Fayat Bomag BW 900-50 Instructions for use

BW 900-50
Tandem vibratory roller
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 861 834 07 1001> / S/N 101 834 51 1001>
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terminals, tank trucks and other facilities and equipment.
plants, transport and storage operations such as pipelines, marine
For more information go to www.P65Warnings.ca.gov/petroleum.
These exposures can occur in and around oil fields, refineries, chemical
WARNING: Crude oil, gasoline, diesel fuel and other petroleum
products can expose you to chemicals including toluene and benzene,
which are known to the State of California to cause cancer and birth
defects or other reproductive harm.
WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
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Table of contents
1Introduction........................................................................................................................................... 5
1.1 Foreword........................................................................................................................................ 6
1.2 Machine type plate and engine type plate.................................................................................. 8
2 Technical data........................................................................................................................................ 9
3Safety regulations............................................................................................................................... 13
3.1 Signage........................................................................................................................................ 22
4 Indicators and control elements........................................................................................................ 29
4.1 Description.................................................................................................................................. 31
5 Operation............................................................................................................................................. 37
5.1 Checks prior to start up.............................................................................................................. 38
5.2 Starting the engine...................................................................................................................... 39
5.3 Driving the machine.................................................................................................................... 42
5.4 Stopping the machine, operating the parking brake............................................................... 44
5.5 Shutting down the engine.......................................................................................................... 45
5.6 Switching the vibration on and off............................................................................................ 46
5.7 Switching the pressure sprinkling system on and off............................................................. 48
5.8 Towing.......................................................................................................................................... 49
5.9 Loading and transport................................................................................................................ 51
6 Maintenance........................................................................................................................................ 55
6.1 General notes on maintenance ................................................................................................. 56
6.2 Fuels and lubricants................................................................................................................... 58
6.3 Table of fuels and lubricants...................................................................................................... 60
6.4 Running-in instructions.............................................................................................................. 61
6.5 Maintenance Table...................................................................................................................... 62
6.6 Every 10 operating hours........................................................................................................... 63
6.6.1 Checking the engine oil level..................................................................................................... 63
6.6.2 Checking the fuel level............................................................................................................... 63
6.6.3 Checking the hydraulic oil level ................................................................................................. 65
6.6.4 Checking the hydraulic oil filter element..................................................................................... 65
6.6.5 Checking the water level............................................................................................................ 66
6.6.6 Cleaning the scrapers................................................................................................................ 66
6.6.7 Cleaning the cooling air intake openings................................................................................... 67
6.7 Every 125 operating hours......................................................................................................... 68
6.7.1 Check, clean the air filter, replace if necessary.......................................................................... 68
6.7.2 Clean, check the spark plugs, replace if necessary................................................................... 69
6.7.3 Changing engine oil and oil filter................................................................................................ 71
6.7.4 Lubricating the rear drum bearings............................................................................................ 72
6.8 Every 250 operating hours......................................................................................................... 73
6.8.1 Change the fuel pre-filter............................................................................................................ 73
6.8.2 Clean the water sprinkler system............................................................................................... 73
6.8.3 Battery service........................................................................................................................... 74
6.8.4 Checking, adjusting the valve clearance.................................................................................... 76
6.8.5 Check, adjust the idle speed...................................................................................................... 77
Table of contents
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6.9 Every 2000 operating hours....................................................................................................... 78
6.9.1 Changing the hydraulic oil.......................................................................................................... 78
6.9.2 Change the hydraulic oil filter..................................................................................................... 79
6.9.3 Checking fuel lines and clamps.................................................................................................. 80
6.10 As required................................................................................................................................ 82
6.10.1 Water sprinkler system, maintenance in case of frost.............................................................. 82
6.10.2 Engine conservation................................................................................................................. 82
7 Troubleshooting.................................................................................................................................. 85
7.1 Preliminary remarks.................................................................................................................... 86
7.2 Starting the engine with jump leads.......................................................................................... 87
7.3 Engine problems ........................................................................................................................ 88
8 Disposal............................................................................................................................................... 91
8.1 Final shut-down of machine....................................................................................................... 92
Table of contents
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1 Introduction
Introduction
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1.1 Foreword
BOMAG manufactures machines for earth, asphalt and refuse
compaction, stabilizers/recyclers as well as planers and
pavers.
BOMAG’s vast experience in connection with state-of-the-art
production and testing methods, such as lifetime tests of all
important components and highest quality demands guar-
antee maximum reliability of your machine.
These operating and maintenance instructions are part of your
machine.
They provide necessary information to operate your machine
safely and properly.
They also contain information on required operating, maintenance
and repair measures.
Carefully read the operating and maintenance instructions before
taking your machine into operation.
Please observe the safety regulations strictly and follow all instruc-
tions to ensure safe operation.
If you are not yet acquainted with the controls and indicating ele-
ments on this machine, you should thoroughly read the corre-
sponding chapter
Ä Chapter 4 „Indicators and control ele-
ments“ on page 29.
