Table of Contents
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Operating instructions
Maintenance instructions
Original operating instructions
BW 100 AD-4 / BW 120 AD-4 / BW 125 AD-4
BW 100 AC-4 / BW 120 AC-4 / BW 125 AC-4
S/N 101 880 06 .... > / S/N 101 880 16 .... > / S/N 101 880 08 .... > / S/N 101 880 14 .... > / S/N 101 880 10 .... >
S/N 101 880 07 .... > / S/N 101 880 17 .... > / S/N 101 880 09 .... > / S/N 101 880 15 .... > / S/N 101 880 11 .... >
Tandem Vibratory Roller
Combination Roller
Catalogue No.
008 053 01
01/2012
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Table of Contents
Related Manuals for Bomag BW 120 AD-4
Summarization of Contents
Technical Data
Noise value
Details on sound pressure level on the place of the operator and guaranteed sound power level.
Vibration value
Information on weighted effective acceleration values for body and hand-arm vibration.
Safety regulations
General
Overview of machine compliance with standards, and general safety compliance.
Intended use
Specifies the approved uses for the machine, such as compaction of bituminous material.
Unintended use
Lists dangers arising from using the machine for purposes other than intended.
Remaining dangers, remaining risks
Highlights that risks remain despite adherence to standards, and persons must be attentive.
Regular safety inspections
Recommends expert inspection of the machine at least once a year.
Who is allowed to operate the machine?
Defines authorized personnel for operating, maintenance, and repair, including age and sobriety.
Changes and conversions to the machine
Prohibits unauthorized changes and warns against using non-original parts or accessories.
Damage, deficiencies, misuse of safety installations
States that unsafe machines must be taken out of service and safety installations must not be bypassed.
Notes on safety in the operating and maintenance instructions
Explains symbols used for danger, caution, and note within the manual.
Loading/transporting the machine
Provides guidelines for loading using ramps, chip spreader preparation, and articulation lock.
Lashing
Details on using shackles, checking lashing points, and securing the machine for transport.
After transport
Instructions for ensuring the foldable ROPS is properly fastened after transport.
Towing the machine
Guidance on using tow bars, towing speed, and restrictions when a chip spreader is attached.
Checking the Roll Over Protective Structure (ROPS)
Explains inspection points for the ROPS, including frame condition and fastening.
Starting the machine
Pre-operation checks including seat belt, servicing intervals, and familiarization with controls.
Before mounting the machine check whether:
Pre-mount checks including safety, cleanliness, and operational readiness of grips and platforms.
Starting
Instructions for starting the machine, including seat belt usage and control lever positions.
Starting with jump wires
Procedure for jump-starting the engine using an external battery, with safety precautions.
Starting and operation of the machine is closed rooms and trenches
Warning about exhaust gases and the need for adequate ventilation in enclosed spaces.
Driving the machine
Covers safe driving practices, including seat belt use, avoiding unstable bases, and emergency stop actuation.
Persons in the danger area
Emphasizes checking the danger zone before operating and giving warning signals.
Driving
General advice on driving, including seat belt use, road conditions, and emergency stop.
In case of unusual noises and development of smoke
Recommends troubleshooting for noises and smoke, and maintaining distance from excavation walls.
Driving on inclinations and slopes
Details on safe operation on slopes, avoiding side driving, and gear selection.
Inclination
Diagram and explanation of tipping angle measurement and risks.
Behaviour in traffic
Guidance on matching speed to conditions, giving way, and avoiding edges.
Checking the effect of vibration
Advises checking nearby buildings and supply lines when using vibration, and stopping if necessary.
Parking the machine
Steps for parking, including neutral lever, parking brake, and ignition key removal.
Parking on slopes and inclinations
Recommends measures to secure the machine against rolling away on slopes.
Refuelling
Instructions on safe refueling practices, avoiding fumes, and shutting down the engine.
Fire protection measures
Advises familiarization with fire fighting equipment and procedures.
Mounting and removing the chip spreader
Procedure for mounting/removing the chip spreader, including safety precautions.
Maintenance
General notes on performing maintenance tasks by qualified personnel and using access installations.
Working on hydraulic lines
Safety measures for working on hydraulic lines, including depressurizing and checking for leaks.
Changing hydraulic hoses
Guidelines for inspecting and replacing hydraulic hoses, including signs of wear and damage.
Working on the engine
Safety precautions for working on the engine, including shutting down and draining hot oil.
Working on electrical equipment
Safety measures for electrical work, including battery disconnection and fuse handling.
Working on the battery
Safety advice for battery work, avoiding contact with acid, and preventing short circuits.
Working on the fuel system
Safety guidelines for working on the fuel system, prohibiting open flames and smoking.
Working on wheels and tires
Safety advice for tire assembly, pressure checks, and driving with damaged tires.
Cleaning
Instructions for cleaning the machine, including steam cleaning precautions.
After maintenance work
Reminder to reinstall protective devices after maintenance.
