Bomag BW 100 AD-4 BW 120 AD-4 BW 100 AC-4 BW 120 AC-4 Vibratory Roller Operating instructions Manual

Operating instructions Maintenance instructions

BW 100 AD-4 / BW 120 AD-4 BW 100 AC-4 / BW 120 AC-4 S/N 101 880 00 .... > / S/N 101 880 02 ... .> S/N 101 880 01 .... > / S/N 101 880 03 ... .>

Tandem Vibratory Roller Combination Roller

Catalogue number

008 114 81

03/2004

Foreword

BOMAG machines are products from the wide range of BOMAG compaction equipment.

F oreword

BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your machine.

You should only operate the machine after you have been instructed and in compliance with these instructions.

Strictly observe the safety regulations.

Please observe also the guidelines of the Civil Engineering Liability Association ”Safety Rules for the Operation of Road Rollers and Soil Compactors” and all relevant accident prevention regulations.

This manual comprises: l

Safety regulations

l

Operating instructions

l

Maintenance instructions

l

Trouble shooting

For your own personal safety you should only use original spare parts from BOMAG. In the course of technical development we reserve the right for technical modifications without prior notification.

These operating and maintenance instructions are also available in other languages.

Using these instructions will l

help you to become familiar with the machine.

l

avoid malfunctions caused by unprofessional operation.

Compliance with the maintenance instructions will l

enhance the reliability of the machine on construction sites,

l

prolong the lifetime of the machine,

l

reduce repair costs and downtimes.

BOMAG will not assume liability for the function of the machine l

if it is handled in a way that does not comply with the usual modes of use,

l

if it is used for purposes other than the ones it is intended for, see safety regulations.

Furthermore, the spare parts catalogue is available from your BOMAG dealer against the serial number of your machine.

Your BOMAG dealer will also supply you with information about the correct use of our machines in soil and asphalt construction.

The above notes do not constitute an extension of the warranty and liability conditions specified in the general terms of business of BOMAG. We wish you successful work with your BOMAG machine.

BOMAG GmbH Printed in Germany Copyright by BOMAG

No warranty claims can be lodged in case of damage resulting from l

operating errors,

l

insufficient maintenance and

l

wrong fuels and lubricants.

Please note!

This manual was written for operators and maintenance personnel on construction sites.

Always keep this manual close at hand, e.g. in the tool compartment of the machine or in a specially provided container. These operating and maintenance instructions are part of the machine.

BW 100/120 AD/AC-4

BOMAG

3

Foreword

Please fill in ............................

Machine type (Fig. 1) ............................

Serial-number (Fig. 1 and 2) ............................

Engine type (Fig. 3) ............................

Engine number (Fig. 3)

i Note

Fig. 1

Supplement the above data together with the commissioning protocol.

During commissioning our organisation will instruct you in the operation and maintenance of the machine.

Please observe strictly the safety regulations and all notes on risks and dangers!

Fig. 2

Fig. 3

4

BOMAG

BW 100/120 AD/AC-4

Table of Contents

Technical Data

7

Safety regulations

13

Indicators and Controls

21

3.1 General notes

24

3.2 Description of indicators and control elements

24

Operation

33 4.1 General notes

34

4.2 Inspections before starting operation

34

4.3 Starting the engine

35

4.4 Starting the engine (cold start)

37

4.5 Starting with jump wires

39

4.6 Driving the machine

40

4.7 Stopping the machine / operating the parking brake

41

4.8 Switching the vibration on and off

42

4.9 Switching the gravity sprinkling system on and off

44

4.10 Switching the pressure sprinkling system on and off

44

4.11 Switching the vibration on or off

46

4.12 Shutting the engine down

46

4.13 Shutting down the engine in events of emergency

47

4.14 Adjusting the driver's seat

48

4.15 Towing

49

4.16 Loading and transport

51

Maintenance

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55 5.1 General notes on maintenance

56

5.2 Fuels and lubricants

57

5.3 Table of fuels and lubricants

59

5.4 Running-in instructions

60

5.5 Maintenance chart

61

5.6 Check the engine oil level

63

5.7 Check the coolant level

63

5.8 Check the water separator

64

5.9 Check the fuel level

64

5.10 Check the hydraulic oil level

65

5.11 Checking the hydraulic oil filter element

65

5.12 Check the water level

66

5.13 Checking the emulsion level

66

5.14 Checking the tire pressure

67

5.15 Cleaning radiator and hydraulic oil cooler

67

5.16 Checking, tensioning, replacing the V-belt

68

5.17 Checking, adjusting the scrapers

70

5.18 Checking radiator hoses and hose clamps

71

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5

Table of Contents

5.19 Changing the engine oil

72

5.20 Changing the engine oil filter cartridge

73

5.21 Service the battery

74

5.22 Drain the sludge from the fuel tank

75

5.23 Changing the fuel pre-filter

76

5.24 Check, adjust the valve clearance

77

5.25 Changing the fuel filter cartridge, bleeding the fuel system

78

5.26 Check the engine mounts

79

5.27 Change the hydraulic oil

80

5.28 Changing the hydraulic oil filter

82

5.29 Change the coolant

83

5.30 Changing fuel lines

84

5.31 Check the injection valves

85

5.32 Checking the fuel injection pump

85

5.33 Check, clean, change the combustion air filter

86

5.34 Cleaning the water sprinkler system

89

5.35 Draining the water sprinkler system, maintenance in case of frost

91

5.36 Tightening torques for screws with metric unified thread

92

5.37 Engine conservation

92

Trouble shooting

6

93 6.1 General notes

94

6.2 Engine

95

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1 Technical Data

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7

Technical Data

Fig. 4

Dimensions in mm

A

B

D

H

H2

K

L

W

BW 100 AD-4

1728

1076

700

1800

2475

255

2475

1000

BW 120 AD-4

1728

1276

700

1800

2475

255

2475

1200

*

BW 100 AD-4

BW 120 AD-4

kg kg kg kg/cm

2220 2416 1208 11,8

2390 2586 1293 10,8

Dimensions Oscillation angle Inner track radius

+/-° mm

12 2720

12 2620

8

BOMAG

Weights Basic weight with ROPS Operating weight (CECE) Mean axle load (CECE) Mean static linear load (CECE)

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Technical Data

*

Travel characteristics Travel speed Working speed Max. gradability/with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Engine speed 1/2 Fuel tank capacity (diesel) Electrical equipment Battery Drive system Driven axles

km/h km/h %

kW rpm l V V/AH

Brakes Service brake Parking brake Steering Type of steering Steering operation Vibration system Drive system Frequency 1/2 Amplitude Vibrating drum Water sprinkler system Type Interval control Water tank capacity

Hz mm

l

BW 100 AD-4

BW 120 AD-4

0 - 12 0-7 40/30

0 - 12 0-7 40/30

Kubota D 1703 MDI Water 3 25,2 2200/2700 40 12 12/88 hydrost. front+rear

Kubota D 1703 MDI Water 3 25,2 2200/2700 40 12 12/88 hydrost. front+rear

hydrost. hydro-mechanical

hydrost. hydro-mechanical

Oscill.-articul. hydrost.

Oscill.-articul. hydrost.

hydrost.

55/67 0,53 front+rear

hydrost.

55/67 0,51 front+rear

Gravity feed

Gravity feed

**

***

220

220

* The right for technical modifications remains reserved ** Optional equipment *** Optional equipment

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9

Technical Data

Fig. 5

Dimensions in mm

A

B

BW 100 AC-4

1765

BW 120 AC-4

1765

C

D

H

H2

K

L

1076

700

1800

2490

210

2475

1000

1276

700

1800

2490

210

2475

1200

*

O

S

W

BW 100 AC-4

BW 120 AC-4

kg

2200

2380

kg kg kg/cm kg

1150 1050 11,5 263

1240 1140 10,3 285

Dimensions Oscillation angle Inner track radius

+/-° mm

12 2720

12 2620

10

BOMAG

Weights Operating weight with ROPS (CECE) Axle load, drum (CECE) Axle load, wheels (CECE) static linear load (CECE) Wheel load (CECE)

BW 100/120 AD/AC-4

Technical Data

*

BW 100 AC-4

BW 120 AC-4

0 - 10 0-6 40/30

0 - 10 0...6 40/30

Kubota D 1703 MDI Water 3 25,2 2600 2200 2700 40 12 12/88 hydrost. front+rear

Kubota D 1703 MDI Water 3 25,2 2600, 2200, 2700, 40 12 12/88 hydrost. front+rear

Tires Number of tires Tire size

4 205/60-15

4 205/60-15

Brakes Service brake Parking brake

hydrost. hydro-mechanical

hydrost. hydro-mechanical

Oscill.-articul. hydrost.

30/12

Oscill.-articul. hydrost.

30/12

hydrost.

55/67 0,53 front

hydrost.

55/67 0,50 front

Pressure Standard 220 20

Pressure Standard 220 20

Travel characteristics Travel speed Working speed Max. gradability/with vibration (soil dependent)

km/h km/h %

Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Fixed engine speed 1 Fixed engine speed 2 Fuel tank capacity (diesel) Electrical equipment Battery Drive system Driven axles

Steering Type of steering Steering operation Steering/oscillation angle

kW rpm rpm rpm l V V/AH

degree

Vibration system Drive system Frequency Amplitude Vibrating drum Water sprinkler system Type Interval control Water tank capacity Emulsion tank capacity *

Hz mm

l l

The right for technical modifications remains reserved

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11

Technical Data

The following noise and vibration values according to the EC-directive for machines, edition (98/37/ EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with the vibration switched on. The machine was standing on an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level at the work place of the operator (with cabin): BW 100 AD-4 LpA =85,3 dB(A) BW 100 AC-4 LpA = dB(A) BW 120 AD-4 LpA =83,6 dB(A) BW 120 AC-4 LpA = 83,2dB (A) The nose emission value for the machine according to the noise emission regulation 2000/14/EG is guaranteed sound capacity level of the machine: BW 100 AD-4 LWA = 106 dB(A) BW 100 AC-4 LWA = dB(A) BW 120 AD-4 LWA = 106 dB(A) BW 120 AC-4 LWA = 106 dB(A) These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 11204 for sound pressure level (LpA) at the place of the operator.

Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire boy (driver’s seat) The weighted effective acceleration value determined according to ISO 7096, is <=0,5 m/sec2.

Hand-arm vibration values Der The weighted effective acceleration value determined according to EN 500/ISO 5349, is <=2,5 m/sec2.

12

BOMAG

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2 Safety regulations

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BOMAG

13

Safety regulations

General Notes

Unintended use

This BOMAG machine has been built in accordance 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:

However, dangers may arise from this machine if it is operated by untrained personnel or if it is subject of unintended use.

l

it is used for purposes other than the ones it is intended for

l

it is operated by untrained personnel

l

it is changed or converted in an unprofessional way

l

Each person involved in the operation, maintenance and repair of the machine must therefore read and comply with these safety regulations. If necessary, this must be confirmed by obtaining the signature of the customer.

