Bomag BW 120 AD-4 Repair Service Manual

Service - Manual Catalogue number. 008 915 24 07/2010 BW 100 AD-4 / BW 100 AC-4 BW 120 AD-4 / BW 125 AD-4 BW 120 AC-4 / BW 125 AC-4 S/N 101 880 16 .... > / S/N 101 880 17 ....> S/N 101 880 08 .... > / S/N 101 880 09 ....> S/N 101 880 10 .... > / S/N 101 880 11 ....> Tandem Vibratory Roller Combination Roller

Table of Contents BOMAG 3 008 915 24 General 5 1.1 Introduction 6 1.2 Safety regulations 7 1.3 General repair instructions 11 1.4 Tightening torques 21 Technical data 25 2.1 Technical data 26 Maintenance 33 3.1 General notes on maintenance 34 3.2 Fuels and lubricants 35 3.3 Table of fuels and lubricants 37 3.4 Running-in instructions 38 3.5 Maintenance table 39 Electrics 41 4.1 Understanding wiring diagrams 42 4.2 Designation of components in the wiring diagram 51 4.3 Terminal designations in wiring diagram 52 4.4 Circuit symbols in the circuit diagram 54 4.5 Identification of switch blocks in the wiring diagram 57 4.6 Battery ground and analog ground 58 4.7 Current and voltage 58 4.8 Resistance 60 4.9 Series / parallel connection 62 4.10 Ohm's law 64 4.11 Electrical energy 65 4.12 Formula diagram 66 4.13 Metrology 67 4.14 Diodes, relays, fuses 71 4.15 Telemecanique switch 74 4.16 Inductive proximity switches 76 4.17 Angle sensors 77 4.18 Plug connectors 79 4.19 Magnetic coil plug 80 4.20 Deutsch plug, series DT and DTM 82 4.21 Plugs and terminals in spring clamping technology 89 4.22 Batteries 93 4.23 Starting with jump wires 95 4.24 Main fuse 96 4.25 Generator 97 4.26 Generator repair 103 4.27 Electric starter 107 4.28 Repair of starter 114 4.29 Glow plugs 118 4.30 Engine shut-down solenoid 119 4.31 Engine oil pressure monitoring 121 4.32 Coolant temperature monitoring 121

Table of Contents BOMAG 4 008 915 24 4.33 Modules 122 4.34 Switching the vibration on 123 4.35 Switching the pressure sprinkler system on 123 4.36 Fuses 124 4.37 Installation locations for electrical components 125 Description of the modules 143 5.1 Electric modules 145 Service Training 161 6.1 Service Training 163 Flushing and bleeding 235 7.1 Special tools for flushing 236 7.2 Flushing - general 241 7.3 Flushing schematic for front drum drive 243 7.4 Flushing the front drum drive 244 7.5 Flushing schematic for rear drum drive system 248 7.6 Flushing the rear drum drive 249 7.7 Flushing schematic, rear wheel drive motors 253 7.8 Flushing the rear wheel drive 254 7.9 Flushing schematic for vibration drive on AD-machines 258 7.10 Flushing schematic for vibration circuit on AC-machines 259 7.11 Flushing the vibration circuit 260 7.12 Bleeding the travel circuit 262 Drum 265 8.1 Special tools 266 8.2 Repair overview for drum 268 8.3 Removing and installing the drum 270 8.4 Dismantling the drum 275 8.5 Assembling the drum 281 Oscillating articulated joint 289 9.1 Special tools 290 9.2 Repair overview Oscillating articulated joint 292 9.3 Removing and installing the oscillating articulated joint 294 9.4 Dismantling the oscillating articulated joint 296 9.5 Assembling the oscillating articulated joint 299 Suppliers documentation 305 10.1 Steering valve 307 10.2 Travel pump 341 10.3 Drum drive 399 10.4 Wheel drive 417 Circuit diagrams 493 11.1 Hydraulic diagram 880 100 50 495 11.2 Hydraulic diagram 880 100 52 499 11.3 Hydraulic diagram 880 100 55 503 11.4 Wiring diagram 880 100 63 507 11.5 Wiring diagram 880 100 64 533

