Fayat BOMAG BW 161 AC-50 User manual

BW 161 AC-50 / BW 161 AD-50 /
BW 161 ADO-50
Tandem vibratory roller
Service Manual
S/N 101 921 37 1001> / S/N 101 921 17 1001> / S/N 101 921 18 1001>
© 02/2018008 401 94 EN

2
Find manuals at https://best-manuals.com

Table of contents
1 General................................................................................................................................................... 9
1.1 Introduction................................................................................................................................. 10
1.2 Concerning your safety.............................................................................................................. 12
1.2.1 General prerequisites................................................................................................................. 12
1.2.2 Definition of responsible persons............................................................................................... 15
1.2.3 Fundamentals for safe operation............................................................................................... 16
1.2.4 Handling fuels and lubricants..................................................................................................... 17
1.2.5 Loading / transporting the machine............................................................................................ 22
1.2.6 Start-up procedure..................................................................................................................... 23
1.2.7 Driving the machine, working operation..................................................................................... 24
1.2.8 Refuelling................................................................................................................................... 26
1.2.9 Emergency procedures.............................................................................................................. 27
1.2.10 Maintenance work.................................................................................................................... 28
1.2.11 Repair....................................................................................................................................... 30
1.2.12 Signage.................................................................................................................................... 31
1.3 Maintenance and repair.............................................................................................................. 37
1.3.1 Notes on repair........................................................................................................................... 37
1.3.2 Preliminary remarks and safety notes........................................................................................ 53
1.3.3 Preparations / concluding work.................................................................................................. 54
1.3.4 Parking the machine in secured condition................................................................................. 59
2 Fuels and lubricants........................................................................................................................... 61
2.1 Fuels and lubricants................................................................................................................... 62
2.1.1 Engine oil................................................................................................................................... 62
2.1.2 Fuel............................................................................................................................................ 63
2.1.3 Coolant....................................................................................................................................... 64
2.1.4 Hydraulic oil................................................................................................................................ 67
2.1.5 Gear oil SAE 75W-90................................................................................................................. 67
2.2 List of fuels and lubricants, BW 161 AD/AC............................................................................. 68
2.2.1 List of fuels and lubricants.......................................................................................................... 68
2.3 List of fuels and lubricants, BW 161/202 ADO......................................................................... 69
2.3.1 List of fuels and lubricants.......................................................................................................... 69
3 Technical data...................................................................................................................................... 71
3.1 Technical data, BW 161 AD-50................................................................................................... 72
3.1.1 Technical data............................................................................................................................ 72
3.2 Technical data, BW 161 ADO-50................................................................................................ 75
3.2.1 Technical data............................................................................................................................ 75
3.3 Technical data, BW 161 AC-50................................................................................................... 78
3.3.1 Technical data............................................................................................................................ 78
3.4 Additional technical data............................................................................................................ 81
3.5 Terms and basis of calculation.................................................................................................. 83
4 Overview of machine.......................................................................................................................... 85
4.1 Electric systems.......................................................................................................................... 89
4.2 Diesel engine............................................................................................................................... 91
4.3 Hydraulic system........................................................................................................................ 93
Table of contents
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
3
Find manuals at https://best-manuals.com