The description of the individual operating steps including the
notes on safety to be followed can be found in chapter “Operation”
Ä Chapter 5 „Operation“ on page 37.
Before every start up, carry out all required visual inspections and
function tests.
Ensure the compliance with the specified operating, maintenance
and repair measures to maintain the functional safety of your
machine.
A description of all necessary maintenance work, maintenance
intervals as well as information on fuels and lubricants can be
found in the chapter “Maintenance”
Ä Chapter 6 „Mainte-
nance“ on page 55.
Do not service or repair your machine by yourself to avoid harming
persons or damaging material or environment.
The machine must only be serviced and repaired by qualified and
authorized personnel.
Contact our Customer Service to carry out the required mainte-
nance work or necessary repairs.
In case of operating errors, inadequate maintenance or the use of
unapproved fuels and lubricants all warranty claims will become
null and void.
For your own personal safety you should only use original parts
from BOMAG.
For your machine we offer service kits to make maintenance
easier.
Introduction – Foreword
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In the course of technical development we reserve the right for
technical modifications without prior notification.
These operating and maintenance instructions are also available in
other languages.
Apart from that, you can also order the spare parts catalogue
against the serial number of your machine.
The above notes do not constitute an extension of the warranty
and liability conditions specified in the general sales and delivery
conditions of BOMAG GmbH.
We wish you successful work with your BOMAG machine.
Introduction – Foreword
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1.2 Machine type plate and engine type plate
Please enter here:
Machine type (1):
Serial number (2):
Please enter here:
Engine type:
Engine number:
Fig. 1: Machine type plate (example)
Engine type and engine number
1
B-HON-0008
Fig. 2
Introduction – Machine type plate and engine type plate
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2 Technical data
Technical data
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Fig. 3
A B C D H H2K L O S W
1223
(48)
961
(38)
450
(18)
560
(22)
1727
(68)
2290
(90)
250
(10)
1967
(86)
31
(1.2)
8
(0.3)
900
(35)
Dimensions in millimetres
(Dimensions in inch)
Weights
Max. operating weight 1200
(2646)
kg
(lbs)
Operating weight (CECE) 1600
(3527)
kg
(lbs)
Average static linear load (CECE) 6.7
(37.5)
kg/cm
(pli)
Dimensions
Technical data
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Travel characteristics
Travel speed 0 - 8.7
(0 - 5.4)
km/h
(mph)
Working speed with vibration 0 - 4
(0 - 2.5)
km/h
(mph)
Max. gradeability without/with vibration (soil dependent) 40/30 %
Drive
Engine manufacturer Honda
Type GX 630
Cooling system Air
Number of cylinders 2
Rated power SAE J 1349 14.9 kW
Rated speed 3300 min-1
Driven drum front + rear
Electric system
Voltage 12 V
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering angle +/- 33 °
Oscillation angle +/- 6 °
Inner track radius 1647
(65)
mm
(in)
Technical data
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Exciter system
Vibrating drum front
Drive system hydrostatic
Frequency 70
(4200)
Hz
(vpm)
Amplitude 0.50
(0.020)
mm
(in)
Centrifugal force 15
(3372)
kN
(lbf)
Water sprinkler system
Type of sprinkling Pressure
Filling capacities
Fuel (gasoline) 27
(7)
l
(gal us)
Water 137
(36)
l
(gal us)
Technical data
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3 Safety regulations
Safety regulations
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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 regulations. If necessary, this must be confirmed
by obtaining the signature of the customer.
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 these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.
This machine must only be used for:
nCompaction of bituminous material, e.g. road surface layers,
nlight to medium compaction work in earth construction or road
sub-bases.
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)
nPassing over too high borders (e.g. curbstones, embankments,
trenches, potholes)
nunauthorized use of public roads
nUsing 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 prohibited.
General
Intended use
Improper use
Safety regulations
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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 ion the area of the machine must be
informed about the dangers that arise from the operation of the
machine.
Have the machine inspected by an expert (capable person) as
required for the conditiosn the machine is working under, but at
least once every year.
Only trained, instructed and authorized persons of at least 18 years
of age are permitted to drive and operate this machine. For opera-
tion of the machine the responsibilities must be clearly specified
and complied with.
Persons under the influence of alcohol, medicine or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
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.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.
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.
Remaining dangers, remaining
risks
Regular safety inspections
Who is allowed to operate the
machine?
Changes and conversions to the
machine
Damage, deficiencies, misuse of
safety installations
Safety regulations
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WARNING!
Paragraphs marked like this highlight possible dan-
gers for persons.
NOTICE!
Paragraphs marked like this highlight possible dan-
gers for machines or parts of the machine.
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the
machine.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubri-
cants as well as replacement parts.
Observe the regulations for the protection of the
environment.
Check the fastening of the central lifting hook before each use.
Use only stable loading ramps of sufficient load bearing capacity.
The ramp inclination must be less than the gradability of the
machine.
Secure the machine against tipping or slipping off.
