BW 100 AD-4
Bomag BW 100 AD-4, BW 120 AD-4, BW 125 AD-4, BW 100 AC-4, BW 120 AC-4 Operator Manual
...
Operating instructions
Maintenance instructions
Original operating instructions
01/2012
Catalogue No.
008 053 01
BW 100 AD-4 / BW 120 AD-4 / BW 125 AD-4
BW 100 AC-4 / BW 120 AC-4 / BW 125 AC-4
S/N 101 880 06 .... > / S/N 101 880 16 .... > / S/N 101 880 08 .... > / S/N 101 880 14 .... > / S/N 101 880 10 .. .. >
S/N 101 880 07 .... > / S/N 101 880 17 .... > / S/N 101 880 09 .... > / S/N 101 880 15 .... > / S/N 101 880 11 .. .. >
Tandem Vibratory Roller
Combination Roller
Foreword
BOMAG 3BW 100/120/125 AD-4/AC-4
1 Foreword
These BOMAG machines are products from
the wide product range of BOMAG machines
for earth and asphalt construction, refuse
compaction and stabilizing/recycling.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your ma-
chine.
This manual comprises:
l Safety regulations
l Operating instructions
l maintenance instructions
l Trouble shooting
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 con-
struction 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 not complying with the
usual modes of use,
l if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-
age resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance 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 mainte-
nance instructions are part of the 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 En-
gineering Liability Association ”Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors” and all relevant accident prevention regula-
tions.
For your own personal safety you should only
use original spare parts from BOMAG.
For your machine BOMAG offers service kits
to ease maintenance.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Apart from that, the spare parts catalogue is avail-
able from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation 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
Copyright by BOMAG
Foreword
BOMAG4 BW 100/120/125 AD-4/AC-4
Please fill in
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Machine type (Fig. 1)
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Serial-number (Fig. 1 and 2)
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Engine type (Fig. 3)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine number (Fig. 3)
Note
i
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 1
Fig. 2
Fig. 3
Table of Contents
BOMAG 5BW 100/120/125 AD-4/AC-4
1Foreword 3
2 Technical Data 9
3 Safety regulations 17
4 Indicators and Controls 31
4.1 General notes 34
4.2 Description of indicators and control elements 34
5 Operation 45
5.1 General 46
5.2 Tests before taking into operation 46
5.3 Electronic immobilizer 47
5.4 Adjusting the operator's seat 47
5.5 Starting the engine 48
5.6 Starting with jump wires 50
5.7 Driving the machine 51
5.8 Stopping the machine, operating the parking brake 53
5.9 Shutting down the engine 53
5.10 Switching the vibration on and off 54
5.11 Switching the gravity sprinkling system on and off 57
5.12 Switching the pressure sprinkling system on and off 57
5.13 Switching the tire sprinkling system on and off (only AC) 59
5.14 Actuating the emergency stop switch 59
5.15 Mounting/removing the chip spreader 60
5.16 Filling/emptying the chip spreader 62
5.17 Operating the chip spreader 63
5.18 Towing 64
5.19 Loading/transport 67
6 Maintenance 71
6.1 General notes on maintenance 72
6.2 Fuels and lubricants 73
6.3 Table of fuels and lubricants 76
6.4 Running-in instructions 77
6.5 Maintenance table 78
Every 10 operating hours 81
6.6 Check the engine oil level 81
6.7 Checking the fuel level 81