4.3.1 Pump overview........................................................................................................................... 94
4.4 Water spraying system............................................................................................................... 97
4.4.1 Tandem rollers............................................................................................................................ 97
4.4.2 Combination rollers.................................................................................................................... 97
4.4.3 Pump overview........................................................................................................................... 98
4.5 Air conditioning......................................................................................................................... 101
4.6 Drum........................................................................................................................................... 103
5 Electric systems................................................................................................................................ 105
5.1 Overview of electric system..................................................................................................... 106
5.2 Table of fuels and lubricants.................................................................................................... 114
5.3 Wiring......................................................................................................................................... 122
5.4 CAN BUS overview................................................................................................................... 136
5.5 Power board.............................................................................................................................. 138
5.6 Control console cabin ............................................................................................................. 142
5.7 Fuse assignment....................................................................................................................... 144
5.7.1 Notes on safety........................................................................................................................ 144
5.7.2 Central electrics....................................................................................................................... 144
5.7.3 Engine compartment................................................................................................................ 145
5.7.4 Control console cabin............................................................................................................... 146
5.7.5 Fuses ROPS............................................................................................................................ 147
5.8 Operator’s stand....................................................................................................................... 148
5.9 Starting the engine with jump leads........................................................................................ 150
5.10 Asphalt temperature sensor, B106........................................................................................ 151
5.11 Acceleration transducer, B84 & B85...................................................................................... 152
5.12 Switching on the pressurized spraying system................................................................... 153
5.13 Data collector, A80.................................................................................................................. 155
5.14 Differential pressure switch for hydraulic oil filter, B21...................................................... 160
5.15 Air filter vacuum switch, B03................................................................................................. 161
5.16 Sensor, water in fuel, B124..................................................................................................... 162
5.17 Float switch coolant tank, B55............................................................................................... 163
5.18 Oil pressure switch, B06........................................................................................................ 164
5.19 Coolant temperature switch, B53.......................................................................................... 165
5.20 Removing and assembling the coolant temperature switch.............................................. 166
5.21 Boost fuel solenoid valve, Y01.............................................................................................. 167
5.22 Solenoid actuator to shut down the engine, Y58................................................................. 168
5.23 Electric throttle control, Y120................................................................................................ 169
5.24 Heating flange on engine....................................................................................................... 172
5.25 Checking the heating flange control..................................................................................... 175
5.26 Charge control lamp............................................................................................................... 176
5.27 Electric module, A108............................................................................................................. 177
5.28 Telemecanique switch............................................................................................................ 178
5.29 Deutsch plug, series DT and DTM......................................................................................... 180
5.30 Old version of instrument cluster, A15................................................................................. 184
5.30.1 CAN bus overview.................................................................................................................. 187
5.30.2 Level sensor in diesel tank, R03............................................................................................ 188
5.30.3 Immersion pipe sensor in water tank, R14............................................................................. 189
Table of contents
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
4
Find manuals at https://best-manuals.com

5.30.4 Float switch in water tank, B33.............................................................................................. 190
5.30.5 Float switch for coolant compensation tank, B55................................................................... 190
5.31 Inspection and maintenance work........................................................................................ 191
5.31.1 Maintenance Table................................................................................................................. 191
5.31.2 Every 500 operating hours..................................................................................................... 191
5.31.3 Every 5000 operating hours................................................................................................... 192
5.31.4 As required............................................................................................................................. 193
6 Diesel engine..................................................................................................................................... 195
6.1 Overview of diesel engine........................................................................................................ 196
6.2 Service side............................................................................................................................... 198
6.3 Starter side................................................................................................................................ 199
6.4 Lubrication oil circuit................................................................................................................ 200
6.5 Coolant circuit........................................................................................................................... 202
6.6 Replacing the thermostat......................................................................................................... 204
6.7 Fuel supply................................................................................................................................ 206
6.8 Injection system........................................................................................................................ 208
6.9 Injection pump replacement during service........................................................................... 210
6.9.1 Disassembling the injection pump............................................................................................ 210
6.9.2 Determining the start of injection.............................................................................................. 212
6.9.3 Installing the injection pump..................................................................................................... 215
6.10 Injection valve replacement during service.......................................................................... 220
6.11 Checking / repairing injection valves.................................................................................... 223
6.12 Checking the compression.................................................................................................... 229
6.13 Inspection and maintenance work........................................................................................ 231
6.13.1 Maintenance Table................................................................................................................. 231
6.13.2 Checks prior to start up.......................................................................................................... 232
6.13.3 Every 250 operating hours..................................................................................................... 233
6.13.4 Every 500 operating hours..................................................................................................... 238
6.13.5 Every 1000 operating hours................................................................................................... 240
6.13.6 Every 2000 operating hours................................................................................................... 247
6.13.7 Every 3000 operating hours................................................................................................... 250
6.13.8 As required............................................................................................................................. 250
7 Hydraulic system.............................................................................................................................. 255
7.1 Overview of hydraulics............................................................................................................. 256
7.1.1 Pump overview......................................................................................................................... 258
7.2 Open and closed hydraulic circuit.......................................................................................... 261
7.3 Hydraulic units.......................................................................................................................... 263
7.3.1 Travel pump, A4VG71 EP........................................................................................................ 263
7.3.2 Vibration pump, A10VG28 / 45 EP........................................................................................... 269
7.3.3 Swash plate principle, pump.................................................................................................... 274
7.3.4 Drum drive motor..................................................................................................................... 276
7.3.5 Vibration motor......................................................................................................................... 280
7.3.6 External gear pumps................................................................................................................ 282
7.3.7 Outer gear motors non-reversible............................................................................................ 284
7.3.8 Steering valve.......................................................................................................................... 285
7.4 Charge circuit and fan circuit.................................................................................................. 287
Table of contents
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
5
Find manuals at https://best-manuals.com

