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Fayat Bomag BW 900-50, Service Manual

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Fayat Bomag BW 900-50 Service Manual Download Page 210

Fig.  277

10 Pressure resistance plugs

1.

Connect pressure gauges (6) for high pressure and charge

pressure.

2.

Disconnect hydraulic motor/s (3) and close the ports with

pressure resistant plugs (10).

ð

The variable displacement pump can now be pressure

tested.

NOTICE!

Do not run the test over a longer period of time

(danger of overheating).

3.

Start the engine and accelerate to full speed.

4.

Shift the travel lever to forward and reverse.

5.

Read the pressure gauges (6).Read the pressure gauge.

ð

If the pressure gauges show the correct values, the vari-

able displacement pump is OK. The fault is in the

hydraulic motor/s (3).

Troubleshooting closed circuit

using the example of a travel circuit

Troubleshooting – Trouble shooting, hydraulics

 

BW 900-50

 

215

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Summary of Contents for Bomag BW 900-50

Page 1: ...dem vibratory roller Service Manual S 834 0013 S N 101 834 51 1001 S N 861 834 07 2170 07 2019 008 403 18 EN www discount equipment com G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 2: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

Page 3: ... 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 ...

Page 4: ...ing 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 join...

Page 5: ...h 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 Table of contents BW 900 50 5 G o t o D i s...

Page 6: ...1 General information General information BW 900 50 7 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 7: ...x 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 n Electrical operating means n Plug designations n Overviews n Fault codes n Troubleshooting n For t...

Page 8: ...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 man...

Page 9: ...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 n Compaction of bituminous material e g road surface layers n light 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 intende...

Page 10: ...ears 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 ch...

Page 11: ... 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 n they step or stand under loads being lifted n they remain in the drive range of the machine during an instruction and during loading The machine must not swing about when being ...

Page 12: ... 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 pro...

Page 13: ... 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 th...

Page 14: ...eed 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 compac...

Page 15: ...d maintenance and assembly work use the access steps and working platforms provided or other secure means Do not use machine parts as access steps Keep unauthorized persons away from the machine Do not perform maintenance work while the machine is driving or the engine is running Park the machine on horizontal level firm ground Pull the key out of the ignition switch Secure the articulated joint w...

Page 16: ...nnection is impaired Only genuine BOMAG replacement hydraulic hoses ensure that the correct hose type pressure range is used at the right location Working on the engine Shut the engine down before opening the engine hood Drain the engine oil at operating temperature danger of scalding Wipe off spilled oil catch running out oil and dispose of environ mentally Store used filters and other oil contam...

Page 17: ...aning equipment do not subject elec trical parts and insulation material to the direct jet of water or cover it beforehand n Do not guide the water jet into the exhaust and into the air filter After maintenance work After all maintenance work is completed reinstall all guards and safety installations Mark a defective machine by attaching a warning tag to the steering wheel Repair work must only be...

Page 18: ...5 The engine exhaust of this product contains chemicals known to the state of California to cause cancer birth defects or other productive harm Fig 1 General information Safety regulations BW 900 50 19 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 19: ...xhaust gases Prohibition sticker High pressure cleaning B DEC 0197 Fig 2 Fig 3 B DEC 0294 The engine exhaust of this product contains chemicals known to the state of California to cause cancer birth defects or other productive harm Fig 4 Fig 5 General information Safety regulations BW 900 50 20 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 20: ... Information sticker Filler opening for hydraulic oil Information sticker Engine oil drain Fig 6 Fig 7 B DEC 0214 Hydraulic Oil Fig 8 B DEC 0211 Fig 9 General information Safety regulations BW 900 50 21 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 21: ...ontrol Information sticker Travel lever control Operation sticker Throttle lever Fig 10 B DEC 0295 Fig 11 B DEC 0296 Fig 12 Fig 13 General information Safety regulations BW 900 50 22 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 22: ...cker Gasoline Information sticker Travel lever control B DEC 0297 Fig 14 B DEC 0298 GASOLINE BENZIN Fig 15 B DEC 0299 Fig 16 General information Safety regulations BW 900 50 23 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 23: ...s and connect negative and positive cables Pull the plugs off the control units Always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location When choosing the location for the earth clamp make sure that the welding current will not pass through joints or bearings Maintenance free batteries also need care Mainte nance free only means that the fluid level does ...

Page 24: ...ator can only be operated with the battery con nected Under special conditions emergency operation without battery is permitted the lifetime of the generator is in such cases especially limited n Plus and minus cables must be disconnected during rapid charging of the battery or electric welding on the vehicle n When cleaning the generator with a steam or water jet make sure not to direct the steam...

Page 25: ...y Do not install parts that show traces of corrosion n Avoid the formation of rust on fine machined parts caused by hand sweat n Use new O rings or seal rings for reassembly n Use only hydraulic oil as sliding agent when reassembling Do not use any grease n Use only the specified pressure gauges Risk of damaging the pressure gauges under too high pressure n Check the hydraulic oil level before and...

Page 26: ...l or gasket make sure that the sealing surface is free of pitting flutes corrosion or other damage n Inappropriately stored or handled seals e g hanging from hooks or nails must under no circumstances be used n Install seals and gaskets only with sealing compound grease or oil if this is specifically specified in the repair instructions n If necessary remove any old sealing compound before assem b...

Page 27: ...t 4 Press or knock the seal into the housing until it is flush with the housing surface NOTICE Use an assembly bell If possible use an assembly bell 1 to make sure that the seal will not skew In some cases it may be advisable to assemble the seal into the housing first before sliding it over the shaft Under no circumstances should the full weight of the shaft rest on the seal If you have no proper...

Page 28: ...al n Check shaft and bearing housing for discolouration or other signs of movement between bearing and seats n Make sure that shaft and housing are free of burrs before assembling the bearing n Always mark the individual parts of separable bearings e g taper roller bearings to enable correct reassembling Never assemble the rollers to an outer race that has already been used replace the complete be...

Page 29: ...rength can cause damage n Nuts of a higher strength can generally be used instead of nuts of a lower strength classification n When checking or retightening screw joints to the specified tightening torque you should first relieve by a quarter turn and then tighten to the correct torque n Before tightening you should slightly oil the thread in order to ensure low friction movement This however does...

Page 30: ...r screw connections with limited load capacity The preceding 0 indicates that due to their low height nuts 2 Ä Fig 24 in this group are only able to withstand the force of a screw to a limited extent Nut height below 0 8 d d nominal dimension Nuts 3 for screw connections without specified load capacity This standard contains strength classes hardness classes for nuts 3 Ä Fig 24 for which no load v...

Page 31: ...amped in round cavity 1 3 1 2 Tightening torques The values specified in the table apply for screws n black oiled n with surface protection A4C n with surface protection DACROMET DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix DACROMETIZATION provides excel lent corrosion protection for metal surfaces by applying a mineral coating with metalli...

Page 32: ...2400 Tightening torques for screws with metric unified fine thread Screw dimension Tightening torques Nm Coefficient of friction µ tot 0 14 8 8 10 9 12 9 M8 x 1 26 37 48 M10 x 1 25 52 76 88 M12 x 1 25 98 137 162 M12 x 1 5 93 127 152 M14 x 1 5 152 216 255 M16 x 1 5 225 318 383 M18 x 1 5 324 466 554 M20 x 1 5 461 628 775 M22 x 1 5 618 863 1058 M24 x 2 780 1098 1294 M27 x 2 1147 1578 1920 M30 x 2 156...

Page 33: ...0 M30 x 2 1255 1804 2156 3 4 10 UNC 276 388 464 3 4 16 UNC 308 432 520 Anti seizure paste copper paste is used for the assembly of screw connections which are exposed to high temperatures and corrosive effects Prevents seizure and corrosion Tightening torques for wheel nuts fine thread Thread diameter Tightening torques Nm Coefficient of friction µ tot 0 14 10 9 M12 x 1 5 100 M14 x 1 5 150 M18 x 1...

Page 34: ...2000 1 1 4 7 1700 2400 2900 1 3 8 6 2200 3100 3700 1 1 2 6 3000 4200 5100 Tightening torques for screws with UNF thread UNF Unified National Fine Thread Series American Unified Fine Thread Screw dimension Tightening torques Nm Coefficient of friction µ tot 0 14 8 8 10 9 12 9 1 4 28 13 18 22 5 16 24 25 35 42 3 8 24 45 63 76 7 16 20 70 100 120 1 2 20 110 155 185 9 16 18 155 220 260 5 8 18 220 310 37...

Page 35: ...ion µ tot 0 14 8 8 10 9 12 9 1 1 8 12 1350 1900 2300 1 1 4 12 1900 2700 3200 1 3 8 12 2600 3700 4400 1 1 2 12 3300 4600 5600 General information Maintenance and repair BW 900 50 36 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 36: ... pressures up to 400 bar Thread Spanner width Tightening torque Nm M14 x 1 5 17 14 M16 x 1 5 19 25 M18 x 1 5 22 27 M20 x 1 5 24 48 M22 x 1 5 27 55 M24 x 1 5 30 65 M30 x 2 36 110 M36 x 2 46 140 M42 x 2 50 180 M52 x 2 60 220 Tightening torques for hydraulic fittings with UNF thread Unified Fine Thread Thread Spanner width Tightening torque Nm 7 16 20 14 15 1 2 20 17 20 9 16 18 19 27 3 4 16 22 55 7 8...

Page 37: ...eve hydraulic pressures before working on hydraulic lines 5 Before working on electric parts of the machine disconnect the battery and cover it with insulation material 6 When working in the area of the articulated joint attach the articulation lock transport lock ENVIRONMENT During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system Dispose...

Page 38: ...ing maintenance work on the hydraulic system cleanliness is of major importance Make sure that no dirt or other contaminating substances can enter into the system Small particles can produce flutes in valves cause pumps to seize clog nozzles and pilot bores thereby making expensive repairs inevitable 1 If during the daily inspection of the oil level the hydraulic oil level is found to have dropped...