BOMAG 5 008 915 24 1 General

1.1 Introduction BOMAG 6 008 915 24 1.1 Introduction This manual addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and effi- cient repair and maintenance work. This manual describes the disassembly, dismantling, assembly, installation and repair of components and assemblies. The repair of components and assemblies is only described as this makes sense under due consideration of working means and spare parts supply. Documentation For the BOMAG machines described in this manual the following documentation is additionally available: 1 Operating and maintenance instructions 2 Spare parts catalogue 3 Wiring diagram* 4 Hydraulic diagram* 5 Service Information Use only genuine BOMAG spare parts. Spare parts needed for repairs can be taken from the spare parts catalogue for the machine. These repair instructions are not subject of an updat- ing service; for this reason we would like to draw your attention to our additional "Technical Service Bulle- tins". 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 notifica- tion. Information and illustrations in this manual must not be reproduced and distributed, nor must they be used for the purpose of competition. All rights according to the copyright law remain expressly reserved. ! Danger These safety regulations must be read and ap- plied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be additionally observed. BOMAG GmbH Printed in Germany Copyright by BOMAG * The applicable documents valid at the date of print- ing are part of this manual.

Safety regulations BOMAG 7 008 915 24 1.2 1.2 Safety regulations Important notes These safety regulations must be read and ap- plied by every person involved in the repair /maintenance of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be additionally observed. Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG. Workshop equipment and facilities as well as the use and waste disposal of fuels and lubricants, cleaning agents and solvent as well as gases and chemicals are subject to legal regulations, which are intended to provide a minimum on safety. It is obviously your own responsibility to know and adhere to these regulations. This manual contains headers like "Note", "Attention", "Danger" and "Environment", which must be strictly complied with in order to inform about and avoid dangers to persons, property and the environment. i Note Paragraphs marked like this contain technical information for the optimal economical use of the machine. ! Caution Paragraphs marked like this highlight possible dangers for machines or parts of the machine. ! Danger Paragraphs marked like this highlight possible dangers for persons. Environment Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts. Observe the regulations for the protection of the environment. General ● For repair and maintenance work move the machine on a firm base and shut it down. ● Always secure the machine against unintended roll- ing. ● Secure the engine reliably against unintentional starting. ● Mark a defective machine and a machine under repair by attaching a clearly visible warning label to the dashboard. ● Block the articulated joint with the articulation lock. ● Use protective clothes like hard hat, safety boots and gloves. ● Keep unauthorized persons away from the machine during repair work. ● Tools, lifting gear, lifting tackle, supports and other auxiliary equipment must be fully functional and in safe condition. ● Use only safe and approved lifting gear of sufficient load bearing capacity to remove and install parts or components from and to the machine. ● Do not use easily inflammable or harmful substances, such as gasoline or paint thinners for cleaning. ● Do not smoke or use open fire and avoid sparks when cleaning or repairing a tank. ● When performing welding work strictly comply with the respective welding instructions. Transport work with cranes and lifting tackle i Note Cranes must only be operated by instructed persons who had been trained in handling cranes. ● Follow the operating instructions of the manufacturer when working with cranes. ● Follow the operating instructions of the operator when working with cranes. ● Always comply with the applicable accident prevention instructions when working with cranes and lifting tackle. Precautions and codes of conduct for welding work Welding work must only be carried out by properly trained personnel. ! Danger Electric shock! Sparks, fire hazard, burning of skin! Infrared or ultraviolet radiation (arc), flashing of eyes! Health hazard caused by welding work on highly alloyed work pieces, metal coatings, paint coatings, plastic coatings, oil containing dirt deposits, grease or solvent residues, etc.! ● Check welding equipment and cables for damage before use (also the validity of inspection stickers). ● Ensure good conductivity between ground cable and workpiece, avoid joints and bearings.