Furthermore, the following instructions and regulations must obviously also be complied with: l

applicable accident prevention instructions

l

generally accepted safety and road traffic regulations

l

country specific safety regulations. It is the duty of the operator to be acquainted with these instructions and to apply these accordingly. This applies also for local regulations concerning different types of handling work.

Should the recommendations in these instructions be different from the regulations valid in your country, you must comply with the safety regulations valid in your country.

This machine must only be used for: l

compaction of bituminous material, e.g. road surface layers

l

light compaction work in earth construction (road sub-bases)

l

You should only operate the unit with fully functional safety equipment.

l

Have the machine inspected by an expert once every year.

14

Starting and operation of the machine in explosive environments is prohibited.

Who has permission to operate the machine?

the safety instructions are not observed

Intended use

Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground.

Only trained and instructed persons of at least 18 years of age are permitted to drive and operate this machine. For operation of the machine the responsibilities must be clearly specified and complied with.

Persons under the influence of alcohol, medicine or drugs are not allowed to operate, service or repair the machine.

Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists.

Conversions and changes to the machine Unauthorized alterations to the machine are prohibited for safety reasons.

Original parts and accessories have been specially designed for this machine. We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive driving safety. The manufacturer explicitly excludes any liability for damage caused by the use of non-original parts or accessories.

Notes on safety in the operating and maintenance instructions: Danger Paragraphs marked like this highlight possible dangers for persons. !

Caution Paragraphs marked like this highlight possible dangers for machines or parts of the machine. !

BOMAG

BW 100/120 AD/AC-4

Safety regulations

Checking the roll over protection structure (ROPS)

i Note Paragraphs marked like this contain technical information for the optimal economical use of the machine.

The frame of the machine must not be warped, bent or cracked in the area of the ROPS fastening.

Environment Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.

Observe environmental regulations.

Information and safety stickers/decals on the machine Keep safety stickers in good and legible condition (see parts manual) and comply with their meaning.

The ROPS must not show any rust, damage, hairline cracks or open fractures.

The ROPS must not rattle about when driving.

This would indicate that it is not properly fastened.

All bolted connections must comply with the specifications and should be absolutely tight (observe the tightening torques). Screw and nuts must not be damaged, bent or deformed.

No accessories may be welded or bolted on and no additional holes must be drilled without the consent of the distributor, since this will impair the strength of the unit.

Replace damaged and illegible stickers/decals.

Starting the machine Loading the machine

Before starting

Use only strong and stable loading ramps of sufficient load bearing capacity. The ramp inclination must be less than the gradability of the machine.

Secure the machine against tipping or slipping off.

Secure the machine on the transport vehicle against rolling, slipping and turning over.

The machine must only be operated from the driver's seat.

Use only machines which are serviced at regular intervals.

Become acquainted with the equipment, the control elements, the working principle of the machine and the working area.

Persons are highly endangered when l

they step or stand under loads being lifted

l

they remain in the drive range of the machine during an instruction and during loading.

Wear your personal protective outfit (hard hat, safety boots, etc.).

Before climbing on the machine check whether:

The machine must not swing about when being lifted.

l

persons or obstructions are beside or under the machine

Use only safe lifting gear of sufficient load bearing capacity.

l

the machine is free of oily and combustible material

Fasten the lifting gear only at the specified lifting points.

l

all grips, steps and platforms are free of grease, oils, fuel, dirt, snow and ice

l

the engine hood is closed and locked

Towing the machine You should generally use a tow bar.

Max. towing speed 1 km/h, max. towing distance 500 m.

Before releasing the multi-disc brake secure the machine against unintended rolling.

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Use steps and grips to climb onto the machine.

Before starting the machine check whether: l

the machine shows any obvious faults

l

all guards and safety elements are in place

l

steering, brakes, control elements, light system and warning horn work correctly

BOMAG

15

Safety regulations

l

the seat is correctly adjusted

l

mirrors (if present) are clean and correctly adjusted.

Do not start the machine with defective gauges, control lights or control elements.

not use the emergency stop switch as service brake.

Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.

If the engine oil pressure control light lights up stop the engine immediately.

Do not take any loose objects with you or fasten them to the machine.

If the machine has contacted high-voltage power lines:

On machines with roll over protection system you must always wear your seat belt.

l

Do not leave the operator's platform

l

Warn others from coming close to or touching the machine

l

if possible drive the machine out of the danger zone

l

Have the electric power switched off

Starting Start and operate the machine only from the driver's seat.

For starting set all control levers to 'neutral position'.

Do not use any starting aids like start pilot or ether.

After starting check all gauges and control lights.

Operate the machine only from the operator's stand.

Starting with jump wires

Keep the cabin doors closed.

Connect plus with plus and minus with minus (ground cable) - always connect the ground strap last and disconnect it first! A wrong connection will cause severe damage in the electric system.

Do not adjust the driver's seat while driving.

Do not climb onto or off the machine while the machine is driving.

Do not start the engine by shorting the electric terminals on the starter motor, because the machine may start to drive immediately.

Starting in closed rooms Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!

Do not use the machine to transport persons.

In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected.

Always keep a sufficient distance to excavation walls and embankments and do not use working methods that could impair the stability of the machine.

Driving the machine

Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground.

Persons in the danger area

Always keep a sufficient distance when passing through subways, under bridges, tunnels, electric power lines etc.

Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions, especially when driving in reverse.

Driving on inclinations and slopes

If necessary give warning signals. Stop work immediately if persons remain in the danger zone, despite the warning.

Do not drive on gradients exceeding the maximum gradability of the machine.

On slopes drive extremely carefully and always directly up or down the slope. Change to a lower gear before starting to drive.

Do not step or stand in the articulation area of the machine when the engine is running. Danger of squashing!

Driving In events of emergency and in case of danger actuate the emergency stop switch immediately. Do

16

Change the travel direction only at standstill.

Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes. Higher risk of accident!

BOMAG

BW 100/120 AD/AC-4

Safety regulations

Behaviour in traffic

Fire protection measures

Match the speeds to the working conditions.

Familiarise yourself with the location and the operation of fire fighting equipment. Observe all fire reporting and fire fighting possibilities.

Always allow loaded transport vehicles to pass.

Switch the lights on if the visibility is poor.

Keep away from edges and embankments.

Maintenance work

Check the effect of vibration

Comply with the maintenance work described in the operating and maintenance instructions, including the information concerning the replacement of parts.

When compacting with vibration you must always check the effect of the vibration on nearby buildings and underground supply lines (gas, water, sewage, electric power) and stop compaction work with vibration, if necessary.

Maintenance work must only be performed by qualified and authorized persons.

Do not switch the vibration on when working on hard (frozen, concrete) ground. Danger of bearing damage!

For overhead maintenance and assembly work use the access steps and working platforms provided or other secure means. Do not use machine parts as access steps.

Parking the machine

Keep unauthorized persons away from the machine.

Park the machine on level and firm ground.

Do not perform maintenance work while the machine is driving or the engine is running.

Before leaving the machine: l

return the control lever to neutral position

l

apply the parking brake

l

shut the engine down and pull the ignition key out

l

secure the machine against unintended use.

Park the machine on horizontal, level and firm ground.

Do not jump off the machine, but use access steps and grips.

Mark parked machines, which could be in the way, with a clearly visible sign.

Parking on slopes and inclinations Secure the machine against rolling, place metal chocks in front of and behind the drums.

Pull the key out of the ignition switch.

Secure the articulated joint with the articulation lock.

Working on hydraulic lines Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. When being injured by hydraulic oil consult a medical doctor immediately, as otherwise this may cause severe infections.

Filling the fuel tank

Do not step in front of or behind the drums/rubber wheels when performing adjustment work in the hydraulic system.

Do not inhale any fuel fumes.

Do not change the setting of pressure relief valves.

Refuel only with the engine stopped.

Drain hydraulic oil at operating temperature - danger of scalding!

Do not refuel in closed rooms.

No open fire, do not smoke.

Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.

Wipe off spilled fuel. Keep dirt and water away from the fuel.

Leaking fuel tanks can cause explosions. Ensure tight fit of the fuel tank cover, if necessary replace immediately.

BW 100/120 AD/AC-4

Catch running out hydraulic oil and dispose of environmentally.

Always catch and dispose of biodegradable hydraulic oils separately.

Do not start the engine after draining the hydraulic oil.

BOMAG

17

Safety regulations

Working on electric components

Once all work is completed (with the system still depressurized!) check all connections and fittings for leaks.

Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.

Changing hydraulic hoses Hydraulic hoses must be visually inspected at regular intervals.

Hydraulic hoses must be immediately replaced if: l

the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks)

l

the outer layer is brittle (formation of cracks in the hose material)

l

Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fire hazard!

Before starting welding work on the machine disconnect the battery.

Working on the battery When working on the battery do not smoke, do not use open fire.

the hose shows deformations in pressurized and depressurized condition, which do not comply with the genuine shape of the hydraulic hose

Do not let acid come in contact with hands or clothes! 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!

l

the hose shows deformations in bends, e.g. squeezing, buckling, layer separation, formation of blisters

l

leakages.

l

incorrect installation.

When recharging serviceable batteries remove all plugs, to avoid the accumulation of explosive gases.

l

the hydraulic hose has separated from the fitting

Observe the applicable instructions when starting with an auxiliary battery.

l

mixing up of hoses by mistake.

l

the fitting shows corrosion that impairs both function and strength.

Dispose of old batteries in accordance with valid regulations.

l

Switch off the charging current before removing the charging clamps.

fittings are damaged or deformed, whereby the function and strength of the hose/hose connection is impaired.

Ensure sufficient ventilation, especially if the battery is to be charged in a closed room.

Only genuine BOMAG replacement hydraulic hoses ensure that the correct hose type (pressure range) is used at the right location.

Working on the engine Shut the engine down before opening the engine hood.

Drain the engine oil at operating temperature danger of scalding!

Wipe off spilled oil, catch running out oil and dispose of environmentally.

Store used filters and other oil contaminated materials in a separate, specially marked container and dispose of environmentally.

Do not leave any tools or other objects, that could cause damage, in the engine compartment.

Working on the fuel system Do not inhale any fuel fumes.

No open fire, do not smoke, do not spill any fuel.

Catch running out fuel, do not let it seep into the ground and dispose of environmentally.

Working on wheels and tires Explosion-like bursting of tires or parts of tires and rims can cause most severe or even deadly injuries.

Assembly of tires must only be performed with appropriate experience and tools. If necessary have tires assembled in a qualified workshop.

Always ensure the correct tire pressure and do not exceed the specified maximum pressure.

Check tires and wheels every day for specified pressure, cuts, bulges, damaged rims, missing

18

BOMAG

BW 100/120 AD/AC-4

Safety regulations

wheel studs or nuts. Do not drive with damaged tires or wheels.

Anti-sticking emulsions for tires must only consist of water and anti-sticking agent, in a concentration in accordance with the specifications of the manufacturer of the anti-sticking agent. Observe applicable environmental regulations.

Cleaning work Do not clean the machine while the engine is running.

Do not use gasoline or other inflammable substances for cleaning.