Repair
Guidance on marking defective machines and performing repairs by qualified personnel.
Test
Recommends safety checks by a specialist at least annually for compaction equipment.
Information and safety stickers/decals on the machine
Emphasizes maintaining safety stickers and replacing damaged or illegible ones.
Stickers and decals BW 100/120/125 AD-4
Identifies various warning, information, and operation stickers/decals on the machine.
Stickers and decals BW 100/120 AC-4
Identifies various warning, information, and operation stickers/decals on the machine.
Operation sticker - Foldable ROPS
Explains the operation sticker for the foldable ROPS.
Warning sticker - Foldable ROPS
Explains the warning sticker related to the foldable ROPS.
Instruction sticker - Always wear your seat belt
Highlights the instruction sticker to always wear the seat belt.
Operation sticker - Central lifting device
Explains the operation sticker for the central lifting device.
Information sticker - Main battery switch
Describes the information sticker for the main battery switch.
Information sticker - Biodegradable hydraulic oil
Details the information sticker regarding biodegradable hydraulic oil.
Information sticker - Panolin 46
Provides information about Panolin 46, likely a lubricant.
Operation sticker "Chip spreader"
Explains the operation sticker for the chip spreader.
Warning sticker "Chipping temperature"
Highlights the warning sticker related to chipping temperature.
Indicators and Controls
Instrument cluster
Details the components of the instrument cluster, including indicators and gauges.
Start switch
Details the start switch and its different positions for ignition and engine start.
Emergency stop push button
Details the function and operation of the emergency stop push button.
Travel lever
Details the travel lever for controlling forward and reverse movement.
Throttle lever
Explains the throttle lever for adjusting engine speed.
Rotary switch for vibration, manual or automatic
Explains the rotary switch for selecting manual or automatic vibration modes.
Interval switch for pressure sprinkling system
Explains the interval switch for the pressure sprinkling system.
4.1 General notes
Introduces the chapter, advising to read 'Indicators and Control Elements' for familiarization.
4.2 Description of indicators and control elements
Detailed description of gauges, warning lights, and control elements on the instrument cluster.
Operation
5.1 General
Introduces the operation chapter, advising to read 'Indicators and Control Elements' for familiarization.
5.2 Tests before taking into operation
Lists pre-operation checks and inspections required before using the machine.
5.3 Electronic immobilizer
Explains the procedure for disarming the anti-theft protection using a code.
5.4 Adjusting the operator's seat
Details how to adjust the operator's seat for longitudinal position, backrest, and weight.
5.5 Starting the engine
Step-by-step guide for starting the engine, including safety checks and ignition sequence.
5.6 Starting with jump wires
Procedure for jump-starting the engine using an external battery, with safety precautions.
5.7 Driving the machine
Covers safe driving practices, including speed control, slopes, and seat belt usage.
5.8 Stopping the machine, operating the parking brake
Instructions for stopping the machine and applying the parking brake.
5.9 Shutting down the engine
Steps for safely shutting down the machine's engine.
5.10 Switching the vibration on and off
Details how to activate and deactivate the vibration system, including safety warnings.
Pre-selecting vibration (only AD)
Explains how to pre-select vibration for drums on AD models.
Vibration in manual mode
Describes how to select manual mode for vibration control.
Switching the vibration on
Procedure for turning on the vibration system, including throttle and travel lever settings.
Vibration in automatic mode
Explains how vibration operates automatically based on travel speed.
Switching the vibration off
Instructions on how to turn off the vibration system.
5.11 Switching the gravity sprinkling system on and off
Details how to operate the gravity feed sprinkling system.
5.12 Switching the pressure sprinkling system on and off
Explains how to operate the pressure sprinkling system using an interval switch.
5.13 Switching the tire sprinkling system on and off (only AC)
Procedure for operating the tire sprinkling system on AC models.
5.14 Actuating the emergency stop switch
Details how to actuate the emergency stop switch in critical situations.
5.15 Mounting/removing the chip spreader
Step-by-step guide for mounting and removing the chip spreader, including safety.
5.16 Filling/emptying the chip spreader
Instructions for filling and emptying the chip spreader, including capacity and safety.
5.17 Operating the chip spreader
Guidance on preparing and operating the chip spreader for material application.
Switching the chip spreader on and off
Procedure for turning the chip spreader on and off using the vibration button.
5.18 Towing
Detailed instructions and safety precautions for towing the machine.
Releasing the brake (only AD)
Procedure for releasing the brake system on AD models.
Releasing the brakes on drum and rubber wheels (only AC)
Instructions for releasing brakes on drum and wheels for AC models.
5.19 Loading/transport
Comprehensive guide to loading and transporting the machine, including ramps and cranes.
Loading with loading ramp
Specific instructions for loading the machine using a ramp.
Loading by crane
Guidelines for safely loading the machine using a crane.
Lashing
Details on securing the machine using lashing points for transport safety.
After transport
Instructions for post-transport procedures, including ROPS and articulation lock.