Page 39: ...2 Technical data Technical data BW 900 50 41 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 40: ...f fuels and lubricants 50 2 1 Technical data Fig 27 A B C D H H2 K 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 Dimensions Technical data Technical data BW 900 50 42 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 41: ...ation 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 Technical data Technical data BW 900 50 43 G o...

Page 42: ...ostatic 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 Technical data BW 900 50 44 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 43: ... Max displacement cm3 rev 19 High pressure limitation bar 300 Charge pressure high idle bar 20 Drum drive motor Type TG405 System Gerotor motor Displacement cm3 rev 405 Perm leak oil rate l min 0 5 Steering charge vibration pump System Gear pump Max displacement cm3 rev 5 5 Starting pressure bar 220 Operating pressure soil dependent bar 50 to 100 Vibration motor System Gear motor Displacement cm3 ...

Page 44: ...Type OSPM 80 ON Manufacturer Sauer Danfoss System Rotary spool valve Technical data Additional technical data BW 900 50 46 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 45: ... lubricants 9 Travel speed km h n Path covered by the machine in kilometres km in an hour h 10 Frequency Hz min 1 n Number of revolutions made by the exciter shaft per second Hz ore minute min 1 For example 50 Hz 50 rev sec 50 x 60 3000 rev min min 11 Fuel consump tion l h n Average engine fuel consumption at 70 capacity utilisation 12 Rated power SAE J 1349 ISO 3046 kW n Effective output at the e...

Page 46: ... 86 or higher Use only commercially available brand fuel You can use unleaded standard grade petrol with maximum 10 per cent by volume of ethanol E10 or maximum 5 percent by volume of methanol Methanol must also contain co solvents and corrosion inhibitors Using fuels with higher ethanol or methanol contents exceeding the values specified above may cause starting difficulties and or per formance p...

Page 47: ...an EP high pressure grease lithium saponified penetration 2 acc to DIN 51502 KP 2G Lubrication grease Technical data Fuels and lubricants BW 900 50 49 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 48: ...C to 40 C Fuel Gasoline unleaded approx 7 gal approx 27 l Hydraulic system Hydraulic oil ISO HLP 46 or ester based biodegradable hydraulic oil approx 5 gal approx 19 l Sprinkler system Water Anti freeze mixture water Mix water and anti freeze agent by following the instructions of the manufacturer approx 36 gal approx 137 l Rear drum bearings High pressure grease lithium saponified as required Tec...

Page 49: ...3 Overview of machine Overview of machine BW 900 50 51 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 50: ...S 834 0002 Fig 29 Areas of application Earthwork and asphalt construction New build and repair work in medium to small construction proj ects car parks pavements and paths bicycle lanes playgrounds and sports grounds as well as finishing work in road construction Overview of machine General information BW 900 50 52 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 51: ...2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Fig 30 1 Battery G01 and fuse for charge regulator F148 Overview of machine Electric systems BW 900 50 53 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 52: ...on E32 11 Warning buzzer for reverse travel H14 12 Working head lights rear E27 and E28 13 Spraying pump M02 14 Float switch for fuel B201 15 Central electrics 16 Proximity switch reversing monitoring B32 17 Warning horn B11 18 Working head lights front E24 and E26 Overview of machine Electric systems BW 900 50 54 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 53: ...nit travel pump with steering charge vibration pump 4 Steering valve 5 Rear drum drive motor 6 Steering cylinder 7 Charge circuit filter 8 Front drum drive motor 9 Vibration motor Overview of machine Hydraulic system BW 900 50 55 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 54: ...ated joint 57 3 4 3 Drums 59 3 4 1 Engine S 834 0014 1 2 3 4 Fig 32 1 Charge regulator A61 2 Engine 3 Exhaust system 4 Oil drain hose Overview of machine Machine assemblies BW 900 50 56 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 55: ...urnal 6 Rocker bearings for steering cylinder When tightening the bearing housing 4 move the bearing housing slightly to and fro to ensure a uni form wear pattern of the individual bearing rollers Overview of machine Machine assemblies BW 900 50 57 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 56: ... axis The advantage of the oscillating articulated joint is the fact that front and rear frame move in the same track The oscillation compensates for uneven surfaces and creates an even drum pressure Both the pivot point of the oscillating joint which was purposely designed to be low as well as the low centre of gravity of the machine ensure good stability Overview of machine Machine assemblies BW...

Page 57: ... Vibratory drum front 1 Support legs 2 Rubber buffer 3 Exciter shaft 4 Travel motor 5 Drive disc 6 Vibration motor Overview of machine Machine assemblies BW 900 50 59 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 58: ... 834 0015 1 1 2 3 4 5 Fig 35 Rear drum 1 Support legs 2 Brake operation Overview of machine Machine assemblies BW 900 50 60 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 59: ...3 Travel motor 4 Drive disc 5 Parking brake Overview of machine Machine assemblies BW 900 50 61 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 60: ...4 Electric systems Electric systems BW 900 50 63 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 61: ...and maintenance work 93 4 8 1 Maintenance Table 93 4 8 2 Every 250 operating hours 93 4 1 Basic principles 4 1 1 Measuring technology 64 4 1 2 Understanding circuit diagrams 69 4 1 3 Telemecanique switch 80 4 1 1 Measuring technology NOTICE This type of tester must not be used for testing on electronic components The high power consump tion of the test lamp may destroy electronic compo nents in th...

Page 62: ...he test cable must be plugged into the correct socket n the voltage type AC DC must be set n In case of direct voltage the correct polarity must be assured n the measuring range should be chosen higher at the beginning of the test n In order to avoid any influence on the circuitry to be measured the internal resistance of the voltage tester should be as high as possible Resistance and continuity m...

Page 63: ...by parallel components n Polarity is of no significance Voltage and voltage drop measurement with multimeter n Measurement at the voltage source measures the currently available voltage n The meter is always connected parallel to consumer compo nent or power source n A measurement at the consumer measures the voltage drop at this component Fig 40 Fig 41 Measuring voltage Fig 42 Voltage measurement...

Page 64: ...esistance of the consumer is known the voltage may also be measured at the consumer The current value can then be calculated with the help of Ohm s law The clip on measuring instrument can be used to measure current voltage and resistance Fig 43 Measuring current Fig 44 Current measurement Clip on measuring instrument Fig 45 Clip on measuring instrument Electric systems Basic principles BW 900 50 ...

Page 65: ...ule within a circuit can be indirectly determined calculated by separate measuring of current and voltage However there are also pure power meters with 4 connections available The power meter has a electro dynamic measuring mechanism The current circuit must be opened for measuring Take care when performing power measurements Voltage or cur rent path may already be overloaded during the measuremen...

Page 66: ...circuit diagram consists of following individual parts n Cover sheet with general information Ä Cover sheet on page 69 n Table of contents Ä Table of contents on page 70 n Overview of structural symbols only if the structural view is used Ä Overview of structural symbols on page 70 n Overview of installation locations only if the structural view is used Ä Overview of installation locations on page...

Page 67: ...he structure of the machine with respect to equipment functions and installation loca tions as a summary Structural symbols are mainly abbreviations for machine parts machines functions and installation locations which were derived from designations in English Table of contents Overview of structural symbols Electric systems Basic principles BW 900 50 70 G o t o D i s c o u n t E q u i p m e n t c...

Page 68: ...ction roof PLA Attachment plates HOOD Rotor hood CAB Cabin and attachment parts SPR Spraying module PUM Pump module RWT Reaction water tank FRA Frame LBOX Side mounted driver s stand left RBOX Side mounted driver s stand right SBOX Screed driver s stand SCRD Screed ROOF Roof structure Overview of installation locations only if the struc tural view is used Overview of installation locations Electri...

Page 69: ... The main reading direction is sheet by sheet from top to bottom and from left to right n All sheets are numbered successively n BOMAG uses the resolved type of representation In this case parts and components with different functions which belong to the same components e g relay coil and relay contact can be represented on different sheets Cross references which refer to the sheet and current pat...

Page 70: ...s references serve the purpose of tracking signals which are transmitted from one func tional diagram to another Potential cross references may additionally have structural symbols assigned to them Example S15 11 OPT 41 0 is continued to the right to page 41 current path 0 OPT stands for option 4 Contact overview of relay 5 Current paths are numbered successively from 0 to 9 The list of components...

Page 71: ...oller a paver or a planer n The component identifications are alphabetically sorted in the list of components Each component has the corresponding cross references assigned identifying where it can be found in the circuit diagram which installation location it is assigned to and to which part of the system it belongs to Moreover the functions function text and the technical characteristics are als...

Page 72: ...X1 X1 X1 17 2 130 130 130 130 X1 X1 X1 X1 20 5 131 131 131 131 X1 X1 X1 X1 27 6 132 132 132 132 X1 X1 X1 X1 27 6 133 133 133 133 X1 X1 X1 X1 28 4 134 134 134 134 X1 X1 X1 X1 28 5 135 135 135 135 X1 X1 X1 X1 27 2 136 136 136 136 X1 X1 X1 X1 27 3 137 137 137 137 X1 X1 X1 X1 18 4 138 138 138 138 X1 X1 X1 X1 18 5 139 139 139 139 X1 X1 X1 X1 27 6 139 139 139 139 X1 X1 X1 X1 37 4 140 140 140 140 X1 X1 X...

Page 73: ...48 6 6 18 7 6 8 8 8 18 9 8 18 Contact Kontakt Page Blatt Plug Stecker Function text Funktionstext Path Pfad Mounting location Einbauort Plug type Steckertyp Wire harness Kabelbaum 16 1 3 12 18 9 X1 B Plug access harness engine controller Stecker Anschluß Kabelbaum Motorsteuergerät EBOX AMP Junior Power Timer 18 pole blue EMR 1 2 20 2 2 20 3 4 5 6 7 8 9 5 20 10 7 20 11 12 6 20 13 7 20 14 4 20 15 7 ...