When using a steam cleaner for cleaning do not subject electrical parts and insulation material to the direct jet or cover these items beforehand.

Do not guide the water jet into the exhaust and into the air filter.

After maintenance work After completion of maintenance work reinstall all guards and safety features.

Repair Mark a defective machine by attaching a warning tag to the steering wheel.

Repair work must only be performed by qualified and authorized persons. Use our repair instructions for this work.

Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!

Test The safety of compaction equipment must be checked by a specialist as required in dependence on the application and the operating conditions, however at least once every year.

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BOMAG

19

Safety regulations

20

BOMAG

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3 Indicators and Controls

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BOMAG

21

Indicators and Controls

Fig. 6

22

BOMAG

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Indicators and Controls

1

Instrument cluster

11 Interval switch for pressure sprinkler system

2

Rotary switch for lighting (STVZO)*

12 Fuse boxes

3

Rotary switch for working light

13 Ignition switch

4

Rotary switch for flashing beacon*

14 Ball valve, vibration (only AD)

5

Rotary switch for hazard light system*

15 Push button for vibration

6

Rotary switch for vibration pre-selection

16 Travel lever / brake

7

Emergency stop push button

17 Throttle lever

8

Push button for warning horn

18 Rotary switch for edge cutter

9

Rotary switch for direction indicators*

19 Water level gauge

10 Rotary switch for gravity feed sprinkling system *

20 Foot switch for rubber tire sprinkling system (only AC), foot switch for flow divider (only AD)

Optional equipment

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BOMAG

23

Indicators and Controls

3.1

General notes

3.2

Description of indicators and control elements

Please read this section thoroughly before operating this machine if you are not yet conversant with the indicators and control elements. All functions are described in detail hereunder.

Paragraph 4 "Operation" contains only concise descriptions of the individual operating steps.

Fig. 7

No. 1 = Instrument cluster

i Note With the ignition switch in position I all gauges and instruments are switched on for 3 seconds. a red flashing = Overheating of engine, higher than 110°C, warning buzzer sounds.

Switch off vibration, run engine with idle speed or shut down engine if necessary, clean engine oil cooler and radiator, if necessary repair engine. b red flashing = Engine oil pressure too low, engine is shut down after 10 seconds. Check engine oil level, repair the engine if necessary. c yellow = not connected. d yellow = Charge control light, batteries are not being charged, check V-belt, repair the generator if necessary e yellow = not connected. f yellow = Seat contact monitoring while machine is travelling, warning buzzer sounds, engine is shut down after 4 seconds. g red

24

BOMAG

= Parking brake, with lever shifted to parking brake position, with driver’s seat unoccupied.

BW 100/120 AD/AC-4

Indicators and Controls

Position "middle" = Parking light on

h green flashing = Travel direction indicator, with travel direction lever actuated.

Position "right" = Travel light and parking light on, with ignition switch 28 in position "I".

i yellow = not connected. j red flashing = not connected. k yellow = Pre-heating* and after-heating = Between -30°C and +10°C pre-heating in ignition switch position I and momentary contact switch for engine speed in idle speed position. After light goes out start within 14 seconds. l red flashing = Hazard light, with hazard light switch depressed m

= Operating hour meter, counts the operating hours while the engine is running. All maintenance work must be performed according to the indicated operating hours.

n

Fig. 9

No. 3 = Rotary switch for working light Position "left"

= Fuel tank filling level

= Working light off

Position "right" = Working light on, with ignition switch 28 in position "I"

i Note Nine green and one red LED. When falling below the lowest filling level the last green LED will light and the red LED will additionally come on.

When the fuel tank is empty only the red LED will flash.

Fig. 10

No. 4 = Rotary switch for flashing beacon*** Position "left"

= Flashing beacon off

Position "right" = Flashing beacon on

Fig. 8

No. 2 = Rotary switch for lighting (STVZO)** Position "left" * **

= Light off

Optional equipment Optional equipment

BW 100/120 AD/AC-4

*** Optional equipment

BOMAG

25

Indicators and Controls

Fig. 11

Fig. 13

No. 5 = Rotary switch for hazard light system with control light *

No. 7 = Emergency stop push button

Position "left"

= Hazard light system switched off

Danger Danger of accident! !

Position "right" = Hazard light switched on, control light in instrument cluster lights up.

Use only in events of emergency during operation.

Do not use as parking brake.

Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.

The machine is braked immediately, the engine is shut down. actuate

switch off/unlock

= press the button completely down, it automatically locks in fully pressed position. = Turn button clockwise. Restart the engine.

Fig. 12

No. 6 = Rotary switch for vibration, manual or automatic Position left

= Pre-selection for vibration activation during travel via the vibration push button in the travel lever.

Position right

= Pre-selection for automatic activation and deactivation of vibration when exceeding or falling below a certain slow travel speed.

Fig. 14

No. 8 = Push button for warning horn *

26

Optional equipment

BOMAG

BW 100/120 AD/AC-4

Indicators and Controls

Fig. 15

Fig. 17

No. 9 = Rotary switch for direction indicators*

No. 11 = Interval switch for pressure sprinkler system

Position "middle" = Direction indicators off

Position 0

= Interval and pressure sprinkling system switched off.

Position "left"

= Indication left, control light and instrument cluster flashes.

Position 11

= Permanent sprinkling and function test.

Position "right" = Indication right, control light in instrument cluster flashes.

further positions

= various sprinkling intervals, activation period always 5 seconds.

Fig. 16

No. 10 = Rotary switch for gravity feed sprinkling system

Fig. 18

Position "left"

No. 12 = Fuses

= Gravity feed sprinkling system "OFF"

Position "right" = Gravity feed sprinkling system "ON"

!

Danger

Fire hazard!

Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire.

Fuse box A

*

(1) 20A

= (F68) potential 30

(2) 30A

= (F139) engine solenoid

Optional equipment

BW 100/120 AD/AC-4

BOMAG

27

Indicators and Controls

(3) 10A = (F04) gauges (4) 10A = (F119) engine (5) 10A = (F03) vibration (6) 10A = (F45) edge cutter (7) 10A = (F23) warning horn (8) 10A = (F48) pre-heating system Fuse box B (1) 15A = (F11) head lights, left * (2) 15A = (F12) head lights, right* (3) 15A = (F08) direction indicators* and working head lights

Fig. 20

(4) 15A = (F09) parking and tail light, left*

No. 13 = Ignition switch

(5) 15A = (F10) parking and tail light, right*

Position "P"/"0" = Ignition off, key can be pulled out, engine off.

(6) 15A = (F07) hazard light* (7)

= Spare

(8)

= Spare

Position "I"

= Ignition on, control and warning lights in the instrument cluster light up. The lighting system can be switched on.

i Note The engine can only be started if the travel lever is in braking position, the seat is occupied and the emergency stop switch is unlocked.

The ignition switch is designed with a lock to prevent repetitive starting. For a new starting attempt the ignition key must first be turned back to position "0".

Position "II"

= Notch for pre-heating, starting at temperatures below +10 °C, hold ignition key in position "II", until the pre-heating control light in the instrument cluster goes out.

Position "III"

= turn further against spring pressure, the engine starts, turn the ignition key back to position "I" once the engine has started.

Fig. 19

Main fuse for battery 80A

= F 00

!

Caution

Run the engine warm for a short while before starting work. Do not allow the engine to run longer than 10 minutes with idle speed.

*

28

Optional equipment

Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization.

BOMAG

BW 100/120 AD/AC-4

Indicators and Controls

Fig. 21

Fig. 23

No. 14 = Ball valve, vibration (only AD)

No. 15 = Push button vibration

Position upward

press = Vibration of both drums

= to switch the vibration on and off.

Position downward = Vibration of front drum only

Fig. 24

No. 16 = Travel lever / brake Fig. 22

Ball valve for 3-stage vibration* Position upward

= Vibration of rear drum only

Position horizontal = Vibration of both drums Position downward = Vibration of front drum only

*

Position "0"

= Neutral position for engine start, brake closed.

Position "I"

= Forward travel without vibration, brake is released.

Position "II"

= Backward travel without vibration, brake is released.

Position "III"

= max. forward/reverse travel with vibration, brake is released.

Optional equipment

BW 100/120 AD/AC-4

BOMAG

29

Indicators and Controls

Fig. 25

Fig. 27

No. 17 = Throttle lever

No. 19 = Water level gauge

Position forward ’’MAX II“ = Full load position 2700 rpm, operating position for driving and vibration.

shows the water level inside the water tank.

Position forward ’’MAX I“ = Full load position 2200 rpm, operating position for driving and vibration.

Position reverse "MIN" = Idle speed position, engine start.

Fig. 28

No. 20 = Foot switch for tire sprinkler system (only AC) press

= Sprinkling on

release

= Sprinkling off

Fig. 26

No. 18 = Rotary push button for edge cutter* Position "middle" = Edge cutter stops at the presently reached position Position "left"

= Edged cutter is raised.

Position "right" = Edged cutter is lowered.

*

30

Optional equipment

BOMAG

BW 100/120 AD/AC-4

Indicators and Controls

Danger Danger of accident! !

Always secure with locking screw.

Fig. 29

Foot switch for flow divider* (only AD) press

= flow divider switched on

release

= flow divider switched off

Fig. 30

No. 21 = Ball valve, brake releasing device (only AC-machines) Position "I"

= Brake applied

! Danger Danger of accident!

Unscrew the locking screw and secure the machine against rolling away.

i Note Release brake by turning the steering wheel in clockwise direction.

Position "II"

= Brake released

BW 100/120 AD/AC-4

BOMAG

31

Indicators and Controls

32

BOMAG

BW 100/120 AD/AC-4

4 Operation

BW 100/120 AD/AC-4

BOMAG

33

Operation

4.1

General notes

Please read section 3 Indicators and Control Elements thoroughly before operating the machine if you are not yet fully familiar with the indicators and control elements of the machine.

All indicators and control elements are described in detail in this chapter.

4.2

Inspections before starting operation

Before the everyday use or before a longer working period the following tests and inspections must be performed.

Danger Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions. !

l

Park the machine on level ground.

Test: l

Check fuel tank and fuel lines for leaks

l

Screw connections

l

Function of steering

l

Function of parking brake

l

Machine for damage

i Note The following inspection work is described in chapter 'Maintenance every 10 Operating Hours'.

34

l

Engine oil level

l

Dry air filter service indicator

l

Hydraulic oil level

l

Fuel level

l

Water level in sprinkler system

l

Emulsion level

l

Tire pressure

BOMAG

BW 100/120 AD/AC-4

Operation

4.3

Starting the engine

Fasten/release your seat belt *.

!

Caution In this chapter it is assumed that the operator is fully acquainted with the functions of the various control elements on the machine.

Fig. 33

Fasten l

Press the releasing button 1 (Fig. 33), pull the seat belt vertically out of the retractor unit and press the tongue into the buckle on the right hand side of the driver’s seat.

Fig. 31

Always start the engine from the driver’s seat with seat contact switch (Fig. 31).

l

Open

Danger Danger of accident! !