1.2 Safety regulations BOMAG 8 008 915 24 ● Start the extraction fan before starting work and guide with the progressing work as required. ● Always isolate the burner when laying it down (remove possible electrode residues). ● Protect cables from being damaged, use cables with insulated couplings. ● Ensure sufficient fire protection, keep a fire extin- guisher at hand. ● Welding work in areas where there is a risk of fire or explosion, must only be carried out with welding permission. ● Remove any combustible materials from the welding area or cover such items appropriately. ● Name a fire watch during and after welding work. ● Place welding rod holders and inert gas welding guns only on properly insulated bases. ● Place the inert gas bottles in a safe place and secure them against falling over. ● Use a protective screen or hand shield with welding filter, wear welding gloves and clothes. ● Switch the welding unit off before connecting welding cables. ● Check electrode holders and electric cables at regular intervals. Behaviour in case of faults ● In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel. ● In case of failure of the extraction system switch the system off and have it repaired by expert personnel. Maintenance; waste disposal ● Replace damaged insulating jaws and welding rod holders immediately. ● Replace the welding wire reels only in de-energized state. What to do in case of accidents; First Aid ● Keep calm. ● Call first air helpers. ● Report the accident. ● In case of an electric accident: Interrupt the power supply and remove the injured person from the electric circuit. If breathing and heart have stopped apply reactivation measures and call for an emer- gency doctor. Old oils Prolonged and repetitive contact with mineral oils will remove the natural greases from the skin and causes dryness, irritation and dermatitis. Moreover, used engine oils contain potentially hazardous contaminants, which could cause skin cancer. Appropriate skin protection agents and washing facilities must therefore be provided. ● Wear protective clothes and safety gloves, if possible. ● If there is a risk of eye contact you should protect your eyes appropriately, e.g. chemistry goggles or full face visor; a facility suitable for rinsing the eyes should also be available. ● Avoid longer and repetitive contacts with oils. In case of open incisions and injuries seek medical advice immediately. ● Apply protective cream before starting work, so that oil can be easier removed from the skin. ● Wash affected skin areas with water and soap (skin cleansers and nail brushes will help). Lanolin containing agents will replace natural skin oils that were lost. ● Do not use gasoline, kerosene, diesel, thinner or solvents to wash the skin. ● Do not put oil soaked cloths into your pockets. ● Avoid clothes getting soiled by oil. ● Overalls must be washed at regular intervals. Dis- pose of non-washable clothes environmentally. ● If possible degrease components before handling. Environment It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Old oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities. Hydraulics ● Always relieve the pressure in the hydraulic system before disconnecting any lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. ● Always make sure that all screw fittings have been tightened properly and that hoses and pipes are in mint condition before pressurizing the system again. ● Hydraulic oil leaking out of a small opening can hardly be noticed, therefore please use a piece of cardboard or wood when checking for leaks. When injured by hydraulic oil escaping under pressure consult a physician immediately, as otherwise this may cause severe infections. ● Do not step in front of or behind the drums, wheels or crawler tracks when performing adjustment work in the hydraulic system while the engine is running. Block drums, wheels or crawler tracks with wedges.

