151 AC-5...

  • Page 233: Cleaning Water Tank And Water Filter

    3. Push in a new safety filter element. 4. Insert the air filter and reassemble the housing cover. Fig. 257 8.13.2 Cleaning water tank and water filter Perform this maintenance work at the latest after one year. BW 151 AC-5...
  • Page 234 – Fill only with clean water. – Use a filling screen. Fig. 260 Insert the filling screen (2). 13. Fill in clean water through the filling screen. 14. Make sure that the ventilation bores in the filler cap are free. BW 151 AC-5...

  • Page 235: Water Spraying System, Maintenance In Case Of Frost

    8.13.3 Water spraying system, maintenance in case of frost NOTICE! Components may get damaged! – Drain all water off if there is a risk of frost! – The water system can alternatively be filled with an anti-freeze mixture. BW 151 AC-5...
  • Page 236 3. Set the rotary switch for water spraying system pre-selection to "Middle" position, to make sure that the water from the water lines for the edge cutter is also drained off. Fig. 263 4. Unscrew the cap. Fig. 264 BW 151 AC-5...
  • Page 237 Fig. 265 A Bottom view 7. Screw the cap back on again. Fig. 266 8. Open the drain valve on the water pumps (handle in flow direction) and let all water run out. Fig. 267 BW 151 AC-5...
  • Page 238 Ä Chapter 6.7 ‘Park the machine in secured condition.’ on page 129. Before the next use 1. Screw the drain cover (3) back on. 2. Screw the drain cover (1) with water filter (2) back on and connect the water hose. Fig. 269 BW 151 AC-5...

  • Page 239: Cleaning The Emulsion Filter

    3. Drain the emulsion completely off and catch it. 4. Switch the emulsion spraying system on for a moment to drain the tank completely. 5. Close the shut-off valve again (lever across the flow direction). Fig. 272 BW 151 AC-5...

  • Page 240: Filling The Provision Tank For The Windscreen Washer System

    2. Open the cover on the back of the cabin. Fig. 274 3. Check the fluid level in the tank, top up if necessary. 4. If there is a risk of frost, you may also fill the tank with an anti-freeze mixture. Fig. 275 BW 151 AC-5...

  • Page 241: Measures Before Longer Downtimes Of The Machine

    5. After shutting down store the machine under cover in a dry and well ventilated room. 6. Check the anti-freeze concentration and the coolant level. 7. Disconnect the ground strap from the bat- tery (this avoids self-discharge caused by closed-circuit consumers). BW 151 AC-5...
  • Page 242 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. BW 151 AC-5...
  • Page 243 10. While the engine is running keep an eye on the gauges for oil pressure and coolant temperature. 11. Check the oil levels. 12. Check the function of electric system, steering and brakes. 13. Clean the machine thoroughly. BW 151 AC-5...
  • Page 244 Maintenance – As required BW 151 AC-5...

  • Page 245: Trouble Shooting

    Trouble shooting Trouble shooting BW 151 AC-5...

  • Page 246: 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 151 AC-5...

  • Page 247: Starting The Engine With Jump Leads

    3. Then connect the ground cable first to the minus pole of the energizing auxiliary bat- tery and then to the ground connection in the engine compartment. Ä Chapter 6.2 ‘Start the 4. Start the engine engine’ on page 116. Fig. 277 BW 151 AC-5...
  • Page 248 5. Once the engine is running switch on a powerful consumer (working light, etc.). 6. After starting disconnect the negative poles (ground cable) first and the positive poles after. 7. Switch off the consumer. 8. Close the engine hood. BW 151 AC-5...

  • Page 249: Fuse Assignment

    Fig. 278 Fuse Amperage Designation 15 A Main fuse 10 A Instruments 20 A Sockets 15 A Emulsion pump 15 A Hazard light Parking and tail light, left Parking and tail light, right Starter switch BW 151 AC-5...
  • Page 250 30 A Starter F161 15 A BLM (potential 30) F165 15 A Seat (potential 15) F166 Seat (potential 30) F244 BOMAG TELEMATIC (potential 15) Electric power supply for electric steering Electric power supply for electric steering Reserved BW 151 AC-5...

  • Page 251: Main Fuses

    Fig. 279 The main fuse box is located in the engine compartment. Fuse Amperage Designation 23 A Engine control, BOMAG Telematic (not via main battery switch) 40 A Preheating system 125 A Main fuse for central electrics BW 151 AC-5...

  • Page 252: Fuse, Cabin

    F264 10 A F271 10 A BCM net F150 F266 10 A Radio/Tachograph F143 20 A Rear windscreen heating 15 A Rear windscreen wiper/washer 15 A Front windscreen wiper/washer F279 15 A Spare F272 Control console cabin BW 151 AC-5...

  • Page 253: Fuses Rops

    Trouble shooting – Fuse assignment 9.3.5 Fuses ROPS The fuses are located inside the ROPS control box. Fig. 281 Fuse Amperage Designation F104 15 A Working headlights ROPS front 15 A Working headlights ROPS rear BW 151 AC-5...

  • Page 254: Engine Faults

    Excessive Engine oil level too high Check, drain off if necessary exhaust Air filter dirty Clean, replace if necessary smoke Poor compression because Have examined by a spe- of burned or broken com- cialist pression rings BW 151 AC-5...
  • Page 255 Fan, radiator or radiator cap Have examined by a spe- defective cialist Engine has Engine oil level too low Check, fill up if necessary insufficient engine oil pressure (engine oil pressure warning lamp lights) BW 151 AC-5...
  • Page 256 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 151 AC-5...

  • Page 257: Waste Disposal

    Waste disposal Waste disposal BW 151 AC-5...

  • Page 258: Final Shut-Down Of Machine

    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. 6. Drain off gear oil. BW 151 AC-5...

  • Page 259: List Of Special Tools

    List of special tools List of special tools BW 151 AC-5...
  • Page 260 List of special tools Belt tension tester BOMAG No. 079 947 09 Fig. Tool kit edge cutter BOMAG No. 059 900 80 Fig. BW 151 AC-5...
  • Page 262 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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