Always wear your seat belt.

Fig. 34 l

Press the release button on the buckle and pull the tongue out.

l

Press the button 1 (Fig. 34) on the retractor unit until the seat belt is completely retracted.

*

Optional equipment

Fig. 32 l

Fasten your seat belt (Fig. 32).

BW 100/120 AD/AC-4

BOMAG

35

Operation

Fig. 35 l

Shift the travel lever (Fig. 35) to position '0'.

The parking brake is closed.

Fig. 38

Turn the ignition key (Fig. 38) to position "I".

l

Fig. 39 Fig. 36 l

Set the throttle lever (Fig. 36) to position MIN, idle speed.

l

All control and warning lights (Fig. 39) in the instrument cluster light up for 3 seconds.

l

Charge control light (d), engine oil pressure warning light (b) and brake warning light (g) stay on.

Caution Perform the starting process for maximum 20 seconds without interruption and pause for a minute between starting attempts. !

If the engine has not started after two attempts perform trouble shooting.

Fig. 37 l

36

Check, whether the emergency stop switch (Fig. 37) is unlocked.

BOMAG

BW 100/120 AD/AC-4

Operation

4.4

Starting the engine (cold start)

With cold engine and temperatures below approx. +10 °C:

i Note After longer periods of standstill refer to the chapter „Starting the engine (normal starting)“.

Fig. 40 l

Turn the ignition key (Fig. 40) through position "II" to position "III" to start the engine.

l

As soon as the engine is running turn the ignition key back to position "I", charge control light and oil pressure control light go out. !

l

Check whether the fuel tap is in position „ON“.

l

Check, whether the travel lever is in “0”-position.

l

Check, whether the emergency stop switch is unlocked.

Caution

If charge control light and oil pressure warning light do not go out when the engine is running, shut the engine down immediately and perform trouble shooting.

Run the engine warm for a short while, but do not run with idle speed for more than 10 minutes.

Fig. 41 l

Set the throttle lever (Fig. 41) to "MAX I".

Fig. 42

BW 100/120 AD/AC-4

l

Turn the ignition key (Fig. 42) through position "I" to position "II" and hold it in this position for about 6 seconds.

BOMAG

37

Operation

Fig. 43

Fig. 45

The preheating control light k (Fig. 43) in the instrument cluster lights for approx. 6 seconds.

l

Shift the throttle lever (Fig. 45) back to position "MIN".

l

Caution Run the engine warm for a short while, but do not run with idle speed for more than 10 minutes. !

Fig. 44 l

Once the preheating control light has gone out turn the ignition key to position "III" (Fig. 44), the starter cranks the engine.

l

As soon as the engine ignites return the ignition key to position "I".

l

Once the engine runs correctly reduce the engine speed.

i Note At temperatures below -5 °C preheat for approx.

10 seconds.

Caution Do not preheat longer than 20 seconds without interruption. !

38

BOMAG

BW 100/120 AD/AC-4

Operation

4.5

Caution If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components. !

Starting with jump wires

l

After starting disconnect the negative poles (ground cable) first and the positive poles after.

l

Switch off the consumer.

l

Close the battery compartment with the cover.

BOMAG

39

Fig. 46 l

Remove the cover from the battery compartment (Fig. 46).

Fig. 47

!

Caution A wrong connection will cause severe damage in the electric system. l

Only use a 12 Volt battery to bridge the machine.

l

When jump starting with an external battery connect both plus poles first.

l

Then connect the ground cable first to the minus pole of the current supplying battery and then to engine or chassis ground, as far away from the battery as possible (Fig. 47).

l

Start as described under 'Starting the engine'.

l

Once the engine is running switch on a powerful consumer (working light, etc.).

BW 100/120 AD/AC-4

Operation

4.6 !

lights when the machine is driving = when the driver’s seat is unoccupied. The warning buzzer sounds. The engine is shut down after 3 seconds and the parking brake closes.

Driving the machine

Danger

Danger of accident!

Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes.

Soil conditions and weather influences impair the gradability of the machine.

Do not drive on gradients exceeding the maximum gradability of the machine.

Before starting to drive make sure that the drive range is absolutely safe.

Always give way to loaded transport vehicles!

Fig. 49

Set the throttle lever (Fig. 49) to full load position engine ’’Max I“ or ’’MAX II“.

l

i Note During operation the throttle lever always remains locked in one of the two full load positions.

Control the travel speed with the travel lever.

Fig. 48

i Note Seat contact switch control light in instrument cluster (Fig. 48): goes out

= when the driver’s seat is occupied.

lights up when the machine is at rest = when the driver’s seat is unoccupied. Drive operation is not possible. (The brake is closed).

i Note When moving the travel lever out of braking position the engine will be shut down immediately.

40

Fig. 50

!

Caution

Do not operate jerkily! l

Disengage the travel lever (Fig. 50) out of braking position and move it slowly to the desired travel direction.

BOMAG

BW 100/120 AD/AC-4

Operation

Position "I"

= max. forward travel without vibration

Position "II"

= max. backward travel without vibration

Position "III"

= Max. forward/backward travel with vibration

4.7

Stopping the machine / operating the parking brake

Fig. 52 l

Fig. 51

The parking brake warning light in the instrument cluster g (Fig. 51) lights up.

Shift the travel lever (Fig. 52) slowly to "0"-position. The machine is automatically braked by the hydrostatic drive. The brake closes.

Fig. 53

The parking brake warning light in the instrument cluster g (Fig. 53) lights up.

BW 100/120 AD/AC-4

BOMAG

41

Operation

4.8

!

Switching the vibration on and off

Pre-selecting vibration (2 stages only AD-machines)

Danger

Risk of damage When compacting with vibration you must check the effect of nearby buildings and underground supply lines (gas, water, sewage, electric power), if necessary stop compaction with vibration.

Caution Danger of bearing damage! !

Do not activate the vibration on hard (frozen, concrete) ground.

i Note Switch on the vibration only at full engine speed, set the throttle lever to full load position.

Fig. 55

Caution Destruction of hydraulic components! !

Switch over only with the vibration switched off. l

Vibration at standstill causes transverse ruts, therefore: l

l

switch the vibration on only after shifting the travel lever to the desired travel direction.

Pre-select the desired drum or drums with the ball valve (Fig. 55).

Position "top"

= Vibration of both drums

Position "bottom"

= Vibration of front drum only

Switch the vibration off before stopping the machine.

Pre-selecting the vibration

Fig. 54 l

42

Turn the rotary switch for vibration in manual or automatic mode (Fig. 54) to manual.

BOMAG

BW 100/120 AD/AC-4

Operation

Pre-selecting vibration (3 stages only AD-machines)*

Switch the vibration on

Fig. 57 Fig. 56

!

l

Set the throttle lever (Fig. 57) to full load position, engine Max I or engine Max II.

Caution

Destruction of hydraulic components!

Switch over only with the vibration switched off. l

Pre-select the desired drum or drums with the ball valve (Fig. 56).

Position upward

= Vibration of rear drum only

Position horizontal = Vibration of both drums Position downward = Vibration of front drum only

Fig. 58 l

Actuate the vibration push button (Fig. 58) only after shifting the travel lever to the desired travel direction.

i Note When shifting the travel lever through position "III" to position "I" or "II", the vibration will be automatically switched off.

Switching the vibration off l

*

Press the vibration push button again.

Optional equipment

BW 100/120 AD/AC-4

BOMAG

43

Operation

4.9

Switching the gravity sprinkling system on and off

4.10 Switching the pressure sprinkling system on and off

Fig. 59 l

l

Turn the rotary switch for gravity feed sprinkling system (Fig. 59) to the right, the gravity feed sprinkling system is switched on.

Fig. 60 l

Check whether the water tank is full (Fig. 60).

Turn the rotary switch for gravity feed sprinkling system to the left, the gravity feed sprinkling system is switched off.

Fig. 61 l

Switch the interval switch for pressure sprinkling (Fig. 61) to the desired flow interval.

Position "0"

= Sprinkling "OFF"

Position 1...10 = Interval sprinkling "ON" Position 11

44

BOMAG

= Permanent sprinkling ’’ON“

BW 100/120 AD/AC-4

Operation

Fig. 64

Fig. 62 l

To switch the sprinkler system on move the travel lever out of braking position towards "0"position (Fig. 62).

l

To switch off the pressure sprinkling system switch the interval switch for pressure sprinkling (Fig. 64) to position ’’0“.

i Note The sprinkler system will only work when the travel lever is in direction "0"-position. This is also the testing position for interval position 11.

Fig. 63 l

To switch off the sprinkler system return the travel lever to the position "brake closed" (Fig. 63).

i Note The warning light (g) in the instrument cluster must light up.

BW 100/120 AD/AC-4

BOMAG

45

Operation

4.11 Switching the vibration on or off

4.12 Shutting the engine down

i Note

Danger of accident!

Only AC-machines.

On particularly steep inclinations place wheel chocks in front of or behind the drum.

!

Danger

Fig. 65 l

Press the foot switch 23 (Fig. 65).

press

= on.

release

= off.

Fig. 66 l

If necessary press push button (Fig. 66) to switch off vibration.

l

Shift the travel lever slowly to "0"-position. The brake closes.

Fig. 67 l

46

BOMAG

The parking brake warning light in the instrument cluster (Fig. 67) lights up.

BW 100/120 AD/AC-4

Operation

4.13 Shutting down the engine in events of emergency !

Danger

Danger of accident!

In events of emergency and in case of danger actuate the emergency stop switch immediately. Do not use the emergency stop switch as service brake.

Fig. 68

Set the throttle lever (Fig. 68) to idle speed position "Engine MIN".

l

Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.

i Note Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization.

Fig. 70 l

Press the emergency stop switch (Fig. 70).

Shuts the engine down immediately and closes the brake.

Fig. 69

Turn the ignition switch (Fig. 69) to position "0" and pull the ignition key out.

l

Danger Danger of accident! !

Secure the machine against unauthorized use, pull the ignition key out.

Mark machines, which could be in the way, with a clearly visible sign.

Fig. 71

BW 100/120 AD/AC-4

l

For restarting turn the emergency stop switch in direction of arrow to unlock (Fig. 71).

BOMAG

47

Operation

i Note After operating the emergency stop switch the engine cannot be started.

4.14 Adjusting the driver's seat

To start the engine the travel lever must be in “Neutral”-position.

Fig. 72

Danger Danger of accident! !

Do not adjust the driver's seat while driving. l

Disengage the lever 1 (Fig. 72) and adjust the seat in longitudinal direction.

l

Pull the lever (2) up and adjust the backrest.

l

Use lever (3) to adjust to the weight of the operator.

i Note In this adjustment the lever (3) is locked in upwards direction. If a lighter driver's weight is to be adjusted, the lever must first be pressed down to the stop in order to release the lock. Then adjust again in downward direction.

48

BOMAG

BW 100/120 AD/AC-4

Operation

Releasing the brakes on drum and rubber wheels (only AC-machines)

4.15 Towing !

Danger

Danger of accident!