7.5 Travel circuit.............................................................................................................................. 290
7.6 Vibration circuit......................................................................................................................... 299
7.7 Steering and crabwalk.............................................................................................................. 312
7.8 Edge cutter................................................................................................................................ 317
7.9 Tests and adjustments............................................................................................................. 319
7.9.1 Pump overview......................................................................................................................... 319
7.9.2 Activate service mode.............................................................................................................. 322
7.9.3 Driving against the closed brake.............................................................................................. 323
7.9.4 Pressure tests in the travel circuit............................................................................................ 325
7.9.5 Checking/adjusting the neutral positions of the travel pump.................................................... 327
7.9.6 Checking the setting of the high pressure limiting valves in the travel system........................ 330
7.9.7 Pressure tests in the front vibration circuit............................................................................... 333
7.9.8 Pressure tests in the rear vibration circuit................................................................................ 335
7.9.9 Checking the high pressure limiting valves in the front vibration circuit................................... 336
7.9.10 Checking the high pressure relief valves in the rear vibration circuit..................................... 338
7.10 Flushing and bleeding............................................................................................................ 341
7.10.1 Flushing - general.................................................................................................................. 341
7.10.2 Flushing diagram for front drum drive.................................................................................... 344
7.10.3 Flushing the front drum drive................................................................................................. 346
7.10.4 Flushing diagram for rear drum drive..................................................................................... 350
7.10.5 Flushing the rear drum drive.................................................................................................. 352
7.10.6 Flushing diagram for front vibration circuit............................................................................. 357
7.10.7 Flushing the front vibration circuit ......................................................................................... 359
7.10.8 Flushing diagram for rear vibration circuit.............................................................................. 364
7.10.9 Flushing the rear vibration circuit .......................................................................................... 365
7.10.10 Bleeding the travel circuit..................................................................................................... 369
7.10.11 Bleeding the vibration circuit................................................................................................ 371
7.11 Inspection and maintenance work......................................................................................... 374
7.11.1 Maintenance Table................................................................................................................. 374
7.11.2 Checks prior to start up.......................................................................................................... 374
7.11.3 Every 500 operating hours..................................................................................................... 375
7.11.4 Every 1000 operating hours................................................................................................... 375
7.11.5 Every 2000 operating hours................................................................................................... 378
8 Water spraying system..................................................................................................................... 381
8.1 Overview of water spraying system........................................................................................ 382
8.1.1 Tandem rollers.......................................................................................................................... 382
8.1.2 Combination rollers.................................................................................................................. 382
8.1.3 Pump overview......................................................................................................................... 383
8.2 Inspection and maintenance work.......................................................................................... 386
8.2.1 Maintenance Table................................................................................................................... 386
8.2.2 Checks prior to start up............................................................................................................ 386
8.2.3 As required............................................................................................................................... 388
9 Air conditioning................................................................................................................................. 395
9.1 Overview of air conditioning system...................................................................................... 396
9.2 Physical principles.................................................................................................................... 398
9.3 Refrigerant R134a..................................................................................................................... 401
Table of contents
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
6
Find manuals at https://best-manuals.com