Page 74: ...of such components is in most cases protected or just too complex to be illustrated in the wiring diagram within the context of the actual machine func tion There are two different ways to simplify the representation of such devices in the diagram Fig 59 Example Central lubrication system The Black Box representation shows the device as a Box with the connections required for the machine function ...

Page 75: ...h are not used do not need to be rep resented The PLC box representation enables the representation of further reaching functional descriptions to the individual compo nent connections The PLC box representation is mainly used for controls with BOMAG software or for electronic devices which were specified accordingly and where information on the assignment of signals is available Identification of...

Page 76: ...ple The contact block marked with 4 is called 43 44 if it is a normally open contact and 41 42 if it is a normally closed contact The contact block marked with 2 is called 23 24 if it is a normally open contact and 21 22 if it is a normally closed contact The contact block marked with 1 is called 13 14 if it is a normally open contact and 11 12 if it is a normally closed contact The contact block ...

Page 77: ...3 Loosen the screw 1 4 Lift up the interlock 2 and pull out the front element 3 Dismantling Fig 64 Folding down the switch block Fig 65 Pulling out the front element Electric systems Basic principles BW 900 50 80 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 78: ...ront element and fas tening flange 3 Tighten the screw 1 with a tightening torque of 0 6 Nm 4 Clip on the switch block 4 Hook in the switch block at the bottom first Assembly Fig 67 Observe the marks Fig 68 Install the switch block Electric systems Basic principles BW 900 50 81 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 79: ...s ground as far away from the battery as possible 3 Start the engine NOTICE Danger of damage to the electronic system If no powerful consuming device is switched on voltage peaks may occur when separating the con necting cables between the batteries which could damage electrical components 4 Once the engine is running switch on a powerful consumer working light etc 5 After starting disconnect the ...

Page 80: ...12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Fig 70 1 Battery G01 and fuse for charge regulator F148 Electric systems Overview of electric system BW 900 50 83 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 81: ...32 11 Warning buzzer for reverse travel H14 12 Working head lights rear E27 and E28 13 Spraying pump M02 14 Float switch for fuel B201 15 Central electrics 16 Proximity switch reversing monitoring B32 17 Warning horn B11 18 Working head lights front E24 and E26 Electric systems Overview of electric system BW 900 50 84 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 82: ...hts1 2 H08 Charge control light 3 P00 Operating hour meter 4 H38 Fuel level warning light 5 S05 Rotary switch for spraying system Electric systems Overview of electric system BW 900 50 85 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 83: ...sh button for warning horn 11 S38 Rotary switch for flashing beacon1 12 S13 Push button for vibration 13 Travel lever 14 Throttle lever 15 Parking brake lever 1 Optional equipment Electric systems Overview of electric system BW 900 50 86 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 84: ...3 Relay for spraying pump K29 Relay for vibration K04 Stepping relay for vibration K04 This module is an electronic stepping relay A ground switching pulse on Pin S sets the output 56b operating voltage applied to the output 56b The next pulse resets the output 56a no oper ating voltage applied to the outlet 56b Electric systems Central electrics BW 900 50 87 G o t o D i s c o u n t E q u i p m e ...

Page 85: ...ting voltage 15 54 is switched off the output will remain dead when switching on again Electric systems Central electrics BW 900 50 88 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 86: ... 5 25 A F148 Fuse control MESX potential 15 6 15 A F41 Flashing beacon 7 15 A F06 Spraying system 8 20 A F100 Working head lights n Main fuse WARNING Fire hazard Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire 25 A F 00 Fig 73 Fig 74 Electric systems Fuse assignment BW 900 50 89 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 87: ... If the oil pressure drops below 0 5 bar the engine is shut down Fig 75 Oil pressure switch B06 Electric systems Engine oil pressure monitoring BW 900 50 90 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 88: ...tic stray field This stray field leaks out from the active area of the proximity switch If metal or non ferrous metal enters into the response range energy is absorbed The oscillator is thus dampened and the resulting change in current consumption is evaluated Fig 76 Proximity switches on travel lever Working principle Fig 77 Electric systems Proximity switches B08 and B38 BW 900 50 91 G o t o D i...

Page 89: ...s are 2 or 4 mm The maximum amperage is 300 mA The LED Ä Fig 78 lights up when the initiator has detected metal in its stray field Breaking and making contacts Fig 78 Electric systems Proximity switches B08 and B38 BW 900 50 92 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 90: ...ccumulation of highly explosive gases ENVIRONMENT Dispose of the old batteries environmentally Maintenance free batteries also need care Mainte nance free only means that the fluid level does not need to be checked Each battery suffers under self discharge which may in not checked occa sionally even cause damage to the battery as a result of exhaustive discharge The following therefore applies for...

Page 91: ...resting periods of more than one month you should always disconnect the battery Do not forget to perform reg ular open circuit voltage measurements NOTICE Exhausted batteries batteries with formation of sulphate on the plates are not covered under war ranty 1 Open the engine hood 2 Clean battery Ä Fig 79 and battery compartment 3 Clean battery poles and pole clamps and grease them with pole grease...

Page 92: ...5 Hydraulic system Hydraulic system BW 900 50 95 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 93: ... 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 s...

Page 94: ...ct with atmospheric pressure Reliable equalization of pressure between the air in the hydraulic oil tank and the ambient air ensures problem free suction of the pump In an open circuit the hydraulic oil is fed to the consumer 2 or 3 and also returned to the tank through way valves Open circuit Hydraulic system Basic principles BW 900 50 97 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d ...

Page 95: ...ly the leakage on pump and motor needs to be replenished This is accomplished by a charge pump 1 which permanently draws a sufficient amount of hydraulic fluid charge capacity from the tank and feeds it through a check valves 5 into the low pres sure side of the closed circuit The excess quantity delivered by the charge pump flows through a charge pressure relief valve 6 back into the tank Chargin...

Page 96: ...static energy is converted to mechanical energy When used as a pump the flow volume is proportional to the drive speed and the swashing angle The available pump torque increases with the pressure drop between high and low pressure side Variable displacement pumps and motors can be change their dis placement i e the pump delivery rate or motor throughput by simply changing the angle of the swash pl...

Page 97: ...y guided by a retaining device During a complete rotation of the cylinder block each piston moves through the bottom and top dead centre back to its initial position From dead centre to dead centre is performs a full piston stroke During this process the flow volume determined by the stroke is drawn in through the control slots in the valve plate or pumped out During the suction stroke the hydraul...

Page 98: ... 1 Axial seal 5 Cover 2 Outer pressure field 6 Flange 3 Inner pressure field 7 Sealing zone 4 Radial seal 8 Compensation forces Internal sealing of the pressure chambers is achieved by flow volume dependent forces This results in an excellent rate of effi ciency On the rear side the moveable bearing bushings are pres surized and thus tightly pressed against the gears The pressurized pressure field...

Page 99: ... There the meshing of teeth and tooth gaps displaces the pressure fluid into the upper supply line Fig 86 1 Cover 6 Gear driven 2 Seals 7 Shaft 3 Housing 8 Flange 4 Gear driving 9 Bearing plate 5 Displacement chamber 10 Bearing plate Function Hydraulic system Basic principles BW 900 50 102 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 100: ...fference is the slightly different axial pressure field The pressure fluid flowing into the gear motor works on the gears It generates a torque which is then transferred by the output shaft External gear motors for one sense of rotation are of asymmetrical design i e high and low pressure sides are predetermined Reversing operation is not possible The arising leak oil is internally fed to the outl...

Page 101: ...or 9 Vibration motor The travel pump is directly driven by the crankshaft of the engine via an elastic coupling the pump speed is therefore identical with the engine speed The steering charge vibration pump is a directly driven gear pump which is connected with the travel pump via a coupling The pump speed is identical to the engine speed Hydraulic system Overview of hydraulics BW 900 50 104 G o t...

Page 102: ... charge vibration pump S Pressure port for charge circuit T1 Leak oil connection B T1 S IN S 834 0011 MB 1 2 3 Fig 91 Pump assembly 1 Steering charge vibration pump 2 Travel pump 3 Pump flange with flexible coupling B Working port travel pump reverse IN Suction side steering charge vibration pump Hydraulic system Overview of hydraulics BW 900 50 105 G o t o D i s c o u n t E q u i p m e n t c o m ...

Page 103: ... test port pressure B S Pressure port for charge circuit T1 Leak oil connection Hydraulic system Overview of hydraulics BW 900 50 106 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 104: ...g start up and operation This must also be consid ered for longer periods of rest because the system may run empty through the hydraulic lines The PMVO is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed circuits The volumetric flow is proportional to the drive speed and the displacement The volumetric flow can be infinitely changed by adjusting the ...

Page 105: ...Retracting plate 7 Slipper pad 3 Charge pressure relief valve 8 Slipping disc 4 Cylinder 9 Swashing shaft 5 Valve plate Hydraulic system Description of hydraulic components BW 900 50 108 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 106: ... pressure relief valve M Motor Ma Pressure test port pressure A Mb Pressure test port pressure B PS Control pressure inlet R Ventilation S Pressure port for charge circuit Hydraulic diagram Hydraulic system Description of hydraulic components BW 900 50 109 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 107: ...red oil flow from the charge oil circuit into the closed hydraulic circuit in order to compensate leaks and flushing quanti ties Charge pressure relief valve The charge pressure valve belongs to the group of safety elements in a closed hydraulic circuit This valve limits the pressure in the charge circuit to the pre adjusted value 5 3 2 Travel motor TG405 Gerotor motors are slow running hydraulic ...