6.8 Check the hydraulic oil level 82
6.9 Checking the hydraulic oil filter element 83
Table of Contents
BOMAG6 BW 100/120/125 AD-4/AC-4
6.10 Check the coolant level 83
6.11 Check the water separator 84
6.12 Checking the water level 84
6.13 Checking the emulsion level 85
6.14 Checking the chip spreader and cleaning the spreading beam 85
Every 50 operating hours 87
6.15 Checking fuel lines and clamps 87
6.16 Servicing the chip spreader 87
Every 250 operating hours 89
6.17 Changing engine oil and oil filter 89
6.18 Checking, cleaning, replacing the combustion air filter 91
6.19 Check the air intake lines 94
6.20 Cleaning radiator and hydraulic oil cooler 95
6.21 Checking, tensioning, replacing the V-belt 96
6.22 Checking radiator hoses and hose clamps 96
6.23 Checking, adjusting the scrapers 97
Every 500 operating hours 99
6.24 Battery service 99
6.25 Change the fuel filter 100
6.26 Drain the fuel tank sludge 101
Every 1000 operating hours 103
6.27 Checking, adjusting the valve clearance 103
6.28 Check the engine mounts 104
Every 2000 operating hours 105
6.29 Changing hydraulic oil and breather filter 105
6.30 Changing the hydraulic oil filter 106
6.31 Changing the coolant 107
6.32 Replacing the fuel lines 109
6.33 Check the injection valves 109
Every 3000 operating hours 111
6.34 Checking the fuel injection pump 111
As required 113
6.35 Checking the tire pressure 113
6.36 Cleaning the water sprinkler system 113
6.37 Draining the water sprinkler system, maintenance in case of frost 115
6.38 Filling the provision tank for the windscreen washer system 116
6.39 Tightening torques for screws with metric unified thread 116
6.40 Engine conservation 117
Table of Contents
BOMAG 7BW 100/120/125 AD-4/AC-4
7 Trouble shooting 119
7.1 General notes 120
7.2 Engine 121
8 Disposal 123
8.1 Final shut-down of machine 124
Table of Contents
BOMAG8 BW 100/120/125 AD-4/AC-4
BOMAG 9BW 100/120/125 AD-4/AC-4
2 Technical Data
Technical Data
BOMAG10 BW 100/120/125 AD-4/AC-4
Fig. 4
Dimensions in mm A B C D H H2 K L O S W
BW 100 AD-4
1728 1076 475 700 1800 2475 255 2475 38 13 1000
BW 120 AD-4
1728 1276 474 700 1800 2475 255 2475 38 13 1200
BW 125 AD-4
1728 1276 474 700 1800 2475 255 2475 38 23 1200
1
BW 100 AD-4 BW 120 AD-4 BW 125 AD-4
Weights
Operating weight with ROPS (CECE) kg 2400 2600 3150
Operating weight with ROPS (CECE)
and empty chip spreader
2
kg 2520 2730 3150
Mean axle load (CECE) kg 1200 1300 1575
Mean static linear load (CECE) kg/cm 12.0 10.8 13.1
Max. operating weight kg 2950 3150 3400
Dimensions
Inner track radius mm 2720 2620 2620
Length with chip spreader** mm 3250 3250 -
Width with chip spreader** mm 1180 1276 -
Technical Data
BOMAG 11BW 100/120/125 AD-4/AC-4
Travel characteristics
Working speed with vibration km/h 0 – 6.5 0 – 6.5 0 – 6.5
Travel speed km/h 0 – 12 0 – 12 0 – 12
Max. gradability without/with vibration
(soil dependent)
% 40/30 40/30 40/30
Drive
Engine manufacturer Kubota Kubota Kubota
Type D 1703-M-EU34 D 1703-M-EU34 D 1703-M-EU34
Cooling Water Water Water
Number of cylinders 3 3 3
Rated power ISO 9249 kW 24.3 24.3 24.3
Rated power SAE J 1349 hp 32.6 32.6 32.6
Rated speed min
-1
2600 2600 2600
Fixed engine speed 1 min
-1
2400 2400 2400
Fixed engine speed 2 min
-1
2600 2600 2600
Electrical equipment V 12 12 12
Brake
Service brake hydrost. hydrost. hydrost.
Parking brake hydro-mech. hydro-mech. hydro-mech.
Steering
Type of steering Oscill.-articul. Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost. hydrost.
Steering/oscillation angle +/- ° 30/7 30/7 30/7
Exciter system
Vibrating drum front + rear front + rear front + rear
Drive system hydrost. hydrost. hydrost.