9.4 Compressor oil / refrigeration oil............................................................................................ 404
9.5 Working principle of the air conditioning system.................................................................. 407
9.6 Monitoring devices................................................................................................................... 408
9.7 Description of components...................................................................................................... 409
9.8 Compressor............................................................................................................................... 415
9.9 Emptying in case of repair....................................................................................................... 417
9.10 Drying and evacuation............................................................................................................ 418
9.11 Filling instructions.................................................................................................................. 419
9.12 Steam table for R134a............................................................................................................. 423
9.13 Inspection and maintenance work........................................................................................ 427
9.13.1 Maintenance Table................................................................................................................. 427
9.13.2 Every 500 operating hours..................................................................................................... 427
9.13.3 Every 1000 operating hours................................................................................................... 429
9.13.4 As required............................................................................................................................. 430
10 Drum................................................................................................................................................... 431
10.1 AD drum................................................................................................................................... 433
10.1.1 Overview, AD drum................................................................................................................ 433
10.1.2 AD/AP Removing, assembling the exciter unit....................................................................... 434
10.2 ADO drum................................................................................................................................ 441
10.2.1 Overview, ADO drum............................................................................................................. 441
10.2.2 Assembling the ADO drum..................................................................................................... 443
10.2.3 Changing the toothed belt in machines with metal covers..................................................... 490
10.2.4 Changing the toothed belt in machines with plastic covers and oil filters.............................. 502
10.3 Edge cutter.............................................................................................................................. 520
10.3.1 Changing the pressure roller.................................................................................................. 520
10.3.2 Operating the edge cutter...................................................................................................... 521
10.4 Inspection and maintenance work........................................................................................ 522
10.4.1 Maintenance Table................................................................................................................. 522
10.4.2 Checks prior to start up.......................................................................................................... 522
10.4.3 Every 250 operating hours, ADO machine............................................................................. 523
10.4.4 Every 500 operating hours, AD/AC machine......................................................................... 523
10.4.5 Every 500 operating hours, ADO machine............................................................................. 524
10.4.6 Every 1000 operating hours, AD/AC machine....................................................................... 525
10.4.7 Every 1000 operating hours, ADO machine........................................................................... 527
10.4.8 Every 2000 operating hours, ADO machine........................................................................... 530
11 Cabin assembly................................................................................................................................. 535
11.1 Safety........................................................................................................................................ 536
11.2 Preparations............................................................................................................................ 538
11.3 Cabin assembly....................................................................................................................... 539
11.4 Programming the cabin electrics........................................................................................... 549
11.5 Final function tests and checks............................................................................................. 551
12 Troubleshooting................................................................................................................................ 553
12.1 Preliminary remarks................................................................................................................ 554
12.2 Emergency procedures.......................................................................................................... 555
12.2.1 Actuating the emergency stop switch..................................................................................... 555
12.2.2 Disconnecting the battery....................................................................................................... 555
Table of contents
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
7
Find manuals at https://best-manuals.com

12.2.3 Towing the machine............................................................................................................... 555
12.3 Troubleshooting, electrical systems..................................................................................... 558
12.3.1 Preliminary remarks............................................................................................................... 558
12.3.2 Starting the engine with jump leads....................................................................................... 561
12.3.3 Checking the main battery shutoff.......................................................................................... 562
12.3.4 Fuse assignment.................................................................................................................... 562
12.3.5 Understanding electric circuit diagrams................................................................................. 566
12.3.6 Measuring method................................................................................................................. 579
12.3.7 ESX, checking the electric power supply............................................................................... 583
12.3.8 Diagnostics concept............................................................................................................... 591
12.3.9 Electrics training machine control.......................................................................................... 593
12.4 Trouble shooting, diesel engine............................................................................................ 700
12.4.1 Starting the engine with jump leads....................................................................................... 700
12.4.2 Engine faults.......................................................................................................................... 701
12.5 Trouble shooting, hydraulics................................................................................................. 703
12.5.1 Insufficient hydraulic power.................................................................................................... 703
12.5.2 Trouble shooting axial piston pumps...................................................................................... 706
12.5.3 Trouble shooting axial piston motors..................................................................................... 708
12.5.4 Fault table hydraulic components.......................................................................................... 710
12.6 Trouble shooting, air conditioning system........................................................................... 718
12.6.1 Trouble shooting in refrigerant circuit, basic principles.......................................................... 718
12.6.2 Trouble shooting procedure................................................................................................... 724
12.6.3 Leak test................................................................................................................................. 733
12.6.4 Checking the magnetic clutch ............................................................................................... 734
13 Disposal............................................................................................................................................. 737
13.1 Final shut-down of machine................................................................................................... 738
14 Special tools...................................................................................................................................... 739
14.1 Special tools, electrics........................................................................................................... 740
14.2 Special tools, hydraulic system............................................................................................. 741
14.2.1 Special tools, tests and adjustments...................................................................................... 741
14.2.2 Special tools for flushing........................................................................................................ 743
14.3 Special tools for ADO drum................................................................................................... 744
14.3.1 ADO drum.............................................................................................................................. 744
14.4 List of special tools................................................................................................................. 747
15 Index................................................................................................................................................... 749
Appendix............................................................................................................................................ 763
A Circuit diagrams............................................................................................ 765
A.1 Water spraying diagram 921 133 28.......................................................... 765
A.2 Hydraulic diagram 921 125 11................................................................... 767
A.3 Hydraulic diagram 921 132 99................................................................... 769
A.4 Circuit diagram 282................................................................................... 771
A.5 Circuit diagram 486................................................................................... 832
Table of contents
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
8
Find manuals at https://best-manuals.com