Maintenance
6.1 General notes on maintenance
General safety and procedural guidelines for performing maintenance work.
6.2 Fuels and lubricants
Details on recommended fuels, lubricants, and their specifications.
Engine oil
Information on engine oil quality, viscosity, and classification requirements.
Oil viscosity
Guidance on selecting engine oil viscosity based on ambient temperature.
Oil change intervals
Specifies the recommended intervals for engine oil changes.
Winter fuel
Advice on using winter diesel fuel and avoiding paraffin separation.
Coolant
Instructions on preparing and using coolant mixture, including anti-freeze agent.
Mineral oil based hydraulic oil
Details on recommended mineral oil based hydraulic oils for the system.
Bio-degradable hydraulic oil
Information on using synthetic ester based biodegradable hydraulic oil.
6.3 Table of fuels and lubricants
A table summarizing recommended fuels, lubricants, and their quantities for various conditions.
6.4 Running-in instructions
Procedures and checks required for running in new machines or overhauled engines.
6.5 Maintenance table
A comprehensive table detailing maintenance tasks and their required frequencies.
6.6 Check the engine oil level
Step-by-step guide to checking the engine oil level using the dipstick.
6.7 Checking the fuel level
Instructions for checking the fuel level using the gauge in the instrument cluster.
6.8 Check the hydraulic oil level
Procedure for checking the hydraulic oil level using the dipstick.
6.9 Checking the hydraulic oil filter element
How to check the hydraulic oil filter element using the service indicator.
6.10 Check the coolant level
Procedure for checking and topping up the engine coolant level.
6.11 Check the water separator
Instructions for checking the water separator for signs of water in the fuel.
6.12 Checking the water level
Procedure for checking and topping up the water level in the tank.
6.13 Checking the emulsion level
How to check and top up the emulsion level in the tank.
6.14 Checking the chip spreader and cleaning the spreading beam
Procedure for cleaning the chip spreader's beam and checking hydraulic connections.
6.15 Checking fuel lines and clamps
Instructions for inspecting fuel lines and clamps for damage or leaks.
6.16 Servicing the chip spreader
Lubrication points for the chip spreader components.
6.17 Changing engine oil and oil filter
Step-by-step guide for changing the engine oil and oil filter.
6.18 Checking, cleaning, replacing the combustion air filter
Procedure for checking, cleaning, or replacing the combustion air filter.
6.19 Check the air intake lines
Instructions for checking air intake lines and hose clamps for damage.
6.20 Cleaning radiator and hydraulic oil cooler
Procedure for cleaning the radiator and hydraulic oil cooler using compressed air or cleanser.
6.21 Checking, tensioning, replacing the V-belt
Guide to checking, tensioning, and replacing the V-belt.
6.22 Checking radiator hoses and hose clamps
Instructions for checking radiator hoses and hose clamps for condition and fit.
6.23 Checking, adjusting the scrapers
Procedure for checking and adjusting scrapers on drums and wheels.
6.24 Battery service
Detailed guide on battery service, including safety, checks, and charging.
6.25 Change the fuel filter
Step-by-step instructions for changing the fuel filter and bleeding the system.
6.26 Drain the fuel tank sludge
Procedure for draining sludge from the fuel tank.
6.27 Checking, adjusting the valve clearance
Instructions for checking and adjusting valve clearance on the engine.
6.28 Check the engine mounts
Procedure for checking the tightness of engine mounts and related components.
6.29 Changing hydraulic oil and breather filter
Guide for changing hydraulic oil and the breather filter.
6.30 Changing the hydraulic oil filter
Instructions for changing the hydraulic oil filter element.
6.31 Changing the coolant
Step-by-step guide for draining and refilling the engine coolant.
6.32 Replacing the fuel lines
Procedure for replacing fuel lines and hose clips.
6.33 Check the injection valves
Note that checking injection valves must be done by authorized personnel.
6.34 Checking the fuel injection pump
Note that checking the fuel injection pump must be done by authorized personnel.
6.35 Checking the tire pressure
Instructions for checking tire pressure, applicable to AC-machines.
6.36 Cleaning the water sprinkler system
Procedure for cleaning the water sprinkler system, including tank and filter.
6.37 Draining the water sprinkler system, maintenance in case of frost
Instructions for draining the water sprinkler system for frost protection.
6.38 Filling the provision tank for the windscreen washer system
Procedure for checking and filling the windscreen washer system reservoir.
6.39 Tightening torques for screws with metric unified thread
Table of tightening torques for metric unified thread screws based on strength class.
6.40 Engine conservation
Measures for conserving the engine for long-term storage to prevent corrosion.
Trouble shooting
7.1 General notes
General advice on troubleshooting, emphasizing professional personnel and correct operation.
7.2 Engine
Troubleshooting guide for engine-related faults such as starting issues, power loss, and overheating.
Disposal
8.1 Final shut-down of machine
Procedure for final machine shutdown, including battery removal and fluid draining.
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