Frequency 1/2 Hz 70/55 70/55 60/50
Amplitude mm 0.50 0.51 0.40
Centrifugal force 1/2 kN 37/23 45/28 41/29
Water sprinkler system
Type Gravity feed Gravity feed Gravity feed
Filling capacities
Fuel (diesel) l approx. 40 approx. 40 approx. 40
Water tank capacity l approx. 220 approx. 220 approx. 220
Hydraulic oil l approx. 28 approx. 32 approx. 32
Engine oil l approx. 6,5 approx. 6,5 approx. 6,5
1 The right for technical modifications remains reserved
2 Optional equipment
1
BW 100 AD-4 BW 120 AD-4 BW 125 AD-4
Technical Data
BOMAG12 BW 100/120/125 AD-4/AC-4
Fig. 5
Dimensions in
mm
A B C D H H2 K L O S W
BW 100 AC-4
1728 1076 475 700 1800 2475 255 2475 38 13 1000
BW 120 AC-4
1728 1276 474 700 1800 2475 255 2475 38 13 1200
BW 125 AC-4
1728 1276 474 700 1800 2475 255 2475 38 23 1200
1
BW 100 AC-4 BW 120 AC-4 BW 125 AC-4
Weights
Operating weight with ROPS (CECE) kg 2250 2400 2950
Axle load, drum (CECE) kg 1150 1240 1600
Axle load, wheels (CECE) kg 1100 1160 1350
Static linear load (CECE) kg/cm 11.5 10.3 13.5
Wheel load (CECE) kg 275 290 338
Max. operating weight kg 2600 2800 3250
Dimensions
Inner track radius mm 2720 2620 2620
Technical Data
BOMAG 13BW 100/120/125 AD-4/AC-4
Travel characteristics
Working speed with vibration km/h 0 – 6 0 – 6 0 – 6
Travel speed km/h 0 – 10 0 – 10 0 – 10
Max. gradability without/with vibration
(soil dependent)
% 40/30 40/30 40/30
Drive
Engine manufacturer Kubota Kubota Kubota
Type D 1703-M-EU34 D 1703-M-EU34 D 1703-M-EU34
Cooling Water Water Water
Number of cylinders 3 3 3
Rated power ISO 9249 kW 24.3 24.3 24.3
Rated power SAE J 1349 hp 32.6 32.6 32.6
Rotary speed (nominal speed) rpm 2600 2600 2600
Fixed engine speed 1 rpm 2400 2400 2400
Fixed engine speed 2 rpm 2600 2600 2600
Electrical equipment V 12 12 12
Tires
Number of tires 4 4 4
Tire size 205/60-15 205/60-15 205/60-15
Brake
Service brake hydrost. hydrost. hydrost.
Parking brake hydro-mech. hydro-mech. hydro-mech.
Steering
Type of steering Oscill.-articul. Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost. hydrost.
Steering/oscillation angle degree 30/7 30/7 30/7
Exciter system
Vibrating drum front front front
Drive system hydrost. hydrost. hydrost.
Frequency 1/2 Hz 70/55 70/55 60/50
Amplitude mm 0.50 0.52 0.40
Centrifugal force 1/2 kN 37/23 45/28 42/29
Water sprinkler system
Type Pressure Pressure Pressure
Interval control Standard Standard Standard
Filling capacities
Fuel (diesel) l approx. 40 approx. 40 approx. 40
Water tank capacity l approx. 220 approx. 220 approx. 220
Emulsion l approx. 20 approx. 20 approx. 20
Hydraulic oil l approx. 28 approx. 28 approx. 28
Engine oil l approx. 6,5 approx. 6,5 approx. 6,5
1
BW 100 AC-4 BW 120 AC-4 BW 125 AC-4
Technical Data
BOMAG14 BW 100/120/125 AD-4/AC-4
1 Subject to technical alterations.
Technical Data
BOMAG 15BW 100/120/125 AD-4/AC-4
The following noise and vibration data acc. to
- EC Machine Regulation edition 2006/42/EC
- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC
- Vibration Protection Regulation 2002/44/EC
were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.
During operation these values may vary because of the existing operating conditions.
Noise value
Sound pressure level on the place of the operator:
L
pA
= 84 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:
L
WA
= 106 dB(A), determined acc. to ISO 3744 and EN 500
Danger!
Wear your personal noise protection means (ear defenders) before starting operation.
Vibration value
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is ≤ 0.5 m/s
2
.
Hand-arm vibration values
The weighted effective acceleration value determined according to ISO 5349 is ≤ 2.5 m/s
2
.