Always secure the machine against unintended rolling.

Releasing the brake (only AD-machines)

Fig. 75 l

Unscrew the locking bolt (Fig. 75).

l

Switch the ball valve over.

Position "II"

= Brake released

Turn the steering wheel slowly approx. two turns in clockwise direction.

l

Towing the machine Fig. 73 l

Remove two plugs (Fig. 73).

Fig. 76

Fig. 74

!

l

Press both screws (Fig. 74) in against springs.

l

Tighten both screws alternately and in steps with 35 Nm until they bottom.

BW 100/120 AD/AC-4

Caution

Generally use the tow bar (Fig. 76), max. towing speed 1 km/h, max. towing distance 500 m.

BOMAG

49

Operation

Fig. 77

Tow the machine by the front or rear towing eye 1 (Fig. 77).

l

Fig. 79 l

Switch the ball valve back to position "I", turn the locking screw back in and counter it with the hexagon nut (Fig. 79) (only AC-machines).

BOMAG

BW 100/120 AD/AC-4

After towing Danger The machine must only be started without the mechanical brake releasing device being activated. !

l

Completely release both screws (Fig. 74) to close the brake.

l

Screw both plugs (Fig. 73) back in.

Fig. 78 l

50

Tighten the plugs (Fig. 78) (20 Nm).

Operation

4.16 Loading and transport !

Danger

Life hazard!

Use only stable loading ramps of sufficient load bearing capacity. Make sure that persons are not endangered by the machine tipping or sliding off.

Always use shackles on the lifting points for loading, tying or lifting the machine.

Fig. 81

Lash the machine down, so that it is secured against rolling, sliding and turning over.

Do not stand or step under loads being lifted.

l

Fold up the covers on front and rear frames.

l

Lash the machine to the transport vehicle, use the lashing eyes (Fig. 81) on front and rear frame for this purpose.

Fig. 80 l

After driving the machine onto the transport vehicle swing the articulation lock (Fig. 80) out of its receptacle and fasten it with the bolt to the eye. Secure the bolt with the cotter pin.

BW 100/120 AD/AC-4

Fig. 82 l

To lift the machine pull out the lifting eye from the bracket and hook it into the lifting gear (Fig. 82).

BOMAG

51

Operation

Loading weight: See technical data.

Foldable ROPS*

After transport

Fold down for transport

Fig. 83 l

Pull the bolt out of the articulation locking bar and swing the locking bar back into its receptacle (Fig. 83).

Fig. 85 l

Slacken the eyebolts (Fig. 85) and adjust the clamping plates vertical.

l

Fold the foldable ROPS back.

Fold up after transport

Fig. 84 l

52

Store the lifting eye in the bracket (Fig. 84).

Fig. 86 l

Adjust the clamping plates on both sides vertical (Fig. 86).

*

Optional equipment

BOMAG

BW 100/120 AD/AC-4

Operation

Fig. 87 l

Fold up the foldable ROPS (Fig. 87).

l

Turn the clamping plates to horizontal position and tighten the eyebolts with a tightening torque of 75Nm to 200Nm.

BW 100/120 AD/AC-4

BOMAG

53

Operation

54

BOMAG

BW 100/120 AD/AC-4

5 Maintenance

BW 100/120 AD/AC-4

BOMAG

55

Maintenance

5.1

General notes on maintenance

l

Do not let the hose stir up the slurry at the bottom of the drum.

l

Do not draw off fuel from near the bottom of the drum.

l

The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.

When performing maintenance work always comply with the appropriate safety regulations.

Thorough maintenance of the machine guarantees higher functional safety of the unit and prolongs the lifetime of important components. The effort needed for this work is only little compared with the problems that may arise when not observing this rule.

The terms right/left correspond with travel direction forward.

Notes on the engine performance On diesel engines both combustion air quantity and fuel injection quantity are thoroughly adapted to each other and determine power, temperature level and exhaust gas quality of the engine.

l

Always clean machine and engine thoroughly before starting maintenance work.

If you engine has to work permanently in "thin air" (at higher altitudes) and under full load, you should consult the customer service of BOMAG or the customer service of the engine manufacturer.

l

For maintenance work stand the machine on level ground.

Notes on the hydraulic system

l

Perform maintenance work generally with the engine stopped.

l

Relieve hydraulic pressures before working on hydraulic lines.

l

Before working on electric parts of the machine disconnect the battery and cover it with insulation material.

l

When working in the area of the articulated joint attach the articulation lock (transport lock).

During maintenance work on the hydraulic system cleanliness is of major importance. Make sure that no dirt or other contaminating substances can enter into the system. Small particles can produce flutes in valves, cause pumps to seize, clog nozzles and pilot bores, thereby making expensive repairs inevitable. l

If, during the daily inspection of the oil level, the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks.

l

Seal external leaks immediately. If necessary inform the responsible customer service.

l

Do not store drums with hydraulic oil outdoors, or at least under cover. Water can be drawn in through the bunghole when the weather changes.

l

Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.

Always use the filling and filtering unit (BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is fitted with a fine filter to clean the hydraulic oil, thereby prolonging the lifetime of the filter.

l

Drums with inside zinc lining are not suitable to store fuel.

Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.

l

Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.

Environment During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils and fuels environmentally.

Notes on the fuel system The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel. l

l

l

56

The fuel drum must rest for a longer period of time before drawing off fuel.

BOMAG

BW 100/120 AD/AC-4

Maintenance

5.2

at least once per year, irrespective of the operating hours reached.

Fuels and lubricants

Oil quality

Engine oil In order to assure perfect cold starting it is import to chose the viscosity (SAE-class) of the engine oil according to the ambient temperature.

Lubrication oil are classified according to their performance and quality class. Specifications according to API* are commonly used.

Permitted API-oils CF/CF-4/CG-4 In regions where such qualities are not available you should consult the engine manufacturer.

Lubrication oil change intervals Caution These intervals apply only when using a diesel fuel with maximum 0.5 % sulphur by weight and for ambient temperatures higher than -10 °C. !

Fig. 88

Lubrication oil with a too high viscosity index causes starting difficulties. The temperature when starting the engine is therefore of highest importance when choosing the viscosity of engine oil for winter operation.

Oil viscosity Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAEclass) (see diagram).

Occasional falling short of the temperature limit (e.g. use of SAE 15W/40 down to -15°C) may effect the cold starting ability of the engine, but will not cause any engine damage.

Temperature related lubrication oil changes can be avoided by using multi-purpose oils. The following oil change intervals apply also when using multi-purpose oils.

Regular lubrication oil changes The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed

API: CF/CF-4/ CG-4 = 250 operating hours When using fuels with a sulphur content of more than 0,5% to 1% or under ambient temperatures below -10°C the oil change intervals must be halved.

For fuels with a sulphur content of more than 1% you should consult the responsible service agency.

Fuels Quality You should only use commercially available brand diesel fuel with a sulphur content below 0.5% and ensure strict cleanliness when filling in. A higher sulphur content has a negative effect on the oil change intervals. Use only winter-grade diesel fuel under low ambient temperatures. The fuel level should always be topped up in due time so that the fuel tank is never run dry, as otherwise filter and injection lines need to be bled.

The following fuel specifications are permitted: DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-D.

*

BW 100/120 AD/AC-4

BOMAG

American Petroleum Institute

57

Maintenance

Winter fuel

Caution Do not mix different coolants and additives of any other kind. !

For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.

Observe the instructions of the manufacturer.

In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel additives. Consult the engine manufacturer.

Hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm2/s at 40°C. For topping up or for oil changes use only high-quality hydraulic oil, type HVLP according to DIN 51524, part 3, or hydraulic oils type HV according to ISO 6743/3. The viscosity index (VI) should be at least 150 (observe information of manufacturer).

Bio-degradable hydraulic oil On request the hydraulic system can also be filled with synthetic ester based biodegradable hydraulic oil (Panolin HLP Synth. 46). The biologically quickly degradable hydraulic oil meets all demands of a mineral oil based hydraulic oil according to DIN 51524.

In hydraulic systems filled with Panolin HLP 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 lubrication oil service of the oil manufacturer for details.

Check the filter more frequently after this change.

Coolant For the coolant mixture use only clean tap water (drinking water) and anti-freeze agent acc. to SAE J1034 or SAE J814c.

As a protection against frost, corrosion and boiling point anti-freeze agents must be used under any climatic conditions.

The proportion of cooling system protection agent must be between min. 35% and max. 50% to the water.

58

BOMAG

BW 100/120 AD/AC-4

Maintenance

5.3

Table of fuels and lubricants

Assembly

Fuel or lubricant Summer

Winter

Quantity approx.

Attention Observe the level marks

Engine

Engine oil API: CF/CF-4/CG-4

approx. 6.5 litres up to max. dipstick mark

SAE 10W/40 (-20 °C to +30 °C) SAE 15W/40 (-10°C to + 40°C) SAE 30

SAE 10W

(+5 °C to +30 °C)

(-5 °C to -30 °C)

SAE 40

SAE 20W/20

(+25°C to +40°C)

(+10°C to -10°C) Fuel

Diesel Cooling system

Winter diesel fuel (down to -12 °C) Coolant Water + anti-freeze

Hydraulic system

40 litres

Hydraulic oil (ISO), HV46, kinem. viscosity

4l approx. 28 litres (tank capacity)

46 mm2/s at 40 °C or biodegradable hydraulic oil, ester based Sprinkler system

Sprinkling of tires

*

Water

Anti-freeze mixture

as required

Water*

220 litres

Emulsion

20 litres

Mix water and anti-freeze agent by following the instructions of the manufacturer

BW 100/120 AD/AC-4

BOMAG

59

Maintenance

5.4

Running-in instructions

i Note The maintenance plan under the engine hood helps with the maintenance work!

Maintenance after 50 operating hours With new or totally overhauled engines you should generally: l

Change the engine oil.

l

Change the engine oil filter.

l

Check the engine for leaks

l

Tighten the fastening screws on air filter, exhaust manifold, and other attachments.

Caution Retighten the cylinder head fastening screws to the engine. !

Maintenance after 200 operating hours

60

l

New engines normally have a higher oil consumption. It is recommended to check the oil level twice every day during the running-in period.

l

After the running-in period it is quite sufficient to check the oil level once every day.

l

Check and retighten the screws on the machine.

l

Watch out for leaks.