Page 108: ...ection with internal gearing and a gear wheel the centre of which during rotation orbits around the centre of the ring gear Hydraulic system Description of hydraulic components BW 900 50 111 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 109: ...eering valve The steering unit works hydrostatically i e there is no mechanical connection between the steering wheel and the wheels to be steered articulated joint drum etc The mechanical connection is replaced by hydraulic piping and hoses between the steering unit and the steering cylinder s Notes on repair Hydraulic system Description of hydraulic components BW 900 50 112 G o t o D i s c o u n...

Page 110: ...r spool 6 Neutral position spring 7 Pin 8 Outer spool 9 Cardan shaft 10 Distributor plate 11 Gear 12 Ring gear 13 Cover The steering valve is additionally equipped with a pressure limiting valve which limits the steering pressure Suddenly occurring pressure peaks which may be caused by e g external influences such as driving against a curb stone are com pensated by two shock valves which are integ...

Page 111: ... steering and the charge circuit the return flow from the steering valve passes through the charge oil filter and the charge oil port on the travel pump The filter is equipped with a bypass valve This valve opens at a differential pressure pressure difference between filter inlet and filter outlet of Δp 3 5 bar This differential pressure depends on the filter contamination and the viscosity of the...

Page 112: ...2 M Fig 98 1 Vibration valve Y22 with pressure test port 2 Hydraulic oil tank 3 Steering valve 4 Check valve 1 bar 5 Travel pump Hydraulic system Description of hydraulic circuits BW 900 50 115 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 113: ...hine is braked by the closed hydraulic circuit When moving the travel lever to neutral position the supply from the pump is interrupted the machine is hydrostati cally braked 5 4 2 Vibration circuit The vibration circuit is an open hydraulic circuit Brake Hydraulic system Description of hydraulic circuits BW 900 50 116 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 114: ... from the tank to the vibration valve Y22 When the vibration is switched on hydraulic oil flows to the vibration motor Rotation of the vibration motor causes rotation of the exciter shaft The eccentric weights attached to the exciter shaft generate the vibration of the drum Vibration drive Hydraulic system Description of hydraulic circuits BW 900 50 117 G o t o D i s c o u n t E q u i p m e n t c ...

Page 115: ...er buffer 3 Vibration motor 4 Weights 5 4 3 Steering circuit The steering circuit is an open hydraulic circuit Hydraulic system Description of hydraulic circuits BW 900 50 118 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 116: ...10 Fig 101 1 Vibration valve Y22 with pressure test port 2 Hydraulic oil tank 3 Steering valve 4 Check valve 1 bar 5 Travel pump Hydraulic system Description of hydraulic circuits BW 900 50 119 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 117: ...rough the charge oil filter to the charge ports of the travel circuit When turning the steering wheel the distributor valve directs the oil flow to the piston or piston rod side of the steering cylinder A metering pump inside the steering unit measures the exact oil quantity required for the steering wheel rotation and feeds it to the steering cylinder The steering cylinder is extended or retracte...

Page 118: ...ation motor 130 5 5 8 Pressure tests in the steering circuit 131 5 5 1 Checking the rotation speeds Special tools Vibration reed frequency meter NOTICE Perform measurements at operating temperature of the hydraulic oil 40 C 1 Drive the drum of the machine onto an elastic base rubber buffers Ä Fig 102 and block the rear drum additionally with suitable chocks 2 Pull up the parking brake lever Ä Fig ...

Page 119: ...ing for the petrol engine 1 Switch the vibration on at max engine speed 2 Measure the speed of the exciter shaft by letting the meas uring instrument rest on your thumb Ä Fig 106 ð Nominal value See technical data Evaluation of measurement If the nominal value is not reached per form troubleshooting on the engine or in the vibration circuit Fig 104 Checking the engine speed Fig 105 Checking the ex...

Page 120: ...gauges to the high pressure test ports for MA and MB and a 60 bar pressure gauge Ä Fig 109 to the charge pressure test port NOTICE Do not activate the vibration and do not steer while checking the pressure This would destroy the 60 bar pressure gauge 4 Start the engine and shift the throttle lever to max speed position Fig 107 Fig 108 Fig 109 Hydraulic system Tests and adjustments BW 900 50 123 G ...

Page 121: ... charge pressure drops below the nominal value during the high pressure test check the individual components If the specified high pressure is not reached check the travel pump If the starting pressure is reached to one travel direction only check the high pres sure relief valves 5 5 3 Adjusting the neutral positions of the travel pump Special tools Hydraulic test case NOTICE Perform measurements ...

Page 122: ...ust the travel control cable Ä Fig 112 so that both drums stop 5 5 4 Travel pump high pressure test Special tools Hydraulic test case NOTICE Perform measurements at operating temperature of the hydraulic oil 40 C Fig 110 Fig 111 Fig 112 Hydraulic system Tests and adjustments BW 900 50 125 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 123: ...14 3 Connect 600 bar pressure gauges Ä Fig 115 to high pres sure test ports MA and MB 4 Close high pressure ports MA and MB with plugs Fig 113 Fig 114 Fig 115 Hydraulic system Tests and adjustments BW 900 50 126 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 124: ...nal value is not reached in both directions check the travel pump replace if necessary 5 5 5 Pressure tests in the vibration circuit Special tools Hydraulic test case NOTICE Perform measurements at operating temperature of the hydraulic oil 40 C 1 Drive the drum of the machine onto an elastic base rubber buffers Ä Fig 117 and block the rear drum additionally with suitable chocks Fig 116 Fig 117 Hy...

Page 125: ...trol valve block If the starting pressure is reached but the operating pressure is too low you should also check the leakage quantity of the vibration motors If the operating pressure is too high the bearings for both vibrator shafts must be checked 5 5 6 Vibration pump high pressure test Special tools Hydraulic test case NOTICE Perform measurements at operating temperature of the hydraulic oil 40...

Page 126: ... pump outlet Ä Fig 122 with a 200 bar pressure limiting valve 4 Start the engine for a moment ð Nominal value approx 200 bar Evaluation of test If the nominal value is not reached replace the vibration pump Fig 120 Fig 121 Fig 122 Hydraulic system Tests and adjustments BW 900 50 129 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 127: ...he leak oil hose Ä Fig 125 connect a meas uring hose and hold it into a measuring beaker 4 Start the engine and shift the throttle lever to max speed position 5 Switch the vibration on and measure the running out leak oil during one timed minute ð Nominal value max 0 25 litre min Evaluation of test If the permissible leak oil rate is exceeded replace the vibration motor Fig 123 Fig 124 Fig 125 Hyd...

Page 128: ... test port Ä Fig 127 3 Engage the articulation lock Ä Fig 128 4 Start the engine and run it at idle speed 5 Operate the steering system and read the pressure gauge Nominal value approx 100 bar Evaluation of test If the nominal value is reached check the steering cylinder Fig 126 Fig 127 Fig 128 Hydraulic system Tests and adjustments BW 900 50 131 G o t o D i s c o u n t E q u i p m e n t c o m t o...

Page 129: ... hydraulic hoses to the steering cylinders 9 Close the pump outlet Ä Fig 130 with a 200 bar pressure limiting valve 10 Run the engine for a short while with idle speed and read the pressure gauge ð Nominal value approx 200 bar Evaluation of test If the nominal value is reached replace the steering valve If the nominal value is not reached replace the steering charge vibration pump Fig 129 Fig 130 ...

Page 130: ... fluid systems causes surface damage due to gener ally known wear mechanisms abrasion ero sion surface fatigue Fig 131 Effect of contamination n Coarse particles 15 µm Sudden failure of components n Fine particle contamination 5 15 µm Wear of components internal leaks inaccurate controlling behaviour blockage of valves n Extra fine particle contamination 2 5 µm Silting of oil accelerated ageing of...

Page 131: ...E Clean the hydraulic tank Change the oil in case of excessive contami nation oil discolouration or if the oil change interval is almost due Filter the tank content with the filling and filtering unit and pump it into an oil container 3 Mark all hoses and disconnect them from the hydraulic oil tank 4 Clean the oil tank thoroughly from inside remove the tank cover if necessary 5 Reconnect all hoses...

Page 132: ...of the contamination indicator is pressed out during the flushing process 2 Clean hoses and connections and store the flushing kit in a clean and protected environment Bleeding Fig 134 Servicing the flushing filter kit Fig 135 Hydraulic system Flushing and bleeding BW 900 50 135 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 133: ... 3 Elbow union tool 4 Screw socket 1 25S tool 5 Flushing hose 25S 20S tool 6 Flushing hose 25S 20S tool 7 Flushing filter with filter element 1μ tool Hydraulic system Flushing and bleeding BW 900 50 136 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 134: ...stration the travel pump must therefore be actuated to forward direction 1 Disconnect the high pressure hose 8 from the travel pump port B and connect it with the flushing hose 6 flushing filter inlet IN see chapter Flushing diagram travel system 2 Connect the flushing hose 5 flushing filter outlet OUT to the high pressure port B on the travel pump 1 Take the drum drive motors 9 10 out of the hydr...

Page 135: ...on forward as otherwise the flushing filter will be subjected to oil flow from the wrong direction Start the engine and shift the travel lever to travel direction forward 4 Perform the flushing process at various engine speeds for approx 10 minutes 5 Shut down the engine Bleeding the travel circuit Fig 137 Flushing the hoses Fig 138 Fig 139 Fig 140 Hydraulic system Flushing and bleeding BW 900 50 ...

Page 136: ... oil flow from the wrong direction Start the engine run it with maximum speed and shift the travel lever to travel direction forward 4 Run the flushing procedure for approx 10 minutes During this process keep changing the pump flow by shifting the travel lever several times between full and half speed in reverse travel 5 Shut down the engine 6 Remove the flushing filter and reconnect the high pres...

Page 137: ... for leaks with the engine running visual inspection 3 Perform a test drive load the travel system in forward and reverse travel e g by driving uphill or starting on a gradient 4 Check all ports and connections once again for leak tightness visual inspection Bleeding the travel circuit Fig 144 Circulating the tank content Fig 145 Function test Fig 146 Hydraulic system Flushing and bleeding BW 900 ...

