Fayat Bomag BW 900-50 User manual

BW 900-50
Tandem vibratory roller
Service Manual
S-834-0013
S/N 101 834 51 1001> / S/N 861 834 07 2170>
© 07/2019008 403 18 EN
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Table of contents
1General information.............................................................................................................................. 7
1.1 Introduction................................................................................................................................... 8
1.2 Safety regulations....................................................................................................................... 10
1.2.1 Signage...................................................................................................................................... 18
1.3 Maintenance and repair.............................................................................................................. 24
1.3.1 Notes on repair........................................................................................................................... 24
1.3.2 General notes on maintenance ................................................................................................. 38
2 Technical data...................................................................................................................................... 41
2.1 Technical data............................................................................................................................. 42
2.2 Additional technical data............................................................................................................ 45
2.3 Terms and basis of calculation.................................................................................................. 47
2.4 Fuels and lubricants................................................................................................................... 48
2.5 Table of fuels and lubricants...................................................................................................... 50
3 Overview of machine.......................................................................................................................... 51
3.1 General information.................................................................................................................... 52
3.2 Electric systems.......................................................................................................................... 53
3.3 Hydraulic system........................................................................................................................ 55
3.4 Machine assemblies................................................................................................................... 56
3.4.1 Engine........................................................................................................................................ 56
3.4.2 Oscillating articulated joint......................................................................................................... 57
3.4.3 Drums......................................................................................................................................... 59
4 Electric systems.................................................................................................................................. 63
4.1 Basic principles........................................................................................................................... 64
4.1.1 Measuring technology................................................................................................................ 64
4.1.2 Understanding circuit diagrams.................................................................................................. 69
4.1.3 Telemecanique switch................................................................................................................ 80
4.2 Starting the engine with jump leads.......................................................................................... 82
4.3 Overview of electric system....................................................................................................... 83
4.3.1 Control elements........................................................................................................................ 85
4.4 Central electrics.......................................................................................................................... 87
4.5 Fuse assignment......................................................................................................................... 89
4.6 Engine oil pressure monitoring................................................................................................. 90
4.7 Proximity switches, B08 and B38.............................................................................................. 91
4.8 Inspection and maintenance work............................................................................................ 93
4.8.1 Maintenance Table..................................................................................................................... 93
4.8.2 Every 250 operating hours......................................................................................................... 93
5 Hydraulic system................................................................................................................................ 95
5.1 Basic principles........................................................................................................................... 97
5.1.1 Open and closed hydraulic circuit.............................................................................................. 97
5.1.2 Swash plate principle, pump...................................................................................................... 99
5.1.3 External gear pumps................................................................................................................ 101
5.1.4 Outer gear motors non-reversible............................................................................................ 103
5.2 Overview of hydraulics............................................................................................................. 104
5.3 Description of hydraulic components..................................................................................... 107
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5.3.1 Travel pump, PMVO 13S......................................................................................................... 107
5.3.2 Travel motor TG405................................................................................................................. 110
5.3.3 Steering valve........................................................................................................................... 112
5.4 Description of hydraulic circuits............................................................................................. 114
5.4.1 Travel circuit............................................................................................................................. 114
5.4.2 Vibration circuit......................................................................................................................... 116
5.4.3 Steering circuit.......................................................................................................................... 118
5.5 Tests and adjustments............................................................................................................. 121
5.5.1 Checking the rotation speeds................................................................................................... 121
5.5.2 Pressure tests in the travel circuit............................................................................................ 123
5.5.3 Adjusting the neutral positions of the travel pump................................................................... 124
5.5.4 Travel pump high pressure test................................................................................................ 125
5.5.5 Pressure tests in the vibration circuit....................................................................................... 127
5.5.6 Vibration pump high pressure test........................................................................................... 128
5.5.7 Checking the leakage rate of the vibration motor..................................................................... 130
5.5.8 Pressure tests in the steering circuit........................................................................................ 131
5.6 Flushing and bleeding.............................................................................................................. 133
5.6.1 Flushing in general................................................................................................................... 133
5.6.2 Flushing schematic for travel system....................................................................................... 136
5.6.3 Flushing the travel system....................................................................................................... 137
5.6.4 Bleeding the travel circuit......................................................................................................... 141
5.7 Inspection and maintenance work.......................................................................................... 143
5.7.1 Maintenance Table................................................................................................................... 143
5.7.2 Checks prior to start up............................................................................................................ 143
5.7.3 Every 2000 operating hours..................................................................................................... 144
6 Machine assemblies......................................................................................................................... 149
6.1 Engine........................................................................................................................................ 151
6.1.1 Engine overview....................................................................................................................... 151
6.1.2 Carburettor inspection.............................................................................................................. 153
6.1.3 Inspection and maintenance work............................................................................................ 155
6.2 Oscillating articulated joint...................................................................................................... 166
6.2.1 Repair overview for oscillating articulated joint........................................................................ 167
6.2.2 Removing and installing the oscillating articulated joint........................................................... 169
6.2.3 Repairing the oscillating articulated joint.................................................................................. 170
6.3 Drum........................................................................................................................................... 176
6.3.1 Vibratory drum, front................................................................................................................ 176
6.3.2 Rear drum................................................................................................................................ 192
6.3.3 Inspection and maintenance work............................................................................................ 200
7 Troubleshooting................................................................................................................................ 203
7.1 Preliminary remarks.................................................................................................................. 204
7.2 Emergency procedures............................................................................................................ 205
7.2.1 Actuating the emergency stop switch....................................................................................... 205
7.2.2 Towing...................................................................................................................................... 205
7.3 Troubleshooting, electrical systems....................................................................................... 207
7.3.1 Preliminary remarks................................................................................................................. 207
7.3.2 Fuse assignment...................................................................................................................... 210
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7.3.3 Starting the engine with jump leads......................................................................................... 211
7.4 Trouble shooting, hydraulics................................................................................................... 212
7.4.1 Preliminary remarks................................................................................................................. 212
7.4.2 Insufficient hydraulic power...................................................................................................... 213
7.4.3 Troubleshooting axial piston pumps......................................................................................... 216
7.5 Trouble shooting, diesel engine.............................................................................................. 219
7.5.1 Starting the engine with jump leads......................................................................................... 219
7.5.2 Engine problems ..................................................................................................................... 219
8 Special tools...................................................................................................................................... 221
8.1 Special tools for hydraulic system.......................................................................................... 222
8.1.1 Special tools, tests and adjustments........................................................................................ 222
8.1.2 Special tools for flushing.......................................................................................................... 224
8.2 Special tools, electrics............................................................................................................. 225
8.3 Special tools for drum.............................................................................................................. 226
9 Index................................................................................................................................................... 227
Appendix............................................................................................................................................ 231
A Circuit diagrams............................................................................................ 233
A.1 Circuit diagram 78..................................................................................... 233
A.2 Hydraulic diagram 138............................................................................... 243
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1 General information
General information
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1.1 Introduction................................................................. 8
1.2 Safety regulations..................................................... 10
1.2.1 Signage.................................................................... 18
1.3 Maintenance and repair............................................ 24
1.3.1 Notes on repair........................................................ 24
1.3.2 General notes on maintenance ............................... 38
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)
General
Index
Documentation
General information – Introduction
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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.
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.
Maintenance/parts service
Updating service
Copyright
General information – Introduction
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1.2 Safety regulations
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.
General
Intended use
Improper use
General information – Safety regulations
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starting and operation of the machine in explosive environments
and in underground mining is prohibited.
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.
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
General information – Safety regulations
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