BOMAG

BW 100/120 AD/AC-4

Dipstick mark

5.7

Check the coolant level

X

5.8

Check the water separator

X

5.9

Check the fuel level

X

5.10 Check the hydraulic oil level

X

Dipstick mark

X

5.11 Checking the hydraulic oil filter element contamination indicator

X

5.12 Check the water level

Display gauge

X

5.13 Checking the emulsion level

only AC-machines

X

5.14 Check the tire pressure

X

5.15 Cleaning radiator and hydraulic oil cooler

X

5.16 Check, tension, replace the V-belt

X

5.17 Checking, adjusting the scrapers

X

5.18 Checking radiator hoses and hose clamps

X

5.19 Changing the engine oil

at least 1x per year

5.20 Changing the engine oil filter cartridge with each oil change 5.21 Service the battery

Pole grease

X

X

X

X X

5.22 Drain the sludge from the fuel tank

X

5.23 Change the fuel pre-filter cartridge

X

BW 100/120 AD/AC-4

BOMAG

as required

Check the engine oil level

every 3000 operating hours

5.6

every 2000 operating hours

Remark

every 1000 operating hours

Maintenance work

every 500 operating hours

No.

every 10 operating hours, daily

Maintenance chart

Running-in instructions after 50 operating hours

5.5

every 250 operating hours

Maintenance

61

5.24 Check, adjust the valve clearance

as required

every 3000 operating hours

every 2000 operating hours

every 1000 operating hours

every 500 operating hours

Remark

every 250 operating hours

Maintenance work

every 10 operating hours, daily

No.

Running-in instructions after 50 operating hours

Maintenance

X

Intake and exhaust = 0.18 to 0.22 mm on cold engine

5.25 Change the fuel filter cartridge

X

5.26 Check the engine mounts

X

X

5.27 Change hydraulic oil and breather filter* at least every 2 years

X

5.28 Change the hydraulic oil filter**

at least every 2 years

X

5.29 Replace fuel hoses and hose clamps

at least every 2 years

X

5.30 Change the coolant

at least every 2 years

X

5.31 Check the injection valves

X

5.32 Checking the fuel injection pump

X

5.33 Cleaning, changing the dry air filter car- min. 1x per year, tridge safety cartridge at least every 2 years

X

5.34 Cleaning the water sprinkler system

X

5.35 Water sprinkler system, maintenance in case of frost

X

5.36 Tightening torques

X

5.37 Engine conservation

X

* **

62

Also in case of repair in the hydraulic system.

Also in case of repair in the hydraulic system.

BOMAG

BW 100/120 AD/AC-4

Every 10 operating hours

Every 10 operating hou rs

5.6

Check the engine oil level

5.7

i Note

Check the coolant level

!

Caution Check and change coolant only when the engine is cold.

Park the machine on level ground so that the engine is in horizontal position.

If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks.

Fig. 89 l

Shutting the engine down

l

Pull the dipstick (Fig. 89) out, wipe it off with a lint-free, clean cloth and reinsert it until it bottoms.

Fig. 90 l

Check the coolant level in the compensation tank (Fig. 90).

To top up unscrew the filler cap and fill in coolant up to the MAX-mark.

l

Pull the dipstick back out again.

l

The oil level should reach the upper mark (MAX) on the dipstick.

l

l

If the oil level is too low top up oil immediately.

For quality of coolant refer to the chapter 5.2, fuels and lubricants.

For quality and quantity of oil refer to the ”table of fuels, lubricants and filling capacities”.

BW 100/120 AD/AC-4

BOMAG

63

Every 10 operating hours

5.8

Check the water separator

5.9

i Note

!

The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the water separator every day for signs of water.

l

Slacken the drain plug (Fig. 91) for a few turns and catch running out fuel / water.

l

Tighten the drain plug again and check for leaks, if necessary replace the seal ring.

64

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke.

Do not refuel in closed rooms.

Environment Catch running out fuel and dispose of environmentally.

Fig. 91

Check the fuel level

!

Caution Fill in fuel through the filter screen. l

Clean the area around the filler opening.

Fig. 92 l

Open the fuel filler cap (Fig. 92) and check the fuel level visually.

l

If necessary top up with fuel (diesel or winter diesel), see table of fuels and lubricants.

BOMAG

BW 100/120 AD/AC-4

Every 10 operating hours

5.10 Check the hydraulic oil level !

Caution If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks.

5.11 Checking the hydraulic oil filter element

i Note If the hydraulic oil is very cold the pin may pop up, you should therefore only check the filter and press the pin in at operating temperature.

In hydraulic systems filled with Panolin HLP Synth. 46 always use the same oil to top up.

With other ester based oils consult the lubrication oil service of the respective oil manufacturer. l

Clean the area around the filler opening.

l

Remove the filler cap.

Fig. 94 l

Check the service indicator 1 (Fig. 94) at operating temperature and with the engine running at maximum speed.

l

If necessary press the pin in.

Pin remains pressed in Fig. 93

Pin pops out

l

Check the oil level on the dipstick. The oil level must be between the "MIN" and "MAX" marks (Fig. 93).

l

If the oil level is too low top up hydraulic oil immediately.

= Hydraulic oil filter element o.k. = Replace the hydraulic oil filter element

For quality and quantity of oil refer to the ”table of fuels and lubricants”.

BW 100/120 AD/AC-4

BOMAG

65

Every 10 operating hours

5.12 Check the water level

5.13 Checking the emulsion level

i Note

i Note

If there is a risk of frost observe the special service instructions under "water sprinkler system, maintenance in case of frost".

For mixing ratio of water and emulsion refer to the specification of the respective manufacturer.

Make sure that the ventilation bore in the filler cap is free.

Fig. 97 l

Unscrew the cover (Fig. 97) and check the emulsion level, fill up if necessary.

Fig. 95 l

Check the water tank filling level on the water level gauge (Fig. 95).

Fig. 96 l

Open the cap (Fig. 96) and check the water level.

l

If necessary fill in water through the filler screen and close the cap again.

66

BOMAG

BW 100/120 AD/AC-4

Every 250 operating hours

Every 250 oper ating hours

5.14 Checking the tire pressure

5.15 Cleaning radiator and hydraulic oil cooler

i Note Only AC-machines

!

Danger

Danger of injury!

Do not perform cleaning work while the engine is running.

Cleaning with compressed air

Fig. 98 l

Check the tire pressure with a pressure gauge (Fig. 98).

Nominal value: approx.2.2 bar

i Note Ensure equal pressure in all rubber tires!

Fig. 99 l

Blow the cooling air passages out with compressed air from the air discharge side (Fig. 99).

Fig. 100

BW 100/120 AD/AC-4

l

Blow out the air supply side of the hydraulic oil cooler (Fig. 100).

BOMAG

67

Every 250 operating hours

Cleaning with cold cleansing agent Caution Protect electrical equipment such as generator, regulator and starter against the direct water jet. !

l

l

Spray engine and cooler with a suitable cleansing agent, e.g. cold cleanser, let it soak in for a while and spray it off with a strong water jet.

Run the engine warm for a while to avoid corrosion.

5.16 Checking, tensioning, replacing the V-belt !

Danger

Danger of accident!

Perform this work only with the engine shut down.

Checking the V-belt

Fig. 101

68

l

Check the entire circumference of the V-belt (Fig. 101) for damage and cracks. Replace damaged or cracked V-belts.

l

Check with thumb pressure whether the V-belt can be depressed more than 7 to 9 mm between the V-belt pulleys, retighten if necessary.

BOMAG

BW 100/120 AD/AC-4

Every 250 operating hours

Tensioning the V-belt

Caution Check the V-belt tension again after a running time of 30 minutes. !

Fig. 102 l

Slacken the fastening screws 1 and 2 (Fig. 102) slightly.

l

Press the generator in direction outward using a lever, until the correct V-belt tension is reached.

l

Retighten all fastening screws and check the V-belt tension once again.

Changing the V-belt

Fig. 103 l

Slacken the fastening screws 1 and 2 (Fig. 103) slightly.

l

Press the generator completely against the engine.

l

Take the old V-belt off.

l

Fit the new V-belt to the V-belt pulleys.

l

Tension the V-belt as previously described.

BW 100/120 AD/AC-4

BOMAG

69

Every 250 operating hours

Wheels on AC-machines

5.17 Checking, adjusting the scrapers Drums

i Note If the scrapers (2 per drum) are worn, they must be adjusted or replaced.

Fig. 105 l

Open the rear flap, check the scrapers, replace if necessary (Fig. 105).

l

Adjust the scraper with the screws, so that it has a uniform distance of approx. 2 mm to the rubber tires.

BOMAG

BW 100/120 AD/AC-4

Fig. 104 l

Open the flap, check the scrapers, replace if ncessary.

l

If necessary adjust the scrapers after slackening the hexagon screws (Fig. 104).

70

Every 250 operating hours

5.18 Checking radiator hoses and hose clamps !

Danger

Danger of burning!

Perform inspection work only after the engine has cooled down and with the engine stopped.

Caution If a radiator hose is swollen, hardened or cracked, both hose and hose clamp must be replaced immediately. !

Fig. 106 l

Check the conditon and tight fit of all readiator hoses and hose clamps (Fig. 106).

BW 100/120 AD/AC-4

BOMAG

71

Every 500 operating hours

Every 500 operating h ours

5.19 Changing the engine oil !

Caution The oil change at 250 operating hours refers to the use of oils of oil quality class API CF, CF-4 or CG-4 and a fuel sulphur content of less than 0.5%.

When using fuels with a sulphur content higher than 0.5% the oil change intervals must be halved (see section 5.2 fuel and lubricants).

Drain the engine oil only when the engine is warm.

Fig. 108

! Danger Danger of scalding!

l

Unscrew the left hand drain plug (Fig. 108) and catch running out oil.

l

Turn the drain plug tightly back in.

When draining off hot oil.

By hot oil when unscrewing the engine oil filter.

Environment Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.

Fig. 109 l

Fill in new engine oil (Fig. 109).

For quality and quantity of oil refer to the table of fuels and lubricants. l

Tighten the oil filler cap properly.

Fig. 107 l

72

Unscrew the oil filler plug (Fig. 107).

BOMAG

BW 100/120 AD/AC-4

Every 500 operating hours

5.20 Changing the engine oil filter cartridge !

Caution

The oil change at 250 operating hours refers to the use of oils of oil quality class API CF, CF-4 or CG-4 and a fuel sulphur content of less than 0.5%.

When using fuels with a sulphur content higher than 0.5% the oil change intervals must be halved (see section 5.2 fuel and lubricants).

Fig. 110 l

Check the oil level again after a short test run (Fig. 110), if necessary fill up to the Max.mark.

Drain the engine oil only when the engine is warm.

Danger Danger of scalding! !

By hot oil when unscrewing the engine oil filter.

Environment Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.

Fig. 111

BW 100/120 AD/AC-4

l

Unscrew the filter cartridge 1 (Fig. 111) using an appropriate filter wrench.

l

Clean the sealing face on the filter carrier from any dirt.

BOMAG

73

Every 500 operating hours

5.21 Service the battery !

Danger

Danger of explosion, causticization!

When working on the battery do not use open fire, do not smoke!

Do not let acid come in contact with skin or clothes!

Wear safety goggles!

Do not lay any tools on the battery!

Fig. 112 l

Slightly oil the rubber seal on the new filter cartridge (Fig. 112).

l

Turn the new filter cartridge on by hand, until the seal contacts.

l

Tighten the filter element for another half turn.

l

Check the filter cartridge for leaks after a short test run.

For recharging remove the plugs from the battery to avoid the accumulation of highly explosive gases. !

Caution Dispose of the old batteries environmentally.

Maintenance free batteries:

Fig. 113 l

74

BOMAG

Disassemble the covering flap of the battery compartment (Fig. 113).