Page 138: ...t ports 5 Hold the open ends of the pressure test hoses Ä Fig 149 into a container 6 Operate the starter motor for approx 30 seconds Wait one minute and repeat this procedure until oil starts to run out of the pressure test hoses 7 Remove the pressure test hoses 8 Unlock the emergency stop switch Fig 147 Fig 148 Fig 149 Fig 150 Hydraulic system Flushing and bleeding BW 900 50 141 G o t o D i s c o...

Page 139: ... wrong direction WARNING Only run the engine with idle speed 12 Start the engine 13 Shift the travel lever Ä Fig 152 approx 1 3 to forward direc tion 14 After approx 1 to 2 minutes shut down the engine for a minute ð This waiting time is necessary to allow air bubbles to escape through the leak oil return line 15 After a waiting time of approx 1 minute keep repeating this procedure until the indic...

Page 140: ...pped check all lines hoses and components for leaks In hydraulic systems filled with Panolin Synth 46 use only the same oil to top up With other ester based oils consult the lubrication oil service of the respective oil manufacturer For quality of oil refer to the table of fuels and lubricants 1 Check the oil level in the oil level inspection glass Ä Fig 153 At room temperature of approx 68 F 20 C...

Page 141: ...d 2 If necessary press the pin in Pin remains pressed in Hydraulic oil filter element o k Pin pops out Replacing the hydraulic oil filter ele ment 5 7 3 Every 2000 operating hours 5 7 3 1 Changing the hydraulic oil See also the notes on the hydraulic system in the chapter General notes on maintenance WARNING Danger of scalding When draining off hot hydraulic oil Fig 154 Hydraulic system Inspection...

Page 142: ...ts to clean the system For quality and quantity of oil refer to the table of fuels and lubricants When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil you should consult the lubrication oil service of the oil manufacturer for details ENVIRONMENT Catch running out oil and dispose of environmen tally 1 Drive the machine until the hydraulic oil has reached ...

Page 143: ...il 2 Check the hydraulic oil level in the inspection glass Ä Fig 157 NOTICE The breather filter for the hydraulic oil tank is inte grated in the filler cap you must therefore replace the complete filler cap 1 Close the tank with a new cover 2 Perform a test run and check the system for leaks 5 7 3 2 Change the hydraulic oil filter WARNING Danger of scalding Danger of scalding by hot oil when unscr...

Page 144: ...element Apart from the normal oil change intervals the filter element must also be changed after major repairs in the hydraulic system ENVIRONMENT Catch running out oil dispose of oil and filter ele ment environmentally 1 Remove filter bowl 4 Ä Fig 158 with filter element 3 2 Examine the surface of the filter element thoroughly for any visible dirt 3 Take out the old filter element and clean filte...

Page 145: ...6 Machine assemblies Machine assemblies BW 900 50 149 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 146: ...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 Machine assemblies BW 900 50 150 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 147: ... 4 Oil drain hose Tandem vibratory rollers type BW 900 50 are powered by an air cooled Honda petrol engine series GX630 This engine is a four stroke two cylinder engine with suspended valves Machine assemblies Engine BW 900 50 151 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 148: ...08 Fig 160 Engine 1 Float switch for fuel B201 2 Oil dipstick 3 Oil filler neck 4 Charge regulator A61 5 Air filter 6 Connection for fuel pre filter 7 Spark plug A62 8 Fuel pre filter 9 Oil drain 10 Oil filter 11 Oil pressure switch B06 12 Crankshaft 13 Exhaust outlet 14 Starter motor M01 15 Fuel tank Machine assemblies Engine BW 900 50 152 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d...

Page 149: ...rm 3 Exhaust valve 4 Combustion chamber 5 Push rod 6 Plunger 7 Camshaft 8 Spark plug 6 1 2 Carburettor inspection Machine assemblies Engine BW 900 50 153 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 150: ...ve foreign materials dirt 5 Main nozzle air path clogged Remove foreign materials dirt 6 Fuel strainer screen clogged Blow air and check the screen for clogging 7 Float doesn t move properly Remove foreign materials around float pin 10 For long storage of the engine More than 3 months Drain gasoline from float chamber by running the engine until it stops or by loosening the drain screw while engin...

Page 151: ...ange the fuel pre filter 161 6 1 3 4 2 Checking adjusting the valve clearance 162 6 1 3 4 3 Check adjust the idle speed 163 Every 2000 operating hours 6 1 3 5 1 Checking fuel lines and clamps 163 As required 6 1 3 6 1 Engine conservation 164 6 1 3 2 Every 10 operating hours 6 1 3 2 1 Checking the engine oil level NOTICE The machine must be in horizontal position For quality of oil refer to the tab...

Page 152: ...is too low top up oil immediately 2 If the oil level is too high determine the cause and drain the oil off 6 1 3 2 2 Cleaning the cooling air intake openings NOTICE Dirt in the cooling air intake openings reduces the cooling effect 1 Clean the cooling air intake openings Ä Fig 163 Fig 162 Fig 163 Machine assemblies Engine BW 900 50 156 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r ...

Page 153: ...r 2 years Incorrectly handled filter cartridges may become ineffective because of damage e g cracks and cause damage to the engine 1 Unscrew the air filter cover locking nut 1 Ä Fig 164 and remove the cover 2 2 Unscrew the wing nut 3 3 Take out the paper 4 and foam rubber inserts 6 4 Separate the foasm rubber element from the paper filter insert 5 Check both filter elements and replace if damaged ...

Page 154: ...maining in the foam rubber element is too high the engine will develop smoke during starting 1 Place the foam rubber element 6 Ä Fig 167 on the paper element 4 2 Reinstall the assembled air filter Make sure that the seal 5 under the air filter is present 3 Tighten the wing nut 3 Tighten the screw 3 4 Attach the filter cover 2 to the air filter housing and secure it with the air filter cover lockl ...

Page 155: ...t heat value Recommended spark plug ZFR5F NGK 1 Check the electrode gap with a feeler gauge if necessary adjust the gap to0 03 0 032 in 0 7 0 8 mm 2 Turn the spark plug carefully in by hand 3 Tighten the spark plug with a spark plug spanner until it is correctly seated 4 Tighten a new spark plug for another 1 2 turn 5 Tighten used spark plugs by another 1 8 to 1 4 turn NOTICE A loose spark plug ca...

Page 156: ...1 Place the drain hose Ä Fig 170 into the collecting container and open the drain plug Catch running out oil 2 Turn the oil drain plug back in with a new seal ring 1 Unscrew the filter cartridge 1 Ä Fig 171 using an appro priate tool 2 2 Clean the sealing face on the filter carrier 3 from any dirt 3 Slightly oil the rubber seal 4 on the new filter cartridge 4 Turn the new filter cartridge on by ha...

Page 157: ... not smoke do not spill any fuel WARNING Health hazard Do not inhale any fuel fumes ENVIRONMENT Catch running out fuel do not let it seep into the ground Dispose of the used fuel precleaners environmen tally 1 Loosen the hose clamps Ä Fig 173 2 Pull the fuel filter out of the top and bottom hoses 3 Install the new fuel filter by observing the flow direction 4 Retighten the hose clamps Fig 172 Fig ...

Page 158: ...2 2 Pull off spark plug socket 3 1 Turn the flywheel 1 Ä Fig 175 clockwise until the marks 2 3 are in line Cylinder 1 in top dead centre position in compres sion stroke Both valves closed If not crank the engine for 360 1 A feeler gauge of appropriate thickness Ä Fig 176 must fit with little resistance between rocker arm and valve 2 If the gap is too narrow or too wide for the feeler gauge the val...

Page 159: ...ork carried out by trained personnel or our after sales service Check and adjust only at operating temperature of the engine Setting 1400 150 min 1 1 Run the engine to warm it up to operating temperature 2 Adjust the engine idling speed with the setscrew 1 Ä Fig 178 6 1 3 5 Every 2000 operating hours 6 1 3 5 1 Checking fuel lines and clamps WARNING Danger of burning Perform inspection work only af...

Page 160: ...A machine with conserved engine must be clearly marked by attaching a clear warning tag Depending on the weather condition these con serving measures will provide protection for approx 6 12 months The conserving oil must be replaced by engine oil refer to the section Fuels and lubricants according to the API MIL classification before taking the machine into operation Anti corrosion oils are those ...

Page 161: ...fuel tank 5 Remove the cylinder head covers spray the rocker cham bers with anti corrosion oil Then fasten the covers again 6 Unscrew both spark plugs and spray anti corrosion oil through the spark plug openings Crank the engine several times and install the spark plugs again 7 Close air intake on air filter and exhaust opening tightly Machine assemblies Engine BW 900 50 165 G o t o D i s c o u n ...

Page 162: ...d the ver tical axis by means of an articulated movement the rear frame can oscillate on the horizontal axis The advantage of the oscillating articulated joint is the fact that front and rear frame move in the same track The oscillation compensates for uneven surfaces and creates an even drum pressure Both the pivot point of the oscillating joint which was purposely designed to be low as well as t...

Page 163: ...ng journal 6 Rocker bearings for steering cylinder When tightening the bearing housing 4 move the bearing housing slightly to and fro to ensure a uni form wear pattern of the individual bearing rollers Machine assemblies Oscillating articulated joint BW 900 50 167 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 164: ...r bearing 6 Rocker bearing 7 Tapered roller bearing When tightening the bearing housing move the bearing housing slightly to and fro to ensure a uni form wear pattern of the individual bearing rollers Machine assemblies Oscillating articulated joint BW 900 50 168 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 165: ...afely support front and rear frames 4 Pull up the parking brake lever Ä Fig 184 5 Attach lifting tackle to the articulated joint 6 Remove the split pin form the steering cylinder bearing bolt 1 Ä Fig 185 and knock out the bolt 7 Remove the backing discs 2 8 Unscrew fastening screws 3 with washers and lift out the oscillating articulated joint Fig 182 Fig 183 Fig 184 Fig 185 Machine assemblies Osci...

