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Fayat Bomag BW 900-50, Operating Instruction, Maintenance Instruction

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Fayat Bomag BW 900-50 Operating Instruction, Maintenance Instruction Download Page 84

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 yourself by fol-

lowing the trouble shooting chart, you should contact our customer

service department.

Troubleshooting – Preliminary remarks

 

BW 900-50

 

86

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Summary of Contents for Bomag BW 900-50

Page 1: ...ating Instruction Maintenance Instruction Original Operating Instructions S N 861 834 07 1001 S N 101 834 51 1001 08 2018 008 069 81 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: ...the State of California to cause cancer and birth defects or other reproductive harm WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the outside Do not modify or tamper with the exhaus...

Page 4: ...Maintenance Table 62 6 6 Every 10 operating hours 63 6 6 1 Checking the engine oil level 63 6 6 2 Checking the fuel level 63 6 6 3 Checking the hydraulic oil level 65 6 6 4 Checking the hydraulic oil filter element 65 6 6 5 Checking the water level 66 6 6 6 Cleaning the scrapers 66 6 6 7 Cleaning the cooling air intake openings 67 6 7 Every 125 operating hours 68 6 7 1 Check clean the air filter r...

Page 5: ...d 82 6 10 1 Water sprinkler system maintenance in case of frost 82 6 10 2 Engine conservation 82 7 Troubleshooting 85 7 1 Preliminary remarks 86 7 2 Starting the engine with jump leads 87 7 3 Engine problems 88 8 Disposal 91 8 1 Final shut down of machine 92 Table of contents BW 900 50 4 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 6: ...1 Introduction Introduction BW 900 50 5 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: ...rating steps including the notes on safety to be followed can be found in chapter Operation Ä Chapter 5 Operation on page 37 Before every start up carry out all required visual inspections and function tests Ensure the compliance with the specified operating maintenance and repair measures to maintain the functional safety of your machine A description of all necessary maintenance work maintenance...

Page 8: ...at you can also order the spare parts catalogue against the serial number of your machine The above notes do not constitute an extension of the warranty and liability conditions specified in the general sales and delivery conditions of BOMAG GmbH We wish you successful work with your BOMAG machine Introduction Foreword 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...

Page 9: ...al number 2 Please enter here Engine type Engine number Fig 1 Machine type plate example Engine type and engine number 1 B HON 0008 Fig 2 Introduction Machine type plate and engine type plate BW 900 50 8 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 10: ...2 Technical data Technical data BW 900 50 9 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 11: ...00 35 Dimensions in millimetres Dimensions in inch Weights Max operating weight 1200 2646 kg lbs Operating weight CECE 1600 3527 kg lbs Average static linear load CECE 6 7 37 5 kg cm pli Dimensions Technical data BW 900 50 10 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 12: ... of cylinders 2 Rated power SAE J 1349 14 9 kW Rated speed 3300 min 1 Driven drum front rear Electric system Voltage 12 V Brakes Service brake hydrostatic Parking brake hydro mechanical Steering Type of steering Oscill articul Steering operation hydrostatic Steering angle 33 Oscillation angle 6 Inner track radius 1647 65 mm in Technical data BW 900 50 11 G o t o D i s c o u n t E q u i p m e n t c...

Page 13: ...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 BW 900 50 12 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 14: ...3 Safety regulations Safety regulations BW 900 50 13 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 15: ...n 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 intended for Any danger caused by improper use is the sole re...

Page 16: ...e the responsibilities must be clearly specified and complied with Persons under the influence of alcohol medicine or drugs are not allowed to operate service or repair the machine Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists Unauthorized changes to the machine are prohibited for safety rea sons Original parts and accessories h...

Page 17: ...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 lifted Use only safe lifting gear of sufficient load bearing capacity Fasten the lifting gear only at the sp...

Page 18: ...close coordination with the manufacturer Before starting Use only machines which are serviced at regular intervals Become acquainted with the equipment the control elements the working principle of the machine and the working area Wear your personal protective outfit hard hat safety boots etc Wear ear defenders Before mounting the machine check whether n persons or obstructions are beside or under...