1 General
General
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
9
Find manuals at https://best-manuals.com

1.1 Introduction
This manual:
naddresses the BOMAG Customer Service and professionally
trained personnel.
nprovides support for repair work or maintenance procedures on
the machine.
This manual described the deinstallation, dismantling , assembly,
installation as well as the repair of components and assembly
groups as far as this makes sense with respect to tools and spare
parts supply.
The index is a reference register that will help you to find informa-
tion in this Service Manual. The index lists keywords in alphabet-
ical order. Cross references (keywords related to page numbers)
enable quick and convenient search/navigation.
Keywords concerning the following subjects are listed in the index:
nElectrical operating means
nPlug designations
nOverviews
nFault codes
nTroubleshooting
n...
For the BOMAG machines described in this manual the following
documentation is additionally available:
nOperating and maintenance instructions
nSpare parts catalogue
nService information (if necessary)
nSpecialist teams are available for you in Germany, Europe and
overseas. This tight network ensures close customer contact
all over the world.
nParts for maintenance, service and repair are available from
our branch offices and dealers at very short notice.
nBOMAG guarantees long-term availability of all common parts.
nWell-designed catalogues provide an easy guide to finding and
ordering the required parts.
nOnly use genuine BOMAG parts. These have been specially
adapted to the corresponding machine. In this way, you will
prevent any problems arising and unnecessary downtimes of
your machine.
General
Index
Documentation
Maintenance/parts service
General – Introduction
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
10
Find manuals at https://best-manuals.com

This manual is not subject of an updating service. For this reason
we would like to draw your attention to the additionally published
service informations.
In case of a new release all necessary changes will be included.
In the course of technical development we reserve the right for
technical modifications without prior notification.
Information and illustrations in this manual must not be reproduced
and distributed, nor must they be used for the purpose of competi-
tion without the consent of BOMAG. All rights according to the
copyright law remain expressly reserved.
Updating service
Copyright
General – Introduction
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
11

1.2 Concerning your safety
1.2.1 General prerequisites
1.2.1.1 General
This BOMAG machine has been built in compliance with the latest
technical standard and complies with the applicable regulations
and technical rules.
However, dangers for persons and property may arise from this
machine, if:
nit is used for purposes other than the ones it is intended for,
nit is operated by untrained personnel,
nit is changed or converted in an unprofessional way,
nthe safety instructions are not observed.
Each person involved in the operation, maintenance and repair of
the machine must therefore read and comply with these safety reg-
ulations. If necessary, the operating company must obtain the rele-
vant signatures as confirmation.
Furthermore, the following obviously also applies:
napplicable accident prevention instructions,
ngenerally accepted safety and road traffic regulations,
ncountry specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations and regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
1.2.1.2 Explanation of signal words used:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or
severe injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
General – Concerning your safety
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
12

CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible
dangers for machines or components.
Sections marked accordingly indicate technical
information or notes on using the machine or its
components.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices
for safe and environment-friendly disposal of fuels
and lubricants as well as replacement parts.
1.2.1.3 Personal protective equipment
Depending on the work to be carried out, personal protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protect against
being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on
slippery ground.
Protective gloves To protect the hands against excoriation, punctures or
deep injuries, against irritating and caustic substances
as well as against burns.
General – Concerning your safety
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
13

Safety goggles To protect the eyes against airborne particles and
squirting fluids.
Face protection To protect the face against airborne particles and
squirting fluids.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect the hearing against too loud noise.
1.2.1.4 Intended use
This machine must only be used for:
nCompaction of bituminous material, e.g. road surface layers,
nCompaction work in earth construction and road bases.
Intended use also includes compliance with the specified oper-
ating, maintenance and repair measures.
1.2.1.5 Improper 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 improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
Examples for improper use are:
nwork with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
ncleaning the drums while driving or changing nozzles during
travel
ndriving on subsoils with too low load bearing capacity
ndriving on slippery subsoils (e.g. ice and snow)
ndriving on surfaces of insufficient size (danger of turning over)
nunauthorized use of public roads
nusing the machine for towing
General – Concerning your safety
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
14