Technical Data
BOMAG16 BW 100/120/125 AD-4/AC-4
BOMAG 17BW 100/120/125 AD-4/AC-4
3 Safety regulations
Safety regulations
BOMAG18 BW 100/120/125 AD-4/AC-4
General
This BOMAG machine has been built in com-
pliance 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:
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 the safety instructions are not observed.
Each person involved in the operation, mainte-
nance and repair of the machine must there-
fore read and comply with these safety
regulations. If necessary, this must be con-
firmed by obtaining the signature of the cus-
tomer.
Furthermore, the following obviously also applies:
l applicable accident prevention instructions,
l generally accepted safety and road traffic reg-
ulations,
l country specific safety regulations. It is the
duty of the operator to be acquainted with
these instructions and to apply these accord-
ingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instruc-
tions be different from the regulations valid in
your country, you must comply with the safety
regulations valid in your country.
Intended use
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).
Unintended use
Dangers may arise from the machine when it is
used for purposes other than the one it is intended
for.
Any danger caused by intended use is the sole re-
sponsibility of the customer or driver/operator, the
manufacturer cannot be made liable.
Examples for unintended use are:
l work with vibration on hard concrete, cured bi-
tumen layers or extremely frozen ground
l cleaning the drums while driving or changing
nozzles during travel.
l driving on unstable subbases or insufficient
grip or too small contact area (danger of tip-
ping over)
l Passing over high borders (e.g. curbstones,
embankments, trenches, potholes)
l unauthorized use of public roads
l Using the machine for towing
Transporting persons, except the machine driver,
is prohibited.
Starting and operation of the machine in explosive
environments and in underground mining is pro-
hibited.
Remaining dangers, remaining risks
Despite careful work and compliance with stand-
ards and regulations it cannot be ruled out that fur-
ther dangers may arise when working with and
handling the machine.
Both the machine as well as all other system com-
ponents comply with the currently valid safety reg-
ulations. Nevertheless, remaining risks cannot be
ruled out completely, even when using the ma-
chine for the purpose it is intended for and follow-
ing all information given in the operating
instructions.
A remaining risk can also not be excluded beyond
the actual danger zone of the machine. Persons
remaining in this area must pay particular attention
to the machine, so that they can react immediately
in case of a possible malfunction, an incident or
failure etc.
All persons remaining ion the area of the machine
must be informed about the dangers that arise
from the operation of the machine.
Regular safety inspections
Have the machine inspected by an expert (capa-
ble person) as required for the conditiosn the ma-
chine is working under, but at least once every
year.
Safety regulations
BOMAG 19BW 100/120/125 AD-4/AC-4
Who is allowed to operate the ma-
chine?
Only trained, instructed and authorized persons of
at least 18 years of age are permitted to drive and
operate this machine. For operation of the ma-
chine 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 re-
pair the machine.
Maintenance and repair work requires specific
knowledge and must therefore only be performed
by trained specialists.
Changes and conversions to the ma-
chine
Unauthorized changes to the machine are prohib-
ited for safety reasons.
Original parts and accessories have been special-
ly 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 pas-
sive safety.
The manufacturer explicitly excludes any liability
for damage caused by the use of non-original
parts or accessories.
Damage, deficiencies, misuse of safety
installations
Machines which are not safe to operate or in traffic
must be immediately taken out of service and shall
not be used, until these deficiencies have been
properly rectified.
Safety installations and switches must neither be
removed nor must they be made ineffective.
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.
Note
i
Paragraphs marked like this contain technical in-
formation for the optimal economical use of the
machine.
Environment
Paragraphs marked like this point out practic-
es for safe and environmental disposal of fuels
and lubricants as well as replacement parts.
Observe the regulations for the protection of
the environment.
Loading/transporting the machine
Loading with loading ramp
Use only stable loading ramps of sufficient load
bearing capacity. The ramp inclination must be
less than the gradability of the machine.
Make sure that persons are not endangered by the
machine tipping or sliding off.
During demonstration and when loading the ma-
chine do not remain in the danger zone of the ma-
chine.
Always empty the chip spreader
1
before trans-
port.
After driving the machine onto the transport vehi-
cle attach the articulation lock .
Loading by crane / loading the machine with a
lifting belt
2
With the chip spreader attached the machine must
not be lifted with lifting belts, because of the
changed centre of gravity.