Page 19: ...resuming work and especially when reversing check that there are not any persons or obstructions in the endan gered area If necessary give warning signals Stop work immediately if per sons remain in the danger area despite the warning Do not step or stand in the articulation area of the machine when the engine is running Risk of squashing Driving In events of an emergency operate the emergency sto...

Page 20: ... speed of the machine to the working conditions Always allow loaded transport vehicles to pass Switch the lights on when the visibility is poor Keep clear of edges and embankments Check the effect of vibration When compacting with vibration check the effect of the vibration on nearby buildings and underground supply lines gas water sewage electric power supply stop vibratory compaction if neces sa...

Page 21: ...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 with the articulation lock Work on hydraulic lines Relieve hydraulic pressures before working on hydraulic lines Hydraulic oil escaping under pressure can penetrate the skin and c...

Page 22: ...ne 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 contaminated materials in a sepa rate specially marked container and dispose of environmentally Do not leave any tools or other objects that could cause damage in the engine compartment Working on electric parts of the ...

Page 23: ...r 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 performed by qualified and authorized persons Use our repair instructions for this work Exhaust gases are ...

Page 24: ... 330 05 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 Safety regulations Signage 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 25: ...gine exhaust gases Prohibition sticker High pressure cleaning B DEC 0197 Fig 5 Fig 6 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 7 Fig 8 Safety regulations Signage BW 900 50 24 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 26: ...oint Information sticker Filler opening for hydraulic oil Information sticker Engine oil drain Fig 9 Fig 10 B DEC 0214 Hydraulic Oil Fig 11 B DEC 0211 Fig 12 Safety regulations Signage BW 900 50 25 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 27: ...hoke control Information sticker Travel lever control Operation sticker Throttle lever Fig 13 B DEC 0295 Fig 14 B DEC 0296 Fig 15 Fig 16 Safety regulations Signage BW 900 50 26 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 28: ...on sticker Gasoline Information sticker Travel lever control B DEC 0297 Fig 17 B DEC 0298 GASOLINE BENZIN Fig 18 B DEC 0299 Fig 19 Safety regulations Signage BW 900 50 27 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 29: ...4 Indicators and control elements Indicators and control elements BW 900 50 29 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 30: ...ntrol lamp 3 Operating hour meter 4 Fuel level warning light 5 Rotary switch for sprinkling system 6 Ignition switch 7 Choke lever Indicators and control elements BW 900 50 30 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 31: ...g lights off Position Right Working lights on with ignition switch in position I n Charge control light lights when switching on the ignition test if the battery is not being charged goes out after starting the engine n Operating hour meter Counts the operating hours while the engine is running All maintenance work must be performed according to the indi cated operating hours Fig 21 Fig 22 Fig 23 ...

Page 32: ...in neutral position the emergency stop switch is unlocked and the driver has occupied the driver s seat seat contact switch The ignition switch is designed with a re start lock For a new starting attempt the ignition key must first be turned back to position 0 Position II turn further against spring pressure the engine starts turn the ignition key back to position I once the engine has started Fig...

Page 33: ...n events of emergency during opera tion do not use as service brake Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated actuate Press the button completely down it automatically locks in fully pressed position unlock Turn the button clockwise and let it go to drive return the travel lever first to neutral position then start the engi...

Page 34: ...sition Right stage 1 4 seconds on 32 seconds pause n Push button for warning horn n Rotary switch for flashing beaconOptional equipment Position Left Flashing beacon off Position Right Flashing beacon on n Push button for vibration press to switch the vibration on press again to switch the vibration off n Travel lever Fig 29 Fig 30 Fig 31 Fig 32 Indicators and control elements Description BW 900 5...

Page 35: ...for driving and vibration Position MIN idle speed position NOTICE Always drive and vibrate with max engine speed Control the travel speed with the travel lever n Parking brake lever 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 Fig 33 Fig 34 Fig 35 Indicators and co...