Page 166: ... Ä Fig 187 shims 2 and seal rings 3 from both sides 3 Extract the rocker bearing Ä Fig 188 with a suitable puller Dismantling the oscillating articu lated joint Fig 186 Fig 187 Fig 188 Machine assemblies Oscillating articulated joint BW 900 50 170 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 167: ...2 6 Take disc 1 Ä Fig 191 out of the bearing housing and remove O ring 2 7 Remove the Belleville springs 3 8 Remove taper roller bearing 1 Ä Fig 192 Fig 189 Fig 190 Fig 191 Fig 192 Machine assemblies Oscillating articulated joint BW 900 50 171 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 168: ...94 11 Knock the outer bearing race 1 Ä Fig 195 out of the bearing housing 12 Pull taper roller bearing 1 Ä Fig 196 off the bearing journal Fig 193 Fig 194 Fig 195 Fig 196 Machine assemblies Oscillating articulated joint BW 900 50 172 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 169: ...upside down 4 Press outer bearing race 1 Ä Fig 199 into the bearing housing and fill to 2 3 with lithium saponified high pressure grease 5 Insert a new seal ring 1 Ä Fig 200 into the bearing housing Assembling the oscillating articu lated joint Fig 197 Fig 198 Fig 199 Fig 200 Machine assemblies Oscillating articulated joint BW 900 50 173 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e ...

Page 170: ...stall disc 1 into the bearing housing 11 When tightening the hexagon nut 1 move the bearing housing to and fro to ensure a uniform wear pattern of the individual bearing rollers Cover the thread on the bearing journal with LOCTITE and tighten hexagon nut 1 Ä Fig 204 with 300 Nm Fig 201 Fig 202 Fig 203 Fig 204 Machine assemblies Oscillating articulated joint BW 900 50 174 G o t o D i s c o u n t E ...

Page 171: ... in until they bottom 13 Install new seal rings 3 Ä Fig 206 shims 2 and sup porting discs 1 to the bearing journals of the bearing housing 14 Knock both bearing blocks 1 Ä Fig 207 onto the bearing journals Fig 205 Fig 206 Fig 207 Machine assemblies Oscillating articulated joint BW 900 50 175 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 172: ...ry drum front 6 3 1 1 Repair overview of vibratory drum 177 6 3 1 2 Removing and installing the vibratory drum 178 6 3 1 3 Dismantling the vibratory drum 181 6 3 1 4 Assembling the vibratory drum 186 Machine assemblies Drum BW 900 50 176 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 173: ...1 1 2 2 3 4 5 6 Fig 208 Vibratory drum front 1 Support legs 2 Rubber buffer 3 Exciter shaft 4 Travel motor 5 Drive disc 6 Vibration motor Machine assemblies Drum BW 900 50 177 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 174: ...ings 7 Travel bearings 6 3 1 2 Removing and installing the vibratory drum 1 Park the machine on level and firm ground 2 Always secure the machine against unintended rolling Removing the vibratory drum Machine assemblies Drum BW 900 50 178 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 175: ...ONMENT Collect leaking oil and dispose of in an envi ronmentally friendly way 11 Disassemble the hose brackets 3 12 Close all hydraulic hoses and motor ports with suitable plugs 13 Unscrew the fastening screws 1 remove the spacer 4 and pull the drum with the support leg sideways out of the frame Install the drum in reverse order for this purpose move the drum with attached travel motor and sup por...

Page 176: ...ation shims on either side 1 NOTICE Bleed the travel circuit before starting opera tion Check the hydraulic oil level Ä Fig 215 top up if necessary 2 Perform a test drive check function of travel system vibra tion and spraying system 3 Check all connections and fittings for leak tightness Fig 213 Adjusting the pre load of the rubber buffers Fig 214 Starting up the machine Fig 215 Machine assemblie...

Page 177: ... 2 with travel motor and drive disc from the drum 4 Unscrew hexagon nut 1 Ä Fig 217 and pull the drive disc 2 off the travel motor 3 Removing the travel motor 1 2 S 834 0019 Nm Nm Nm 211 Fig 216 Tightening torque 407 Nm 542 Nm Anziehdrehmoment 407 Nm 542 Nm S 834 0026 1 2 3 Fig 217 Machine assemblies Drum BW 900 50 181 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 178: ...y 5 8 Check the rubber buffers 1 Ä Fig 219 unscrew and replace if necessary 1 Disassemble the rubber buffers 1 Ä Fig 220 S 834 0027 1 2 3 4 5 Fig 218 Fig 219 Dismantling the travel bearing on the vibration drive side Fig 220 Machine assemblies Drum BW 900 50 182 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 179: ...s flange 1 Ä Fig 223 off the bearing flange with forcing screws 2 5 Knock ball bearing 1 Ä Fig 224 out of the flange Fig 221 Fig 222 Fig 223 Fig 224 Machine assemblies Drum BW 900 50 183 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 180: ... 227 2 Force the bearing flange off the drum using forcing screws 2 3 NOTICE Danger of squashing Pull the exciter shaft out of the drum Ä Fig 228 Fig 225 Fig 226 Removing dismantling the exciter shaft Fig 227 Fig 228 Machine assemblies Drum BW 900 50 184 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 181: ... bearing race 1 Ä Fig 231 off both sides of the exciter shaft If the inner bearing race sits very tight heat the ring up with a torch 7 Remove the seal ring 2 from both ends of the exciter shaft Fig 229 Fig 230 Fig 231 Machine assemblies Drum BW 900 50 185 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 182: ... the rolling elements and approx 15 g into the grease chamber of the bearing flange Cool the new cylinder roller bearing 1 Ä Fig 234 down to 25 C press it into the bearing flange until it bottoms and fill it with high pressure grease S 834 0028 1 2 Fig 232 S 834 0029 1 Fig 233 Assembling installing the exciter shaft Fig 234 Machine assemblies Drum BW 900 50 186 G o t o D i s c o u n t E q u i p m ...

Page 183: ...unt flange 2 Ä Fig 236 to the drum with the hexagon screws 1 and washers 4 Lubricate the bearing seat areas Install seal ring 2 Ä Fig 237 on both ends of the exciter shaft 5 WARNING Danger of burning Wear protective gloves Heat the inner bearing races 1 up to approx 80 C and slide on both ends of the exciter shaft S 834 0030 Grease Fett Graise Grasa 1 Fig 235 S 834 0028 1 2 Fig 236 Fig 237 Machine...

Page 184: ...n screws 1 Ä Fig 240 and washers 1 Push the exciter shaft into the bearing flange against the end stop Ä Fig 241 2 Measure the distance between coupling and front face of the bearing flange 3 Pull the exciter shaft out against the end stop Fig 238 Fig 239 Fig 240 Measure the axial clearance Fig 241 Machine assemblies Drum BW 900 50 188 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r ...

Page 185: ...ling element 1 Ä Fig 242 into the coupling hub 1 Attach shim 1 Ä Fig 243 2 Install the new V ring 2 on the bearing flange and grease it as shown 1 Press ball bearing 1 Ä Fig 244 into the flange until it bot toms Fig 242 Assembling the travel bearing on the vibration side Fig 243 Fig 244 Machine assemblies Drum BW 900 50 189 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a ...

Page 186: ...ase it 5 Fill the ball bearing with high pressure grease Fill bearings and cavities to 2 3 with lithium saponified high pressure grease 6 Tighten rubber buffer 1 Ä Fig 248 with a matching rubber buffer mounting bell Tightening torque for rubber buffers 211 Nm Fig 245 Fig 246 Fig 247 Fig 248 Machine assemblies Drum BW 900 50 190 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r ...

Page 187: ...stall the feather key 5 in the travel motor 3 4 Mount the drive disc 2 Ä Fig 251 with fastening nut 1 to the travel motor Tightening torque 407 to 542 Nm Installing the travel motor Fig 249 S 834 0027 1 2 3 4 5 Fig 250 Tightening torque 407 Nm 542 Nm Anziehdrehmoment 407 Nm 542 Nm S 834 0026 1 2 3 Fig 251 Machine assemblies Drum BW 900 50 191 G o t o D i s c o u n t E q u i p m e n t c o m t o o r...

Page 188: ... Rear drum 6 3 2 1 Repair overview of rear drum 193 6 3 2 2 Removing and installing the rear drum 194 6 3 2 3 Dismantling the rear drum 195 6 3 2 4 Assembling the rear drum 198 1 2 S 834 0019 Nm Nm Nm 211 Fig 252 Machine assemblies Drum BW 900 50 192 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 189: ...2 1 Repair overview of rear drum S 834 0015 1 1 2 3 4 5 Fig 253 Rear drum 1 Support legs Machine assemblies Drum BW 900 50 193 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 190: ...the hose brackets 3 8 Close all hydraulic hoses and motor ports with suitable plugs 9 Disconnect the Bowden cable 5 from the parking brake and drum 10 Unscrew the fastening screws 1 remove the spacer 4 and pull the drum with the support leg sideways out of the frame Install the drum in reverse order for this purpose move the drum with attached travel motor and sup port leg parallel into the frame ...

Page 191: ...ing system 3 Check all connections and fittings for leak tightness 6 3 2 3 Dismantling the rear drum WARNING Secure the drum against unintended rolling 1 Pull travel bearing 1 Ä Fig 257 out of the shaft Starting up the machine Fig 256 Removing the travel bearing S 834 0024 1 Fig 257 Machine assemblies Drum BW 900 50 195 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t ...