Engage the articulation lock.
Always use shackles on the lifting points or on the
lifting belt for loading the machine.
Check all lifting points and lifting belt for damage
before lifting the machine. Damaged or in any oth-
er way in their functionality impaired lifting points
or a damaged or in its functionality impaired lifting
belt must not be used.
1 Optional equipment
2 Optional equipment
Safety regulations
BOMAG20 BW 100/120/125 AD-4/AC-4
Lifting tackle must only be attached to loads by ex-
pert personnel (qualified person).
Do not overload the lifting belt.
Lift the machine only with suitable lifting gear. Use
only safe lifting gear of sufficient load bearing ca-
pacity Minimum lifting capacity of lifting gear: see
operating weight in chapter "Technical Data".
Do not lift or lower the machine jerkily.
The tension must always be effective in vertical di-
rection.
The machine must not swing about when being lift-
ed.
Do not step or stand under suspended loads.
After lifting hook the lifting belt back into its recep-
tacle.
Have the lifting tackle inspected by an expert
(properly trained person) once every year.
After 5 years replace the lifting belt with a new one.
Always empty the chip spreader
1
before trans-
port.
Lashing
Always use shackles on the lifting points for lash-
ing down the machine.
Check all lashing points for damage before lashing
down the machine. Do not use a damaged or in
any other way impaired lashing points.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
Never attach the lashing gear to the chip spreader.
After transport
Operate the machine only with the foldable
ROPS
2
properly fastened and the fastening
screws tightened with the correct tightening
torque.
After transport release the articulation lock again
and store it in the receptacle.
Towing the machine
You should generally use a tow bar.
With the chip spreader
3
attached the machine
must not be towed backwards.
Max. towing speed 1 km/h, max. towing distance
500 m.
Before releasing the multi-disc brake secure the
machine against unintended rolling.
Checking the Roll Over Protective
Structure (ROPS)
Note
i
On machines with cab the ROPS is an integral part
of the cab.
The frame of the machine must not be warped,
bent or cracked in the area of the ROPS fastening.
The ROPS must not show any rust, damage, hair-
line cracks or open fractures.
The actual weight of the machine must not exceed
the testing weight of the ROPS.
The ROPS must not rattle about when driving.
This indicates that it is not properly fastened. All
bolted connections must comply with the specifi-
cations and should be absolutely tight (observe
the tightening torques). Screw and nuts must not
be damaged, bent or deformed.
With the cab assembled check also the state of the
cabin mounts (rubber elements and screws).
No accessories may be welded or bolted on and
no additional holes must be drilled without the con-
sent of the manufacturer, since this will impair the
strength of the unit.
The ROPS must therefore also not be straight-
ened or repaired if it is damaged.
A defect ROPS must generally be replaced with an
original spare part in close coordination with the
manufacturer.
Starting the machine
Before starting
The machine must only be operated from the driv-
er’s seat.
Use only machines which are serviced at regular
intervals.
Become acquainted with the equipment, the con-
trol elements, the working principle of the machine
and the working area.
Wear your personal protective outfit (hard hat,
safety boots, etc.). Wear ear defenders.
1 Optional equipment
2 Optional equipment
3 Optional equipment
Safety regulations
BOMAG 21BW 100/120/125 AD-4/AC-4
Before mounting the machine check whether:
l persons or obstructions are beside or under
the machine
l the machine is free of oily and combustible
material
l all grips, steps and platforms are free of
grease, oils, fuel, dirt, snow and ice
l engine hood is closed and locked
Use steps and grips to mount 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 sys-
tem and warning horn work correctly
l the seat is correctly adjusted
l mirrors (if present) are clean and correctly ad-
justed.
Do not start the machine with defective gauges,
control lights or control elements.
Do not take any loose objects with you or fasten
them to the machine.
On machines with roll over protection system you
must always wear your seat belt!
Starting
Start and operate the machine only from the driv-
er’s seat.
For starting set all control levers to 'neutral posi-
tion'.
Do not use any starting aids like start pilot or ether.
After starting check all gauges and control lights.
Starting with jump wires
Connect plus to plus and minus to 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 start the engine by shorting the electric ter-
minals on the starter motor, because the machine
may start to drive immediately.