Page 36: ...rking 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 25A F 00 n Water level gauge Fig 36 Fig 37 Indicators and control elements Description 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 37: ...5 Operation Operation BW 900 50 37 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 38: ...ine and exhaust system for leaks Belt drive for damage Function of steering Function of parking brake Function of emergency stop Machine for cleanliness and for damage Presence of the appropriate operating and maintenance instructions Proper maintenance of the machine For a description of the following tasks refer to the chapter maintenance every 10 operating hours Engine oil level top up if neces...

Page 39: ...d with the function of the different control elements on the machine Fasten your seat belt Ä Fig 38 Close the choke Ä Fig 39 Always close the choke if the engine is cold or has cooled down Always open the choke if the engine is warm Check whether travel lever Ä Fig 40 is in neutral position Fig 38 Fig 39 Fig 40 Operation Starting the engine BW 900 50 39 G o t o D i s c o u n t E q u i p m e n t c ...

Page 40: ...uption and pause for a minute between starting attempts If the engine has not started after two attempts determine the cause Turn the ignition key Ä Fig 44 to position II the starter will crank the engine As soon as the engine ignites return the ignition key to posi tion I Fig 41 Fig 42 Fig 43 Fig 44 Operation Starting the engine BW 900 50 40 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 41: ...e engine warm for a short while before starting work Do not rev up a cold engine to high idle speed full load speed Fig 45 Operation Starting the engine 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 42: ...ve without wearing your seat belt Always give way to loaded transport vehicles Before starting to drive make sure that the drive range is absolutely safe Drive and operate the machine only from the driv er s seat Set the throttle lever Ä Fig 46 to position MAX NOTICE During operation the throttle lever always remains in MAX position Control the travel speed with the travel lever Release the parkin...

Page 43: ...o the desired travel direction Position 0 Neutral position service brake the machine is automatically braked by the hydrostatic drive Position I Forward travel without vibration Position II Reverse travel without vibration Position III Max forward reverse travel with vibra tion Fig 48 Operation Driving the machine BW 900 50 43 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 44: ...hift the travel lever Ä Fig 49 slowly to 0 position Pull up the hand brake lever Ä Fig 50 Fig 49 Fig 50 Operation Stopping the machine operating the parking brake 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 45: ...ll of a sudden from full load speed but let it idle for about 2 minutes Turn the starter switch Ä Fig 54 to position 0 or P and pull out the ignition key WARNING Danger of accident Secure the machine against unauthorized use pull the ignition key out Fig 51 Fig 52 Fig 53 Fig 54 Operation Shutting down the engine BW 900 50 45 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 46: ...throttle lever always remains in MAX position Control the travel speed with the travel lever Switch the vibration on only at maximum engine speed Vibration at standstill causes transverse ruts therefore switch the vibration on only after shifting the travel lever to the desired travel direction Switch the vibration off before stopping the machine Set the throttle lever Ä Fig 55 to position MAX Swi...

Page 47: ...ction to position III Actuate the vibration push button 12 Actuate the vibration push button 12 again Fig 56 Switching off vibration Operation Switching the vibration on and off BW 900 50 47 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: ...the desired sprinkling interval Position Left stage 6 permanent sprinkling when pressure sprinkling is switched on Stage 5 1 Sprinkling intervals of 32 24 16 8 and 4 seconds Activation time always 4 seconds Fig 57 Fig 58 Operation Switching the pressure sprinkling system on and off BW 900 50 48 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 49: ...r the unbraked towed load Use a tow bar Using the machine as towing vehicle is not per mitted Attach the drawbar to the front or rear towing hitch 1 Ä Fig 59 Release the parking brake Ä Fig 60 NOTICE Tow the machine only after having released the parking brake Towing speed 1 km h max towing distance 500 m Fig 59 Fig 60 Fig 61 Operation Towing 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 ...