BW 100/120 AD/AC-4

Every 500 operating hours

5.22 Drain the sludge from the fuel tank !

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke.

Environment Do not spill any fuel.

Fig. 114 l

Clean battery and battery compartment (Fig. 114).

Catch running out fuel, do not let it seep into the ground.

l

Clean battery poles and pole clamps and grease them with pole grease (Vaseline).

i Note

l

Tighten the terminal clamps.

l

Check the fastening of the battery.

When performing this work the fuel tank shall only hold max. 5 litres of fuel, pump off if necessary.

Non-maintenance free batteries: Clean battery and battery compartment.

l

Caution Top up missing fluid with distilled water. !

l

Unscrew the plugs and check the acid level, if necessary top up with distilled water.

With control inserts The acid level must reach the bottom of the control inserts.

Fig. 115

Without control inserts

l

The acid level must reach 10 to 15 mm above the upper edge of the lead plates.

Unscrew the plug (Fig. 115) from underneath the fuel tank and let the fuel run out.

l

Once all fuel has run out screw the oil drain plug back in with a new seal ring.

i Note Measure the acid level with a clean wooden stick.

With transparent battery housing The acid level must reach the mark on the housing. l

Clean battery poles and pole clamps and grease them with pole grease (Vaseline).

l

Tighten the terminal clamps.

l

Check the fastening of the battery.

BW 100/120 AD/AC-4

BOMAG

75

Every 500 operating hours

5.23 Changing the fuel pre-filter !

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke.

Do not spill any fuel. !

Caution Environmental damage!

Catch running out fuel, do not let it seep into the ground.

Fig. 116 l

Loosen the hose clamps (Fig. 116).

l

Pull the fuel filter out of the hoses.

l

Install the new fuel filter by observing the flow direction (arrow).

76

BOMAG

BW 100/120 AD/AC-4

Every 1000 operating hours

Every 1000 operating hours

5.24 Check, adjust the valve clearance

i Note Check and adjust only when the engine is cold.

Caution The first cylinder is the one nearest to the cooling fan side. !

Fig. 119

Crankshaft position 1 (Fig. 119) l

Crank the engine with the starter or a spanner by the V-belt pulley until both valves on cylinder 1 are “overlapping”.

Overlapping means: Exhaust valve not yet closed, intake valve starts to open. l

Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 1", black mark.

l

For control purposes mark the respective rocker arm with while chalk once the corresponding valve is adjusted.

Fig. 117 l

Remove the valve cover (Fig. 117).

Valve adjustment schematic

Fig. 120

Crankshaft position 2 (Fig. 120) Fig. 118

l

Turn the crankshaft one revolution (360°) further.

l

Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 2", black mark.

Valve 1 (Fig. 118) white = not adjustable Valve (2) black = adjustable

I

BW 100/120 AD/AC-4

BOMAG

= Intake valve

77

Every 1000 operating hours

E

= Exhaust valve

5.25 Changing the fuel filter cartridge, bleeding the fuel system

Check the black valves (Fig. 119) on cylinders 1, 2 and 3, adjust if necessary.

l

Danger Fire hazard! !

When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.

Do not inhale any fuel fumes.

Environment Catch running out fuel, do not let it seep into the ground.

Fig. 121

Check the gap between rocker arm and valve with a feeler gauge (Fig. 121).

l

Dispose of used filter cartridges and diesel fuel in compliance with local regulations.

Valve clearance: Intake valve and exhaust valve 0,18 – 0.22 mm.

If the gap is too wide or too narrow for the feeler gauge, the valve clearance must be adjusted.

l

i Note Mark checked and adjusted valves with chalk.

Assemble the cylinder head cover with a new gasket.

l

i Note After a short test run check the engine for leaks.

Fig. 122 l

Slacken and unscrew the fuel filter cartridge (Fig. 122).

l

Clean the sealing face on the filter carrier from any dirt.

l

Apply a thin film of fuel to the seals and screw the filter on hand-tight.

Bleeding of the fuel system Caution Fire hazard! !

Do not bleed the engine while it is hot, running out fuel dripping on the hot exhaust can cause a fire.

78

BOMAG

BW 100/120 AD/AC-4

Every 1000 operating hours

5.26 Check the engine mounts

Fig. 123 l

Open the bleeding screw (Fig. 123) on the top end of the injection pump.

Fig. 125 l

Check the fastening of intake and exhaust tubes (Fig. 125) on the cylinder heads for tight fit.

l

Check sockets and clamps on the air filter for tight fit and leak tightness.

l

Check fastening and tightness of the lubrication oil sump.

Fig. 124 l

Operate the fuel pump (Fig. 124) until fuel runs out of the bleeding screw without air bubbles.

l

Retighten the bleeding screw.

Fig. 126

BW 100/120 AD/AC-4

l

Check the condition and tight fit of the engine pillow blocks (Fig. 126).

BOMAG

79

Every 2000 operating hours

Every 2000 operating hour s

5.27 Change the hydraulic oil !

Danger

Danger of scalding!

Danger of scalding by hot oil. !

Caution

Perform the oil change when the hydraulic oil is warm.

Apart from the normal oil change intervals, the hydraulic oil must also be changed after major repairs in the hydraulic system.

Fig. 127 l

Remove the cover from the hydraulic oil tank (Fig. 127).

Do not use any detergents to clean the system.

Do not start the engine after draining the hydraulic oil. Do not run the pumps without oil.

Replace the hydraulic oil filter element with every hydraulic oil change.

When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details.

Environment Environmental damage!

Catch old oil and dispose of environmentally.

Fig. 128 l

Unscrew the right hand plug (Fig. 128), drain off and collect all hydraulic oil.

l

Turn the plug tightly back in.

i Note Generally replace the hydraulic oil filter element after the test run. l

l

80

Drive the machine, until the hydraulic oil has reached operating temperature.

Shut down the engine.

i Note We recommend to use the filling and filtering unit (BOMAG part-no. 079 930 35) with fine filter to fill the hydraulic system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system.

BOMAG

BW 100/120 AD/AC-4

Every 2000 operating hours

Fig. 129 l

Fill in new hydraulic oil (Fig. 129).

l

Perform a test run and check the system for leaks.

Fig. 131 l

Close the tank with a new cover (Fig. 131).

i Note

For quality and quantity of oil refer to the table of fuels and lubricants.

The breather filter for the hydraulic oil tank is integrated in the filler cap, you must therefore replace the complete filler cap.

Fig. 130 l

Check the hydraulic oil level on the dipstick (Fig. 130).

BW 100/120 AD/AC-4

BOMAG

81

Every 2000 operating hours

5.28 Changing the hydraulic oil filter !

Danger

Danger of scalding!

Danger of scalding by hot oil when unscrewing the oil filter.

Caution If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the oil change and after the test run. !

Fig. 132 l

Unscrew spigot nut 4 (Fig. 132) and take off filter bowl (5) with filter element (3).

l

Examine the surface of the filter element thoroughly for any visible dirt.

l

Take the old filter element (3) out, clean the filter bowl and thread.

l

Assemble the filter bowl with new filter element, check the condition of O-rings (1) and (2), if necessary use new ones.

l

After a short test run check the filter for leaks.

BOMAG

BW 100/120 AD/AC-4

Do not use the oil in the filter bowl again.

Visible dirt may be an early sign for the failure of system components and indicate the possible failure of components. In this case determine the cause and replace or repair the defective components, if necessary. Negligence may cause destruction to the entire hydraulic system.

Do not clean or reuse the filter element.

Apart from the normal oil change intervals, the filter element must also be changed after major repairs in the hydraulic system.

Environment Catch running out oil, dispose of oil and filter element environmentally.

82

Every 2000 operating hours

5.29 Change the coolant !

Danger

Danger of scalding!

Change the coolant only when the engine is cold.

Do not remove the radiator cap when the engine is still hot.

Always wear gloves when handling anti-freeze agent.

Fig. 134

Caution Always screw the radiator cap tightly back on (second detent). !

l

Unscrew the drain plug (Fig. 134).

l

Drain the coolant completely off and collect it.

l

SCrew the drain plug back in.

Always fill the engine cooling system with an anti-freeze mixture (corrosion protection).

Do not use more than 50% anti-freeze.

Do not mix different types of anti-freeze.

Environment Catch running out coolant and dispose of environmentally.

Fig. 135 l

Open the drain cock (Fig. 135).

l

Drain the coolant completely off the engine block and collect it.

l

Close the shut-off cock again

l

Empty the coolant compensation tank.

l

Check the condition of radiator hoses, if necessary replace all radiator hoses.

BOMAG

83

Fig. 133 l

Remove the radiator cap (Fig. 133).

l

Disassemble the left hand side plate from the front frame.

BW 100/120 AD/AC-4

Every 2000 operating hours

5.30 Changing fuel lines

i Note For safety reasons this work should be performed every two years.

Hoses consist of rubber or plastic material and age over the course of time.

Danger Fire hazard! !

Fig. 136 l

When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.

Fill in coolant until the level reaches the bottom edge of the filler socket (Fig. 136).

Do not inhale any fuel fumes.

Environment Catch running out fuel, do not let it seep into the ground. l

Replace all fuel hoses, including their hose clips.

Fig. 137 l

Fill in coolant up to the “MAX” mark (Fig. 137).

For quality of coolant refer to the chapter 5.2, fuels and lubricants. l

Reattach radiator cap and cap of the compensation tank.

l

Start the diesel engine and run it warm to operating temperature.

l

Let the engine cool down and check the coolant level again, if necessary top up in the compensation tank.

84

BOMAG

BW 100/120 AD/AC-4

Every 3000 operating hours

Every 3000 operating hours

5.31 Check the injection valves

5.32 Checking the fuel injection pump

i Note This work must only be performed by authorized service personnel.

BW 100/120 AD/AC-4

i Note This work must only be performed by authorized service personnel.

BOMAG

85

As required

As requir ed

5.33 Check, clean, change the combustion air filter !

Caution

Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.

Do not use gasoline or hot fluids to clean the filter element.

After cleaning the filter element must be inspected for damage using a torch.

Air filter elements with damaged paper bellows or seal lips must be replaced in any case.

The main filter element must be replaced after 3 times cleaning, but at the latest after one year, irrespective of the operating hours.

Each cleaning interval must be marked with a cross on the cover of the filter element.

Cleaning does not make sense if the air filter element is covered with a sooty deposit. Use a new filter element.

Fig. 138

Service of the dry air filter is due when the red piston of the filter service indicator (Fig. 138) reaches into the transparent window, but at the latest after one year. !

Caution After cleaning the air filter press the reset button for the red piston on the filter service indicator.

Incorrectly handled filter elements may become ineffective because of damage (e.g.: cracks) and cause engine damage.

Open the engine hood.

l

i Note Under very dusty conditions you may have to check the filter service indicator every day.

Fig. 139

86

l

Release the locking hook (Fig. 139) and take the filter hood off.

l

Clean filter hood and dust discharge valve.