Safety regulations BOMAG 9 008 915 24 1.2 Reattach all guards and safety installations after all work has been completed. Environment It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Oil oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities. Fuels ! Danger Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG. Follow the valid accident prevention instructions when handling fuels. The following notes refer to general safety precautions for danger free handling of fuel. Fuel vapours not only are easily inflammable, but also highly explosive inside closed rooms and toxic; dilu- tion with air creates an easily inflammable mixture. The vapours are heavier than air and therefore sink down to the ground. Inside a workshop they may easily become distributed by draft. Even the smallest por- tion of spilled fuel is therefore potentially dangerous. ● Fire extinguishers charged with FOAM, CO 2 GAS or POWDER must be available wherever fuel is stored, filled in, drained off, or where work on fuel systems is performed. ● The vehicle battery must always be disconnected, BEFORE work in the fuel system is started. Do not disconnect the battery while working on the fuel system. Sparks could cause explosion of the fuel fumes. ● Wherever fuel is stored, filled, drained off or where work on fuel systems is carried out, all potential ignition sources must be extinguished or removed. Search lights must be fire proof and well protected against possible contact with running out fuel. Hot fuels Please apply the following measures before draining of fuel to prepare for repair work: ● Allow the fuel to cool down, to prevent any contact with a hot fluid. ● Vent the system, by removing the filler cap in a well ventilated area. Screw the filler cap back on, until the tank is finally emptied. Synthetic rubber Many O-rings, hoses, etc. are made of synthetic material, a so-called fluorocarbon elastomer. Under nor- mal operating conditions this material is safe and does not impose any danger to health. However, if this material becomes damaged by fire or extreme heat, it may decompose and form highly caustic hydrofluoric acid, which can cause severe burns in contact with skin. ● If the material is in such a state it must only be touched with special protective gloves. The protective gloves must be disposed of according to applicable environmental regulations immediately after use. ● If the material has contacted the skin despite these measures, take off the soiled clothes and seek medical advice immediately. In the meantime cool and wash the affected area of skin over a sufficient time with cold water or lime water. Poisonous substances Some of the fluids and substances used are toxic and must under no circumstances be consumed. Skin contact, especially with open wounds, must be avoided. These fluids and substances are, amongst others, anti-freeze agents, hydraulic oils, fuels, washing addi- tives, refrigerants, lubricants and various bonding agents. Engine ! Danger Do not work on the fuel system while the engine is running. (Danger to life!) Once the engine has stopped wait approx. 1 min- utes for the system to depressurize. The systems are under high pressure. (Danger to life!) Keep out of the danger zone during the initial test rung. Danger caused by high pressure in case of leaks. (Danger to life!) When performing work on the fuel system make sure that the engine cannot be started uninten- tionally during repair work. (Danger to life!) ● Maintenance and cleaning work on the engine must only be performed with the engine stopped and cooled down. Make sure that the electric system is switched off and sufficiently secured against being switched on again (e.g. pull off ignition key, attach a warning label). ● Observe the accident prevention regulations for electric systems (e.g. -VDE-0100/-0101/-0104/-

1.2 Safety regulations BOMAG 10 008 915 24 0105 Electric precautions against dangerous contact voltages). ● Cover all electric components properly before wet cleaning. Battery ● Always wear goggles and protective clothing to service or clean batteries! Battery acid can cause severe injury by cauterization when coming in contact with skin. ● Work only well ventilated rooms (formation of oxy- hydrogen gas). ● Do not lean over the battery while it is under load, being charged or tested (danger of explosion). ● Keep ignition sources away from the battery. Burn- ing cigarettes, flames or sparks can cause explosion of the battery ● Use battery chargers etc. only in strict compliance with the operating instructions. ● After an accident with acid flush the skin with a sufficient amount of water and seek medical advice. ● Do not allow children access to batteries. ● When mixing battery fluid always pour acid into water, never vice-versa. Special safety regulations ● Use only genuine BOMAG spare parts for repair and maintenance work. Genuine spare parts and original accessories were specially developed, tested and approved for the machine. ● The installation and use of non-genuine spare parts or non-genuine accessories may therefore have an adverse effect on the specific characteristics of the machine and thereby impair the active and/or pas- sive driving safety. The manufacturer explicitly ex- cludes any liability for damage caused by the use of non-original parts or accessories. ● Unauthorized changes to the machine are prohibited for safety reasons. ● Do not perform any cleaning work while the engine is running. ● If tests on the articulated joint need to be performed with the engine running, do not stand in the articulation area of the machine (danger of crushing!). ● If tests must be performed with the engine running do not touch rotating parts of the engine (danger of injury!). ● Always ensure an adequate supply of fresh air when starting in closed rooms. Exhaust gases are highly dangerous! ● Refuel only with the engine shut down. Ensure strict cleanliness and do not spill any fuel. ● Always ensure an adequate supply of fresh air when refuelling in closed rooms. ● Dispose of used filters in accordance with applicable environmental regulations. ● When performing repair and maintenance work col- lect oils and fuels in suitable containers and dispose of in compliance with applicable environmental regulations. ● Do not heat up oils higher than 160 °C because they may ignite. ● Wipe off spilled or overflown oil using suitable cleaning means and dispose of in accordance with applicable environmental regulations. ● Dispose of old batteries according to applicable environmental regulations. ● There is a danger of scalding when draining off engine or hydraulic oil at operating temperature! Allow engine and hydraulic system to cool down to a sufficient level. ● Do not exceed the max. permissible tire pressure.

Bomag BW 120 AD-4 Repair Service Manual

You're Reading a Preview

Recently Viewed