Page 192: ... disc and parking brake from the drum 4 Unscrew hexagon screws 2 Ä Fig 259 with washers and remove the parking brake 1 Removing the travel motor S 834 0025 1 2 LOCTITE 243 Nm Nm Nm 270 Fig 258 1 2 S 834 0031 LOCTITE 243 Fig 259 Machine assemblies Drum BW 900 50 196 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 193: ...ws 1 Ä Fig 261 washers and nuts 2 7 Remove the travel motor 3 from the support leg 4 8 Disassemble the feather key 5 S 834 0032 1 2 3 Nm Nm Nm 407 Nm 542 Nm Fig 260 S 834 0027 1 2 3 4 5 Fig 261 Machine assemblies Drum BW 900 50 197 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 194: ...agon screws 1 washers and nuts 2 to the support leg 4 2 Install the feather key 5 in the travel motor 3 Assembling the travel bearing S 834 0024 1 Fig 262 Installing the travel motor S 834 0027 1 2 3 4 5 Fig 263 Machine assemblies Drum BW 900 50 198 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 195: ...ount parking brake 1 Ä Fig 264 with screws 2 and washers to the support leg ð Insert screws 2 with LOCTITE 243 S 834 0032 1 2 3 Nm Nm Nm 407 Nm 542 Nm Fig 264 1 2 S 834 0031 LOCTITE 243 Fig 265 Machine assemblies Drum BW 900 50 199 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 196: ...0 operating hours 6 3 3 2 1 Cleaning the scrapers 200 Every 125 operating hours 6 3 3 3 1 Lubricating the rear drum bearings 201 6 3 3 2 Every 10 operating hours 6 3 3 2 1 Cleaning the scrapers 1 Fold the scrapers up and clean them Ä Fig 267 This is of particular importance before compacting asphalt surfaces S 834 0025 1 2 LOCTITE 243 Nm Nm Nm 270 Fig 266 Fig 267 Machine assemblies Drum BW 900 50 ...

Page 197: ...he table of fuels and lubricants 1 Clean the grease nipple of the bearing on the rear drum Ä Fig 268 2 Lubricate the grease nipple with a grease gun until grease starts to run out of the bearing Fig 268 Machine assemblies Drum BW 900 50 201 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 198: ...7 Troubleshooting Troubleshooting BW 900 50 203 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 199: ... shooting diesel engine 219 7 5 1 Starting the engine with jump leads 219 7 5 2 Engine problems 219 7 1 Preliminary remarks Malfunctions are frequently caused by incorrect operation of the machine or insufficient maintenance Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance If you cannot locate the cause of a fault or rectify it yo...

Page 200: ...rking brake secure the machine against unintended rolling by using appro priate means e g metal wheel chocks Use a towing vehicle with sufficient traction and braking power for the unbraked towed load Use a tow bar Using the machine as towing vehicle is not per mitted 1 Attach the drawbar to the front or rear towing hitch 1 Ä Fig 270 Fig 269 Fig 270 Troubleshooting Emergency procedures BW 900 50 2...

Page 201: ...e 500 m WARNING Danger of accident Before loosening the drawbar secure the machine against unintended rolling by using appropriate means e g metal wheel chocks or apply the parking brake Fig 271 Fig 272 After towing Troubleshooting Emergency procedures BW 900 50 206 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 202: ...f failures n In approx 10 of the examined cases the problems were caused by control units n In approx 15 sensors and actuators were the cause of the problems By far the highest proportion of all faults could be traced back to wiring and connections plugs etc General Before changing any expensive components such as control units you should run a systematic trouble shooting session to eliminate any ...

Page 203: ...l elec tronics Over the years corrosion and contamination can create high con tact resistances in plugs and switches wiring looms affected by copper worm corrosion are poor conductors In extreme inci dents such a component will be absolutely dead while minor damage more or less reduces the performance of the affected con sumers to a noticeable extent In many cases it is enough to examine the compo...

Page 204: ... is a common procedure to pick up the signals with a break out box the Y cable of which is fas tened between control unit and control unit plug If no break out box is available the measurement takes place directly on the sensor or one must try to gain access to the back of the plug Trouble shooting procedure n First check the corresponding actuator in case of a faulty signal the output signal must...

Page 205: ...permanently discharged n the battery has boiled over and acid has escaped n the headlights light considerably brighter when accelerating n light bulbs burn out frequently at irregular intervals 7 3 2 Fuse assignment n Fuse box The fuse box is located behind the steering column covering WARNING Fire hazard Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire 5 25...

Page 206: ...urrent supplying auxiliary battery and then to engine or chassis ground as far away from the battery as possible 3 Start the engine NOTICE Danger of damage to the electronic system If no powerful consuming device is switched on voltage peaks may occur when separating the con necting cables between the batteries which could damage electrical components 4 Once the engine is running switch on a power...

Page 207: ...re emptively mini mise any faults and malfunctions Nevertheless malfunctions and faults may occur during operation of a hydraulic system or machine which impair the general functional sequence but also the safety of the hydraulic system or machine In addition to impairing product quality this may result in hazards that can no longer guarantee working safely with the machine If the control system i...

Page 208: ...low make operation difficult and the system unpredictable This is usually caused by contamination blockages or tension Many hydraulic systems can already be rem edied by cleaning the corresponding components bleeding the system and replacing the old liquids 7 4 2 Insufficient hydraulic power If the charge pressure is not inside the nominal range no high pressure can be built up in the system Troub...

Page 209: ...rops there is an internal leak in the hydraulic circuit n But there may also be an internal leak in an external compo nent which is also controlled by charge pressure For example Brake valve brake piston etc n However the steering pump could also be defective because the steering pump delivers the the oil that is fed into the closed hydraulic circuit Diesel engine running travel lever position 0 T...

Page 210: ... danger of overheating 3 Start the engine and accelerate to full speed 4 Shift the travel lever to forward and reverse 5 Read the pressure gauges 6 Read the pressure gauge ð If the pressure gauges show the correct values the vari able displacement pump is OK The fault is in the hydraulic motor s 3 Troubleshooting closed circuit using the example of a travel circuit Troubleshooting Trouble shooting...

Page 211: ... Remedy Unusual noises Insufficient suction conditions e g air in the suction line inadequate diameter of the suc tion line excessive viscosity of the pressure fluid extreme suction height too low suction pressure foreign bodies in the suction line Machine or system manufacturer e g optimize feed conditions use suitable pressure fluid Completely purge the axial piston unit fill the suction line wi...

Page 212: ...ter of the suc tion line excessive viscosity of the pressure fluid extreme suction height too low suction pressure foreign bodies in the suction line Completely purge the axial piston unit fill the suction line with pres sure fluid Remove foreign bodies from inside the suction line Pressure fluid not within the optimal viscosity range Use appropriate pressure fluid External control and setting fac...

Page 213: ... Excessive input temperature on axial piston unit Check the system e g malfunc tion of the cooler pressure fluid level in tank too low Malfunction of the pressure control valves e g high pressure limiting valve pressure override valve pressure controller Consult the service department Malfunction of the flushing valve not for nom inal size 18 Consult the service department Wear of the axial piston...

Page 214: ...amage to the electronic system If no powerful consuming device is switched on voltage peaks may occur when separating the con necting cables between the batteries which could damage electrical components 4 Once the engine is running switch on a powerful consumer working light etc 5 After starting disconnect the negative poles first and the posi tive poles after 6 Switch off the consumer 7 5 2 Engi...

Page 215: ...atures Fuel supply too low fuel system clogged Change the fuel filter Check the line connections for leaks and tighten the fittings The specified valve clearance is not correct Adjust the valve clearance Carburettor defective Have examined by a specialist Air filter dirty Clean air filter change if necessary Excessive play in throttle cable Adjust the throttle cable replace if necessary Engine loo...

Page 216: ...8 Special tools Special tools BW 900 50 221 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 217: ...rge n BOMAG part no 007 610 03 4 x 60 bar pressure gauges 4 x 600 bar pressure gauges 8 pressure test hoses n Hydraulic test case small n BOMAG part no 079 930 01 2 x 60 bar pressure gauges 2 x 600 bar pressure gauges 4 pressure test hoses n Measurement lines n 1000 mm BOMAG part no 079 930 02 n 2500 mm BOMAG part no 079 930 03 Fig 279 Fig 280 Fig 281 Special tools Special tools for hydraulic syst...

Page 218: ... 04 n Adapter for pressure test hose n BOMAG part no 055 439 02 n Gear pump testing device n BOMAG part no 007 610 05 Fig 282 Fig 283 Fig 284 Special tools Special tools for hydraulic system BW 900 50 223 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 219: ... no 007 000 01 n Filter element 1μ n BOMAG part no 079 930 52 n Flushing hose 20S 25S 2 pieces n BOMAG part no 055 509 19 n Screw socket R1 25S 2 pieces n BOMAG part no 055 400 52 n Flushing filter L connection n BOMAG part no 079 390 29 n Filter element n BOMAG part no 079 390 14 n Flushing hose 15L 2 pieces n BOMAG part no 055 510 09 n Screw socket R3 4 15L 2 pieces n BOMAG part no 055 400 89 Fi...

Page 220: ... Operating manual and plastic boxes for storing different contacts Equipment kit for special pliers tool kit BOMAG part no 079 950 06 Measuring set BOMAG part no 836 011 68 n Comprising Clamp multimeter Measuring adapter Measurement lines Screwdriver Other accessories Fig 289 Special pliers Fig 290 Equipment kit 1 Fig 291 Measuring set Special tools Special tools electrics BW 900 50 225 G o t o D ...