Page 50: ...awbar secure the machine against unintended rolling by using appropriate means e g metal wheel chocks or apply the parking brake After towing Operation Towing BW 900 50 50 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: ...e down so that it is secured against rolling sliding and turning over Secure the machine with the articulation lock after driving it on the transport vehicle After transport release the articulation lock again and store it in the receptacle The machine must not swing about when being lifted Do not step or stand under suspended loads During demonstration do not remain in the travel range of the mac...

Page 52: ... 64 to lift the machine After transport release the articulation lock Ä Fig 65 again and swing it back into the holding bracket Fold down for transport Fig 63 Loading Fig 64 After transport Fig 65 Foldable ROPSOptional equipment Operation Loading and transport 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 53: ...screws tightened with the cor rect tightening torque Adjust the clamping plates on both sides vertically Ä Fig 67 Fold up the foldable ROPS Ä Fig 68 Turn the clamping plates to horizontal position and tighten the eye bolts with a tightening torque of 37 44 lbf ft 50 60 Nm Fig 66 Fig 67 Fig 68 Operation Loading and transport 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...

Page 54: ...6 Maintenance Maintenance 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 55: ...nance work catch all oils and fuels and do not let them seep into the ground or into the sewage system Dispose of oils and fuels envi ronmentally Keep used filters in a separate waste container and dispose of environmentally Catch biodegradable oils separately The lifetime of the engine mainly depends on the purity of the fuel Keep fuel free of contaminants and water since this will damage the inj...

Page 56: ...zzles and pilot bores thereby making expensive repairs inevitable If during the daily inspection of the oil level the hydraulic oil level is found to have dropped check all lines hoses and components for leaks Seal leaks immediately If necessary inform the responsible customer service We recommend to use our filling and filtering unit with fine filter to fill the system This ensures finest filtrat...

Page 57: ...er 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...

Page 58: ...e an EP high pressure grease lithium saponified penetration 2 acc to DIN 51502 KP 2G Lubrication grease Maintenance Fuels and lubricants 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 59: ...5 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 M...

Page 60: ...ed to the oil consumption will drop to the normal level after approx 100 to 250 operating hours Maintenance after 20 operating hours Change engine oil and filter Check the engine for leaks Retighten the fastening screws on air filter exhaust and other attachments Check screw connections on the machine retighten as nec essary Maintenance Running in instructions BW 900 50 61 G o t o D i s c o u n t ...

Page 61: ...ecessary 69 6 7 3 Changing engine oil and oil filter 71 6 7 4 Lubricating the rear drum bearings 72 Every 250 operating hours 6 8 1 Change the fuel pre filter 73 6 8 2 Clean the water sprinkler system 73 6 8 3 Battery service 74 6 8 4 Checking adjusting the valve clearance 76 6 8 5 Check adjust the idle speed 77 Every 2000 operating hours 6 9 1 Changing the hydraulic oil 78 6 9 2 Change the hydrau...

Page 62: ... it until it bottoms Pull the dipstick back out The oil level must always be between the MIN and MAX marks If the oil level is too low top up oil immediately If the oil level is too high determine the cause and drain the oil off 6 6 2 Checking the fuel level NOTICE Do not drive the fuel tank dry as otherwise the fuel system needs to be bled If fuel needs to be filled up the fuel level warning lamp...

Page 63: ...funnel with screen Monitor the entire refuelling process For quality and quantity of fuel refer to the table of fuels and lubricants ENVIRONMENT Catch running out fuel do not let it seep into the ground Shut down the engine Open the fuel filler cap Ä Fig 72 Clean the area around the filler opening Open the cover Fill in fuel Screw the cover back on again Close the tank lock Refuelling Fig 72 Maint...

Page 64: ... the hydraulic oil level should reach approx the middle of the inspection glass If the oil level is too low top up hydraulic oil immediately 6 6 4 Checking the hydraulic oil filter element NOTICE If the hydraulic oil is very cold the pin may pop up you should therefore only check the filter and press the pin in at operating temperature Check the contamination indicator Ä Fig 74 at operating temper...