Transporting persons, except the machine driver, is prohibited.
Starting and operating the machine in explosive environments and
in underground mining is prohibited.
1.2.2 Definition of responsible persons
1.2.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
its company. It must then take appropriate action to ensure health
and safety at work for its employees and point out any remaining
dangers.
The operating company must determine whether there are special
operational hazards such as a toxic atmosphere or limiting soil
conditions. Such conditions require special, additional measures to
remove or reduce the hazard.
The operating company must make sure that all users read and
understand the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
1.2.2.2 Expert / qualified person
An expert / qualified person is a person who, based on his/her pro-
fessional education and experience, has profound knowledge in
the field of construction equipment and the machine in question in
particular.
This person is acquainted with the applicable governmental indus-
trial safety regulations, accident prevention instructions, guidelines
and generally acknowledged technical rules and regulations
(standards, directives, technical rules of other member states of
the European Union or other contractual states concerning the
agreement about the European Economic Area) in as far as is nec-
essary to be able to judge the safe condition of this machine.
1.2.2.3 Driver / operator
This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:
General – Concerning your safety
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
15

The driver or operator must:
nbe instructed about his rights and obligations,
nwear protective equipment as appropriate for the application,
nhave read and understood the operating instructions,
nhave made himself familiar with the operation of the machine,
nbe physically and psychologically able to drive and operate the
machine.
Persons under the influence of alcohol, medication 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.
1.2.3 Fundamentals for safe operation
1.2.3.1 Remaining dangers, remaining risks
Despite careful work and compliance with standards and regula-
tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
Both the machine as well as all other system components comply
with the currently valid safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even when using the machine
for the purpose it is intended for and following 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 in the area of the machine must be informed
about the dangers that arise from the operation of the machine.
1.2.3.2 Regular safety inspections
Have the machine inspected by an expert / qualified person as
required for the conditions the machine is working under, but at
least once every year.
1.2.3.3 Modifications and alterations to the machine
Unauthorized changes to the machine are prohibited for safety rea-
sons.
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 safety.
General – Concerning your safety
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
16

1.2.3.4 Damage, defects, misuse of safety devices
Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.
1.2.3.5 Roll Over Protective Structure (ROPS)
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, hairline cracks or
open fractures.
The real machine weight must never exceed the testing weight for
the ROPS.
No accessories may be welded or bolted on and no additional
holes must be drilled without the consent of the manufacturer,
since this will impair the strength of the unit.
The ROPS must therefore also not be straightened or repaired if it
is damaged.
A defect ROPS must generally be replaced with an original spare
part in close coordination with the manufacturer.
1.2.4 Handling fuels and lubricants
1.2.4.1 Preliminary remarks
The operating company must ensure that all professional users
have read and follow the corresponding safety data sheets for the
individual fuels and lubricants.
Safety data sheets provide valuable information about the following
characteristics:
nname of substance
npossible dangers
ncomposition / information on constituents
nfirst-aid measures
nfire fighting measures
nmeasures in case of accidental release
nhandling and storage
nlimitation and monitoring of exposure / personal protective
equipment
nphysical and chemical properties
nstability and reactivity
General – Concerning your safety
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
17

ntoxicological data
nenvironmental data
nnotes on waste disposal
ninformation on transport
nlegislation
nother data
1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuel
WARNING!
Danger of burning by ignited diesel fuel!
– Do not allow diesel fuel to come into contact
with hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with diesel
fuel!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any fuel fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous
substance!
– Always keep diesel fuel in proper containers.
– Immediately bind spilled diesel fuel with an oil-
binding agent and dispose of properly.
– Dispose of diesel fuel and fuel filters according
to regulations.
Fig. 1
General – Concerning your safety
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
18

1.2.4.3 Safety regulations and environmental protection regulations for handling oil
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come into contact with hot
components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with oil!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
– Immediately bind spilled oil with an oil-binding
agent.
– Dispose of oil and oil filter according to regula-
tions.
Fig. 2
General – Concerning your safety
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
19

1.2.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil
WARNING!
Danger of injury caused by escaping pressure
fluid!
– Always depressurize the hydraulic system
before starting work in the hydraulic system.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
Should pressure fluid penetrate the skin, imme-
diate medical help is required.
WARNING!
Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil to come into contact
with hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with hydraulic
oil!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
– Immediately bind spilled oil with an oil-binding
agent.
– Dispose of oil and oil filter according to regula-
tions.
Fig. 3
General – Concerning your safety
BW 161 AC-50 / BW 161 AD-50 / BW 161 ADO-50
20