BOMAG

BW 100/120 AD/AC-4

As required

Fig. 140

Fig. 142

Carefully loosen the main filter element (Fig. 140).

l

l

The main filter element is located directly on the air intake tube, thereby providing a seal on the inside of the filter cover. Carefully remove the main filter element, in order to reduce the released amount of dust. To release the seal pull the main filter element carefully up, down and sideways or turn it (Fig. 140).

Caution Avoid contact between main filter element and housing. !

Clean the sealing face on the outlet tube (Fig. 142).

Dust on the outer diameter of the outlet tube can impair effective sealing. l

Check the old main filter element.

The old main filter element can be of help to discover foreign particles on the sealing face, which could lead to leaks. A line of dust on the clean air side of the filter may be a sign for such a leak.

Eliminate this problem before installing a new main filter element. l

If the main filter element is damaged, the safety element must be replaced as well.

l

Clean or replace the main filter element.

i Note We generally recommend to change the filter. A new filter element is far less expensive than a possible engine damage. l

Before installing the new main filter element check it for possible damage from transport, cleaning or incorrect handling. Especially on the inside of the open end (sealing area). Do not install damaged filter elements.

Fig. 141 l

Pull the main filter element (Fig. 141) carefully out of the housing.

BW 100/120 AD/AC-4

Examine the main filter element thoroughly for damage.

l

BOMAG

If necessary use safety elements.

87

As required

Fig. 143

Fig. 144

Insert the main filter element (Fig. 143).

l

The radial sealing area is located at the inside of the open filter edge. This critical sealing area must be under slight tension after the filter has been installed. In order to achieve a tight seal apply pressure to the outer edge of the filter and not to the moveable centre.

i Note For cleaning purposes fit a tube to the compressed air gun (Fig. 144), the end of which should be bent for approx. 90°.

The length should reach down to the bottom of the element.

Reinstall the filter hood with the dust discharge valve.

l

Caution The dust discharge valve must point vertically downwards.

Blow the main filter element out with compressed air (max. 5 bar) from inside to outside by moving the tube up and down inside the element, until it if free of dust.

l

Examine the main filter element with a torch for cracks and holes in the paper bellows.

l

!

Dry cleaning of the main filter element !

Danger

Eye injury!

Wear protective clothing (goggles, gloves).

Caution Do not continue to use a damaged main filter element. If in doubt use a new main filter element. !

Changing the safety filter element Caution The safety filter element must not be cleaned and should not be used again after it has been removed. !

The safety filter element must be replaced: if the main filter element is defective, after three times cleaning of the main filter element, at the latest after 2 years,

88

BOMAG

BW 100/120 AD/AC-4

As required

if the red piston of the filter service indicator is visible again after completion of the service work. l

5.34 Cleaning the water sprinkler system

Remove the housing cover and pull the main filter element off.

i Note If there is a risk of frost observe the special service instructions under "sprinkler system, maintenance in case of frost".

Fig. 145 l

Pull the safety element (Fig. 145) out by turning it lightly.

l

Push in a new safety filter element.

l

Reassemble main filter element and cover.

Fig. 146 l

Remove the water tank cover (Fig. 146).

Fig. 147

BW 100/120 AD/AC-4

l

Open the covering flap (Fig. 147) on the right hand side of the rear frame.

BOMAG

89

As required

l

Screw the olastic caps back on again.

l

Check the function of the sprinkler tubes, if necessary clean or replace the nozzles.

Environment Catch and dispose of old emulsion environmentally. l

Empty the emulsion tank*.

Fig. 148 l

Take out the drain hose (Fig. 148).

l

Open the drain tap, let all water run out and close the drain tap again.

Fig. 150 l

Loosen the fitting, take the emulsion filter (Fig. 150) out and clean it.

l

Flush the emulsion tank thoroughly.

l

Reinsert the emulsion filter and tighten the fitting.

Fig. 149 l

Unscrew the water hose at the water filter (Fig. 149).

l

Unscrew the water filter from the water tank.

l

Unscrew the filter element from the cover, clean it and screw it back onto the cover.

l

Flush the water tank out with a strong water jet.

l

Let all water with dirt run out.

l

Screw the cover with the filter element back on.

l

Unscrew the plastic caps from the end of the sprinkler tube.

l

Fill the water tank with clean water.

l

Activate the sprinkler system for a short while so that all lines are flushed out.

90

Fig. 151 l

Fill the emulsion tank (Fig. 151).

l

Check the function of the sprinkler tubes, if necessary clean or replace the nozzles.

*

AC-machines

BOMAG

BW 100/120 AD/AC-4

As required

5.35 Draining the water sprinkler system, maintenance in case of frost Caution If there is a risk of frost the water sprinkler system must be completely emptied or filled with an anti-freeze mixture. !

In this case frost protection measures are of greatest importance in order to avoid freezing of sensitive components like pump, solenoid valve and water filter.

Fig. 154 l

Take out the drain hose (Fig. 154), open the drain tap and let all water run out.

Draining the water sprinkler system

Fig. 155 Fig. 152 l

l

Remove the water tank cover (Fig. 152).

Open the hose coupling (Fig. 155) and let the water run out.

Filling the sprinkler system with antifreeze mixture l

Close drain tap and drain hose.

l

Join the hose couplings together.

l

Fill the water tank with approx. 5 l of antifreeze mixture (water and anti-freeze agent).

l

Switch the sprinkler system on, until antifreeze mixture comes running out of the sprinkler tubes.

Environment

Fig. 153 l

Open the covering flap (Fig. 153) on the right hand side of the rear frame.

BW 100/120 AD/AC-4

After the frost period drain off the anti-freeze mixture and dispose of environmentally.

BOMAG

91

As required

5.36 Tightening torques for screws with metric unified thread

5.37 Engine conservation If the engine is to be shut down for a longer period of time (e.g. over winter), we recommend to apply the following conserving measures to avoid corrosion: l

Clean the engine, including the cooling system: With cold cleansing agent and a water jet or, even better, with a steam cleaner.

l

Run the engine warm and shut it down.

l

Drain off the still hot engine oil and fill in anticorrosion engine oil.

l

Drain off the coolant and fill in system protection agent.

l

Drain the fuel from the tank, mix it well with 10% anti-corrosion oil and fill it back in.

l

Run the engine for 10 minutes until all lines, filters, pumps and nozzles with this conserving mixture and the new engine oil has been distributed to all parts.

l

Now crank the engine several times (without ignition) to spray the combustion chambers.

l

Take the V-belts off and spray the grooves of the V-belts with anti-corrosion oil. Remove the anti-corrosion oil before resuming operation.

l

Close intake and exhaust openings tightly.

Fig. 156

* Strength classes for screws with untreated, nonlubricated surface. Screw quality designations are stamped on the screw heads.

8.8 = 8G 10.9 = 10K 12.9 = 12K The values result in a 90% utilization of the screw's yield point at a coefficient of friction µ total = 0,14.

Compliance with the tightening torque is checked with torque wrenches.

The specified tightening torques do not apply when using MoS2 lubricants.

i

Note

Self-locking nuts must always be replaced once they have been unscrewed.

i Note Depending on the weather conditions these conserving measures will provide protection for approx. 6 to 12 months.

Before taking the engine back into operation all conserving oil must be drained off and replaced by regular engine oil, see chapter "Fuels and Lubricants" according to the API-(MIL)-classification.

Anti-corrosion oils are those that comply with the specification MIL-L-21260 B or TL 9150037/2 or Nato Code C 640/642.

A machine with a conserved engine must be marked by attaching a clearly visible warning tag.

92

BOMAG

BW 100/120 AD/AC-4

6 Trouble shooting

BW 100/120 AD/AC-4

BOMAG

93

Trouble shooting

6.1

General notes

The following work must only be carried out by qualified and trained personnel or by the BOMAG sales service.

Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions.

Faults occur frequently due to the fact, that the machine has not been properly operated or serviced. Therefore, whenever a fault occurs, read through these instructions on correct operation and maintenance. If you cannot locate the cause of the fault or eliminate it yourself by following the trouble shooting charts, you should contact our customer service departments at our branch office or dealers.

On the following pages you will find a selection of fault remedies. It is quite obvious that we were not able to list all possible causes for faults.

94

BOMAG

BW 100/120 AD/AC-4

Trouble shooting

6.2

Engine

Faults

Possible cause

Remedy

The engine does not start

Fuel tank empty

Fill the tank

Fuel filter clogged,in winter due to paraffin separation

Change the filter Use winter fuel

Fuel lines leaking

Check all line connections for leakages and tighten the fittings.

Travel lever not in "0"-position

Move the travel lever to "0"-position

Battery discharged or not connected

Charge the battery, check the terminal clamps

Operating error

see chapter "Starting the engine"

Incorrect valve clearance

Adjust the valve clearance

Lack of oil

Top up engine oil

Emergency stop switch is engaged.

Emergency stop switch is unlocked.

Battery power too low

Have the battery inspected

Battery clamps loose or oxidized, causing the starter to turn too slowly

Clean the terminal clamps, tighten them and cover them with acid free grease

Especially during winter: the use of too viscous engine oil

Use engine oil suitable for the ambient temperature

Insufficient fuel supply, clogging of the fuel system due to paraffin separation in winter

Change the fuel filter Check the line connections for leaks and tighten the fittings.

Use winter fuel in the cold season.

Incorrect valve clearance

Adjust the valve clearance

Injection valves or injection pump defective

Have examined by a specialist

Air filter cartridge dirty

Clean, change if necessary

Excessive play in the throttle cable

Adjust the throttle cable, change it if necessary

Engine oil level too high

Drain the oil to the upper dipstick mark

Poor fuel quality

Use specified fuel

Air filter dirty

Clean, change if necessary

Poor compression due to burned or broken compression rings or incorrect valve clearance

Have compression rings and pistons examined by a specialist, adjust the valve clearance

Injection valve defective

Have examined by a specialist

The engine starts poorly and works irregularly with poor power

Engine loses power and speed, excessive exhaust smoke

BW 100/120 AD/AC-4

BOMAG

95

Trouble shooting

Faults

Possible cause

Remedy

Engine overheats, shut down immediately!

Radiator excessively soiled

Clean the cooling fins

Coolant level to low

Top up coolant.Danger! Only when the engine is cold

Injection valve defective

Have examined by a specialist

Engine oil level too low

Top up engine oil to the upper dipstick mark

Filling capacity of the injection pump not correctly adjusted

Have adjusted by a specialist

Lack of cooling air at the cooling air blower

Clean the cooling air duct

V-belt loose or broken

Tension or replace the V-belt

Air filter cartridge dirty

Clean, change if necessary

Leakages in the lubrication system, oil level too low

Check fittings on oil lines, lubrication oil filter for leaks, tighten the fittings if necessary. Top up lubrication oil up to the upper mark on the dipstick.

Engine oil of wrong SAE-class

Change the engine oil.

The generator does not charge the battery, because generator or regulator is defective

Have examined by a specialist

Engine oil pressure too low, shut down immediately

The charge control light lights during operation

96

BOMAG

BW 100/120 AD/AC-4