Page 221: ...8 3 Special tools for drum n Bell to change the rubber buffers Fig 292 Special tools Special tools for drum BW 900 50 226 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 222: ...9 Index Index BW 900 50 227 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 223: ...151 152 A62 53 83 152 A63 53 83 B06 90 152 B08 91 B11 53 83 B32 53 83 B38 91 B201 53 83 152 E24 53 83 E26 53 83 E27 53 83 E28 53 83 E32 53 83 F00 89 211 F06 89 210 F100 89 210 F148 53 83 89 210 G01 53 83 H08 85 H14 53 83 H38 85 K04 87 K05 87 K23 87 K26 87 K29 87 Index BW 900 50 228 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 224: ...system 55 104 Hydraulics closed circuit 98 Hydraulics open circuit 97 Machine 52 Oscillating articulated joint 57 167 Rear drum 60 193 T Trouble shooting Diesel engine 219 Electric systems 207 Hydraulic system 212 Troubleshooting Hydraulics axial piston pumps 216 Hydraulics insufficient hydraulic power 213 Index BW 900 50 229 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p ...

Page 225: ...Appendix Appendix BW 900 50 231 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 226: ...A Circuit diagrams 233 Appendix BW 900 50 232 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 227: ...rcuit diagrams A 1 Circuit diagram 78 233 A 2 Hydraulic diagram 138 243 A 1 Circuit diagram 78 Circuit diagrams BW 900 50 233 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 228: ... 1 0 7 6 8 9 3 9 4 1 2 5 Cover sheet T Rau 19 01 2011 D Nallin Higher level function Anlage Function Funktion Mounting location Einbauort 13 01 2011 Checked Erstellt Geprüft Deckblatt Circuit diagrams BW 900 50 234 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 229: ...üft Inhaltsverzeichnis Cover sheet Deckblatt 1 Table of contents Inhaltsverzeichnis 2 Supply Starting unit Versorgung Starten 3 Starting unit seatcontact Starten Sitzkontakt 4 Horn working lights rotary beacon warning buzzer Hupe Arbeitsbel Runkdumkennleuchte Warnsummer 5 Vibration sprinkler Vibration Berieselung 6 Device tag list Betriebsmittelliste 7 Device tag list Betriebsmittelliste 8 Plug ov...

Page 230: ...arter Starter A61 Controller Regler BI W BI Y W Bu Gr Gr A59 Ignition coil left Zündspule links A60 Ignition coil right Zündspule rechts A62 Spark plug Zündkerze A63 Spark plug Zündkerze G01 45Ah Battery Batterie BL BL V02 V01 X2 3 1 2 5 6 4 4 3 6 2 Gr Gr G02 20A Generator Generator G X3 1 X20 1 4 X20 1 X21 87a 30 87 K69 4 3 X20 5 7 X20 8 87a 30 87 K136 4 7 off delay 7 X3 31 4 0 30 4 0 H08 4 0 50 ...

Page 231: ...1 2 Y58 Fuel cut solenoid Kraftstoffabstellung X3 5 X20 3 P00 Operating hours counter Betriebsstundenzähler h 1 2 H08 Charge control Ladekontrolle 2 1 S06 Switch seatcontact Schalter Sitzkontakt X19 6 X12 1 X12 2 85 30 K136 5 off delay Timing relay seatcontact Zeitrelais Sitzkontakt 87a 30 87 3 8 X19 9 11 12 S01 Emergency stop Not Aus 1 2 H38 Indicator light fuel oil Meldeleuchte Kraftstoff 11 12 ...

Page 232: ...on Rundumkennleuchte 13 14 S38 Switch Rotary beacon Schalter Rundumkennleuchte X19 8 H14 0 3A 110dB Back up alarm buzzer Warnsummer Rückwärtsfahrt X18 1 X18 2 X20 2 X19 7 X19 1 86 85 K05 start locking Relay starting current Relais Startstrom 87a 30 87 4 2 X4 3 5 E F100 20A Fuse Working lights Sicherung Arbeisscheinwerfer X19 3 X19 2 X5 2 BN BK BU B38 high 1 Proximity switch vibration lock Näherung...

Page 233: ...tion X7 2 X19 4 1 2 Y22 1 75A Solenoid vibration Magnetventil Vibration 86 85 K23 Relay sprinkler pump Relais Berieselungspumpe 87a 30 87 6 8 13 14 S05 Switch sprinklersystem Schalter Berieselung 4 1 2 A01 Watersaver switch Intervallschalter Berieselung 7 G F06 15A Fuse vibration sprinkler Sicherung Vibration Berieselung X23 1 87a 30 87 K23 6 7 X23 2 M02 6 4A Sprinkler pump Berieselungspumpe 87a 3...

Page 234: ... 5 headlight front 55W Arbeitsscheinwerfer vorne 2 E27 5 headlight rear 55W Arbeitsscheinwerfer hinten 3 E28 5 headlight rear 55W Arbeitsscheinwerfer hinten 4 E32 5 Rotary beacon 55W lamp 3W motor Rundumkennleuchte 5 F00 4 Fuse main 25A Hauptsicherung 1 F06 6 Fuse vibration sprinkler 15A Sicherung Vibration Berieselung 2 F41 5 Fuse rotary beacon 15A Sicherung Rundumkennleuchte 1 F100 5 Fuse Workin...

Page 235: ... 8 6 4A P00 4 Operating hours counter Betriebsstundenzähler 5 S00 4 Ignition switch Startschalter 1 S01 4 Emergency stop Not Aus 1 S03 5 Push button warning horn Taster Signalhorn 1 S05 6 Switch sprinklersystem Schalter Berieselung 7 S06 4 Switch seatcontact Schalter Sitzkontakt 7 S13 6 Pushbutton vibration Taster Vibration 5 S38 5 Switch Rotary beacon Schalter Rundumkennleuchte 5 S53 5 Switch wor...

Page 236: ... 5 3 3 6 3 2 X3 Plug engine functions Type Contact Page Path Kontakt Blatt Pfad Typ 1 3 7 2 3 3 3 3 3 4 3 3 5 4 4 6 3 3 X4 Plug travel lever Type Contact Page Path Kontakt Blatt Pfad Typ 2 5 9 3 5 9 X7 Plug Pushbutton vibration Type Contact Page Path Kontakt Blatt Pfad Typ 2 6 5 X8 Plug rotary beacon Type Contact Page Path Kontakt Blatt Pfad Typ 2 5 5 X12 plug seat contact Type Contact Page Path K...

Page 237: ...A 2 Hydraulic diagram 138 Circuit diagrams BW 900 50 243 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 238: ...oject description BW 900 50 56154 Boppard 56154 Boppard 56154 Boppard 56154 Boppard 14 07 2009 14 07 2009 14 07 2009 14 07 2009 Bearbeitet am Edit date 138 Erstellt am Created on Zeichnungsnummer Drawing number F26_FT001 F26_FT001 F26_FT001 F26_FT001 hagen hagen hagen hagen Hellerwald Hellerwald Hellerwald Hellerwald Typ Type 20 04 2012 20 04 2012 20 04 2012 20 04 2012 von Kürzel by short name Bom...

Page 239: ...I Hagen I Hagen Bearbeiter Spalte X eine automatisch erzeugte Seite wurde manuell nachbearbeitet Column X An automatically generated page was edited Inhaltsverzeichnis Datum Seitenbeschreibung F06_001 X Seite Page Table of contents Page description Date Edited by X hagen 19 04 2012 hagen 20 04 2012 hagen 19 04 2012 1 Deckblatt 2 Inhaltsverzeichnis 1 7 3 Übersicht cover sheet Table of contents 1 7 ...

Page 240: ... 8 9 3 7 7 7 7 4 19 04 2012 19 04 2012 19 04 2012 19 04 2012 3 3 3 3 2 5 138 138 138 138 Zeichnungsnummer drawing number Neil Liu Neil Liu Neil Liu Neil Liu 20 04 2012 20 04 2012 20 04 2012 20 04 2012 Dokumentart document type I Hagen I Hagen I Hagen I Hagen Circuit diagrams BW 900 50 246 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 241: ...20 04 2012 20 04 2012 4 4 4 4 2 5 138 138 138 138 Zeichnungsnummer drawing number Neil Liu Neil Liu Neil Liu Neil Liu 20 04 2012 20 04 2012 20 04 2012 20 04 2012 Dokumentart document type I Hagen I Hagen I Hagen I Hagen 13 cm 300 bar 300 bar 20 bar 3240 1 min 01 B Mb PS T2 T1 R X1 X2 Ma A S 03 05 4 7 05 4 7 D 5 6 F 6 4 Circuit diagrams BW 900 50 247 G o t o D i s c o u n t E q u i p m e n t c o m ...

Page 242: ...8 9 3 7 7 7 7 4 20 04 2012 20 04 2012 20 04 2012 20 04 2012 5 5 5 5 2 5 138 138 138 138 Zeichnungsnummer drawing number Neil Liu Neil Liu Neil Liu Neil Liu 20 04 2012 20 04 2012 20 04 2012 20 04 2012 Dokumentart document type I Hagen I Hagen I Hagen I Hagen 75 bar 200 bar Y22 13 12 09 04 M P1 T P2 06 P T L R 02 A 6 3 B 6 4 D 4 4 Circuit diagrams BW 900 50 248 G o t o D i s c o u n t E q u i p m e ...

Page 243: ... 19 04 2012 19 04 2012 19 04 2012 6 6 6 6 2 5 138 138 138 138 Zeichnungsnummer drawing number Neil Liu Neil Liu Neil Liu Neil Liu 20 04 2012 20 04 2012 20 04 2012 20 04 2012 Dokumentart document type I Hagen I Hagen I Hagen I Hagen F 4 3 A 5 3 B 5 3 Circuit diagrams BW 900 50 249 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 244: ...Metered value QVW X Ref Funktionstext Function text Betriebsmittelkennzeichen Device tag Symbol Symbol Technische Daten technical data Messwert Metered value Technische Daten technical data alle Drücke gemessen bei einer Öltemperatur von ca 50 C Verbrennungsmotor im hohen Leerlauf all pressure measurement at oil temperature 50 C combustion engine at high idle B Mb PS T2 T1 R X1 X2 Ma A S M P1 T P2...

Page 245: ...ne needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

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