Secure the machine on the transport vehicle against rolling, slip-
ping and turning over.
Persons are highly endangered if
nthey step or stand under loads being lifted
nthey remain in the drive range of the machine during an
instruction and during loading.
The machine must not swing about when being lifted.
Use only safe lifting gear of sufficient load bearing capacity
Fasten the lifting gear only at the specified lifting points.
Apply appropriate measures (e.g. with metal wheel chocks, to be
provided by the operating company) to secure the machine against
rolling away before releasing the parking brake.
Use a tow bar (tobe provided by the operating company).
Use a towing vehicle with sufficient traction and braking power for
the unbraked towed load.
Notes on safety in the operating
and maintenance instructions
Loading the machine
Towing the machine
Safety regulations
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The machine cannot be steered.
Tow the machine only after having released the parking brake.
Max. towing speed 1 km/h (0.6 mph), max. towing distance 500 m
(0.3 mi).
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.
The ROPS must not rattle about when driving. This indicates that it
is not properly fastened. All bolted connections must comply with
the specifications and should be absolutely tight (observe the tight-
ening torques). Screw and nuts must not be damaged, bent or
deformed.
No accessories may be welded or bolted on and no additional
holes must be drilled without the consent of the 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.
Before starting
Use only machines which are serviced at regular intervals.
Become acquainted with the equipment, the control elements, the
working principle of the machine and the working area.
Wear your personal protective outfit (hard hat, safety boots, etc.).
Wear ear defenders.
Before mounting the machine check whether:
npersons or obstructions are beside or under the machine.
nthe machine is free of oily and combustible material.
nall grips, steps and platforms are free of grease, oils, fuel, dirt,
snow and ice.
nthe engine hood is closed and locked.
Use steps and grips to mount the machine.
Before starting the machine check whether:
nthe machine shows any obvious faults.
nall guards and safety elements are in place.
nsteering, brakes, control elements, light system and warning
horn work correctly.
nthe seat is correctly adjusted
nmirrors (if present) are clean and correctly adjusted.
Do not start the machine with defective gauges, control lights or
control elements.
Checking the Roll Over Protective
Structure (ROPS)
Starting the machine
Safety regulations
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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 driver’s seat.
For starting set all control levers to 'neutral position'.
Do not use any starting aids like start pilot or ether.
After starting check all display instruments.
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 con-
nection will cause severe damage in the electric system.
Do not start the engine by shorting the electric terminals 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 extremely dangerous! Always ensure an ade-
quate supply of fresh air when starting and operating in closed
rooms and trenches!
Persons in the endangered area
Before starting or resuming work and especially when reversing,
check that there are not any persons or obstructions in the endan-
gered area.
If necessary give warning signals. Stop work immediately if per-
sons remain in the danger area despite the warning.
Do not step or stand in the articulation area of the machine when
the engine is running. Risk of squashing!
Driving
In events of an emergency operate the emergency stop switch
immediately. Do not use the emergency stop switch as a service
brake.
Restart the machine only after the danger, that has caused the
actuation of the emergency stop, has been eliminated.
If the machine has come in contact with high-voltage power lines:
ndo not leave the operator's stand
nwarn others from coming too close to the machine or touching
it
nif possible drive the machine out of the danger zone
nhave the power shut off
Operate the machine only from the operator's seat.
Do not adjust the seat while driving.
Do not climb onto or off the machine while driving.
Change the travel direction only while the machine is standing.
Driving the machine
Safety regulations
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Do not use the machine to transport persons.
Stop the machine if you notice unusual noises or the development
of smoke. Investigate the cause and have the fault corrected.
Keep a sufficient distance to excavations and embankments and
make sure that your work does not impair the stability of the
machine.
Do not work with vibration on hard concrete, on a cured bitumen
surface or heavily frozen ground.
When passing under flyovers, bridges, tunnels, electric power lines
etc. keep a sufficient distance.
Driving on slopes and gradients
Do not drive up and down gradients, which exceed the max. grada-
bility of the machine.
Always drive extremely carefully on slopes and always straight up
and down the slope. Change to the lower speed range before
approaching the slope.
Wet and loose soils reduce the ground adhesion of the machine on
gradients and slopes. Higher risk of accident!
Behaviour in traffic
Match the speed of the machine to the working conditions.
Always allow loaded transport vehicles to pass.
Switch the lights on when the visibility is poor.
Keep clear of edges and embankments.
Check the effect of vibration
When compacting with vibration check the effect of the vibration on
nearby buildings and underground supply lines (gas, water,
sewage, electric power supply), stop vibratory compaction if neces-
sary.
Do not activate the vibration on hard (frozen, concrete) ground.
Risk of bearing damage!
Park the machine on horizontal, level, firm ground.
Before leaving the machine:
nreturn the control lever to neutral position
napply the parking brake
nshut down the engine, pull off the ignition key
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.
Do not inhale any fuel fumes.
Parking the machine
Refuelling
Safety regulations
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