Starting and operation of the machine is
closed rooms and trenches
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
and operating in closed rooms and trenches!
Driving the machine
Persons in the danger area
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.
Give warning signals, if necessary. Stop work im-
mediately if persons remain in the danger zone,
despite the warning.
Do not step or stand in the articulation area of the
machine when the engine is running. Danger of
squashing!
Driving
Always wear the seat belt when driving.
Do not drive on bases with insufficient load bear-
ing capacity.
Do not drive on ice and snow.
In events of emergency and in case of danger ac-
tuate the emergency stop switch immediately. Do
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.
If the machine has contacted high-voltage power
lines:
l do not leave the operator’s stand
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 power switched off
Operate the machine only from the operator’s
stand.
Keep the cabin doors closed.
Do not adjust the driver’s seat while driving.
Do not climb onto or off the machine while the ma-
chine is driving.
Change the travel direction only at standstill.
Do not use the machine to transport persons.
Safety regulations
BOMAG22 BW 100/120/125 AD-4/AC-4
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 ma-
chine.
Do not work with vibration on hard concrete, cured
bitumen layers or extremely frozen ground.
Always keep a sufficient distance when passing
through subways, under bridges, tunnels, electric
power lines etc.
Driving on inclinations and slopes
Do not drive on gradients exceeding the maximum
gradability of the machine.
On slopes drive extremely careful and always di-
rectly up or down the slope. Change to a lower
gear before starting to drive.
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations
and slopes. Higher risk of accident!
Inclination
Fig. 6
The tipping angle was measured in static condition
on level, hard ground with the machine stopped,
no steering and without vibration.
With loose soil, acceleration/deceleration, running
vibration, steering or attached accessoriies the tip-
ping angle may be considerably lower.
Driving across slopes should therefore be strictly
avoided, because of the high risk of tipping over
and the related risk of severe or even fatal acci-
dents.
You should therefore always drive straight up or
down a slope.
For rollers with a drum width of 1 m or less there is
a considerable risk of tipping over near edges (e.g.
curbstones, embankments, trenches, potholes)
when driving over these edges.
Behaviour in traffic
Match the speed to the working conditions. Do not
make extreme steering movements when driving
with high speed, danger of tipping over!
Always give way to loaded transport vehicles.
Switch the lights on if the visibility is poor.
Keep away from edges and embankments.
Checking the effect of vibration
When compacting with vibration you must check
the effect on nearby buildings and underground
supply lines (gas, water, sewage, electric power),
if necessary stop compaction work with vibration.
Do not work with vibration on hard concrete, cured
bitumen layers or extremely frozen ground. Dan-
ger of bearing damage!
Parking the machine
Park the machine on level, firm ground.
Before leaving the machine:
l return the control lever to neutral position
l apply the parking brake
l shut the engine down and pull off the ignition
key
Do not jump off the machine, but use hand grips
and access steps.
Mark machines, which could be in the way, with a
clearly visible sign.
Parking on slopes and inclinations
Apply appropriate measures (e.g. with metal
wheel chocks, to be provided by the operating
company) tp secure the machine against rolling
away.
Refuelling
Do not inhale any fuel fumes.
Refuel only with the engine stopped and the auxil-
iary heater switched off.
Always use access steps.
880116
Max.
36 %
20 °
Safety regulations
BOMAG 23BW 100/120/125 AD-4/AC-4
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.
A leaking fuel tank can cause an explosion. En-
sure tight fit of the fuel tank cover, if necessary re-
place immediately.
Fire protection measures
Familiarise yourself with the location and the oper-
ation of fire fighting equipment. Observe all fire re-
porting and fire fighting possibilities.
Mounting and removing the chip
spreader
1
When mounting or removing the chip spreader do
not step between the chip spreader and the ma-
chine while the engine is running.
Park the machine on a level and solid base to
mount or remove the chip spreader and shut down
the engine.
Mount and remove the chip spreader when it is
empty.
Maintenance
Observe the maintenance tasks described in the
operating and maintenance instructions, including
the exchange of parts.
Maintenance work must only be carried out by
qualified and authorized personnel.
For overhead service and assembly work use the
provided access installations or any other safe ac-
cess ladders and work platforms. Do not use ma-
chine parts as access steps.
Keep unauthorized persons away from the ma-
chine.
Do not perform maintenance work with the ma-
chine driving or the engine running.
Park the machine on horizontal, level and stable
ground.
Pull the key out of the ignition switch.
Lock the articulated joint with the articulation lock.
Working on hydraulic lines
Always depressurize the hydraulic lines before
starting to work on them. Hydraulic oil escaping
under pressure can penetrate the skin and cause
severe injury. If injured by hydraulic oil seek med-
ical advice immediately as otherwise severe infec-
tions may result.
When adjusting the hydraulic system do not stand
behind or in front of the drum/wheels.
Do not change the setting of high pressure relief
valves.
Drain hydraulic oil at operating temperature - dan-
ger of scalding!
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always catch and dispose of biological hydraulic
oils separately.
Do not start the engine after draining off the hy-
draulic oil.
After finishing work (with the system still depressu-
rized!) check all connections and fittings for leaks.
Changing hydraulic hoses
All hydraulic hoses must be inspected visually at
regular intervals.
Hydraulic hoses must be changed immediately if:
l the outer layer is worn down to the metal lining
(e.g. chafing, cuts, cracks)
l embrittlement of the outer layer (development
of cracks in the hose material)
l deformation under pressurized and depressu-
rized condition, which are not in accordance
with the normal shape of the hydraulic hose
l deformation in bends, e.g., squeezes, kinks,
layer separation, formation of blisters
l leakages.
l non-observance of the installation require-
ments.
l separation of the hydraulic hose from the fit-
ting
l corrosion of the fitting, which impairs the func-
tion and the strength.
l Do not mix up hoses by mistake.
l damage or deformation of the fitting, which im-
pairs the function and strength of the hose/
hose connection.
1 Optional equipment
Safety regulations
BOMAG24 BW 100/120/125 AD-4/AC-4
Only genuine BOMAG hydraulic hoses ensure
that the correct type of hose (pressure range) is
used at the right place.
Working on the engine
Shut the engine down before opening the engine
compartment hood.
Drain the engine oil at operating temperature -
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oily materials in a sep-
arate, specially marked container and dispose of
environmentally.
Do not leave any tools or other objects, which
could cause damage, in the engine compartment.
Check and change the coolant only when the en-
gine is cold.
Catch the coolant and dispose of environmentally.
Working on electrical equipment
Before working on electrical equipment disconnect
the battery and cover it with insulating material.
Do not use any fuses with higher Ampere ratings
and do not repair fuses with a piece of wire. Fire
hazard!
Always disconnect the battery before starting to
weld on the machine.
Working on the battery
When working on the battery do not smoke, no
open flames!.
Do not let your hands or clothes come in contact
with acid. In case of injuries caused by acid, flush
off with clear water and consult a doctor.
Metal objects (e.g. tools, rings, wrist watches)
must not contact the battery poles - danger of
short circuit and burns!
When recharging maintenance free batteries re-
move the plugs to avoid the accumulation of explo-
sive gases.
When using an external battery to start the ma-
chine follow the respective instructions.
Dispose of old batteries environmentally.
Switch the charging current off before removing
the charge clamps.
Ensure good ventilation, especially when charging
the battery in a closed room.
Working on the fuel system
Do not inhale 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 and parts of rims
and tires can cause severe or even deadly injuries.
You should only assemble tires if you have the
necessary experience and with the proper equip-
ment. If necessary have the tires mounted by a
specialised workshop.
Ensure correct tire pressure and do not exceed the
highest specified pressure.
Check tires and wheels every day for pressure
drop, cuts, bulges, damaged rims, missing wheel
studs and nuts. Do not drive with damaged tires or
wheels.
Non-sticking emulsions for tires must only be
made up of a mix of water and a concentrated anti-
stick agent according to the instructions of the
manufacturer. Observe the regulations for the pro-
tection of the environment.
Cleaning
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other combustible sub-
stances for cleaning purposes.
When using steam cleaning equipment do not
subject electrical components and insulating ma-
terials to the direct water jet, but cover them be-
forehand.
l Do not guide the water jet into the exhaust or
into the air filter.
After maintenance work
Reinstall all protective devices after completing
the maintenance work.
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 instruc-
tions for this work.
Safety regulations
BOMAG 25BW 100/120/125 AD-4/AC-4
Exhaust gases are highly dangerous! Always en-
sure 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.
Information and safety stickers/decals
on the machine
Keep safety stickers in good and legible condition
(see parts manual) and comply with their meaning.
Replace damaged and illegible stickers/decals.
Safety regulations
BOMAG26 BW 100/120/125 AD-4/AC-4
Fig. 7
1 Warning sticker - Danger of crushing
2 Brief operating instructions
3 Warning sticker - Danger of tipping over
1
4 Information sticker - Ball valve vibration
5 Information sticker - Allocation of fuses
6 Maintenance sticker
7 Operation sticker - Travel lever
8 Operation sticker - Water sprinkling system
9 Information sticker - Water
10 Information sticker - Guaranteed sound capac-
ity level
11 Information sticker - Lashing point
12 Information sticker - Lifting point
13 Information sticker - Engine oil drain
14 Prohibition sticker - High pressure cleaner
15 Information sticker - Hydraulic oil
16 Information sticker - Low sulphur fuel
17 Information sticker - Diesel
880113
=
STOP
10
9
15
17
5
4
8
7
14
2
16
3
11
Box B Box A
F 11/15A
F 12/15A
F 08/15A
F 09/15A
F 10/15A
F 07/15A
F 41/10A
F 05/15A
F 68/20A
F 139/30A
F 04/10A
F 119/10A
F 45/10A
F 23/10A
F 48/10A
008 381 06
F 30/10A
1
13
1
6
12
11
12
Stickers and decals BW 100/120/125 AD-4
1 only BW 100 AD-4
Safety regulations
BOMAG 27BW 100/120/125 AD-4/AC-4
Fig. 8
1 Warning sticker - Danger of crushing
2 Brief operating instructions
3 Operation sticker - Brake releasing device
4 Warning sticker - Danger of tipping over
1
5 Information sticker - Allocation of fuses
6 Maintenance sticker
7 Operation sticker - Travel lever
8 Operation sticker - Water sprinkling system
9 Information sticker - Water
10 Information sticker - Guaranteed sound capac-
ity level
11 Information sticker - Emulsion
12 Information sticker - Lashing point
13 Information sticker - Lifting point
14 Information sticker - Engine oil drain
15 Prohibition sticker - High pressure cleaner
16 Information sticker - Hydraulic oil
17 Information sticker - Low sulphur fuel
18 Information sticker - Diesel
880114
=
STOP
10
9
16
18
5
8
7
15
2
17
11
Box B Box A
F 11/15A
F 12/15A
F 08/15A
F 09/15A
F 10/15A
F 07/15A
F 41/10A
F 05/15A
F 68/20A
F 139/30A
F 04/10A
F 119/10A
F 45/10A
F 23/10A
F 48/10A
008 381 06
F 30/10A
1
14
1
6
12
13
12
13
4
3
Stickers and decals BW 100/120 AC-4
1 only BW 100 AC-4
Safety regulations
BOMAG28 BW 100/120/125 AD-4/AC-4
Fig. 9
Operation sticker - Foldable ROPS
1
Fig. 10
Warning sticker - Foldable ROPS
1
Fig. 11
Instruction sticker - Always wear your seat belt
2
Fig. 12
Operation sticker - Central lifting device
3
Fig. 13
Information sticker - Main battery switch
4
Fig. 14
Information sticker - Biodegradable hydraulic oil
5
1 Optional equipment
2 Optional equipment
S_0005
3 Optional equipment
4 Optional equipment
5 Optional equipment
S_0019
Safety regulations
BOMAG 29BW 100/120/125 AD-4/AC-4
Fig. 15
Information sticker - Panolin 46
1
Fig. 16
Operation sticker - Edge cutter
2
Fig. 17
Information sticker - Ball valve, vibration 3-stages
3
(only AD)
Fig. 18
Operation sticker "Chip spreader"
4
Fig. 19
Warning sticker "Chipping temperature"
5
1 Optional equipment
2 Optional equipment
3 Optional equipment
880122
4 Optional equipment
5 Optional equipment
Safety regulations
BOMAG30 BW 100/120/125 AD-4/AC-4
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