Page 65: ...free Check the water tank filling level on the water level gauge Ä Fig 75 Open the cover Ä Fig 76 and fill in water Close the cover again 6 6 6 Cleaning the scrapers Fold the scrapers up and clean them Ä Fig 77 This is of particular importance before compacting asphalt surfaces Fig 75 Fig 76 Fig 77 Maintenance Every 10 operating hours BW 900 50 66 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 ...

Page 66: ...CE Dirt in the cooling air intake openings reduces the cooling effect Clean the cooling air intake openings Ä Fig 78 Fig 78 Maintenance Every 10 operating hours BW 900 50 67 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 67: ...2 years Incorrectly handled filter cartridges may become ineffective because of damage e g cracks and cause damage to the engine Unscrew the air filter cover locking nut 1 Ä Fig 79 and remove the cover 2 Unscrew the wing nut 3 Take out the paper 4 and foam rubber inserts 6 Separate the foasm rubber element from the paper filter insert Check both filter elements and replace if damaged Clean out the...

Page 68: ...ning in the foam rubber element is too high the engine will develop smoke during starting Place the foam rubber element 6 Ä Fig 82 on the paper element 4 Reinstall the assembled air filter Make sure that the seal 5 under the air filter is present Tighten the wing nut 3 Tighten the screw 3 Attach the filter cover 2 to the air filter housing and secure it with the air filter cover lockl 1 6 7 2 Clea...

Page 69: ...heat value Recommended spark plug ZFR5F NGK Check the electrode gap with a feeler gauge if necessary adjust the gap to0 03 0 032 in 0 7 0 8 mm Turn the spark plug carefully in by hand Tighten the spark plug with a spark plug spanner until it is correctly seated Tighten a new spark plug for another 1 2 turn Tighten used spark plugs by another 1 8 to 1 4 turn NOTICE A loose spark plug can overheat a...

Page 70: ... Place the drain hose Ä Fig 85 into the collecting container and open the drain plug Catch running out oil Turn the oil drain plug back in with a new seal ring Unscrew the filter cartridge 1 Ä Fig 86 using an appro priate tool 2 Clean the sealing face on the filter carrier 3 from any dirt Slightly oil the rubber seal 4 on the new filter cartridge Turn the new filter cartridge on by hand until the ...

Page 71: ...rear drum bearings NOTICE For quality of grease refer to the table of fuels and lubricants Clean the grease nipple of the bearing on the rear drum Ä Fig 88 Lubricate the grease nipple with a grease gun until grease starts to run out of the bearing Fig 87 Fig 88 Maintenance Every 125 operating hours BW 900 50 72 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 72: ...precleaners environmen tally Loosen the hose clamps Ä Fig 89 Pull the fuel filter out of the top and bottom hoses Install the new fuel filter by observing the flow direction Retighten the hose clamps 6 8 2 Clean the water sprinkler system If there is a risk of frost observe the special service instructions under sprinkler system maintenance in case of frost Drain the water tank Fig 89 Maintenance ...

Page 73: ...ry service WARNING Danger of cauterisation Danger of explosion When working on the battery do not use open fire do not smoke The battery contains acid Do not let acid come in contact with skin or clothes Wear protective clothing Do not lay any tools on the battery For recharging remove the plugs from the battery to avoid the accumulation of highly explosive gases ENVIRONMENT Dispose of the old bat...

Page 74: ...k charging The open circuit voltage of the battery occurs approx 10 hours after the last charging process or one hour after the last discharge After each charging process allow the battery to rest for one hour before taking it into service For 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 E...

Page 75: ... Pull off spark plug socket 3 Turn the flywheel 1 Ä Fig 94 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 A feeler gauge of appropriate thickness Ä Fig 95 must fit with little resistance between rocker arm and valve If the gap is too narrow or too wide for the feeler gauge the valve must be ...

Page 76: ...he engine for leaks 6 8 5 Check adjust the idle speed NOTICE We recommend to have this work 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 Run the engine to warm it up to operating temperature Adjust the engine idling speed with the setscrew 1 Ä Fig 97 Fig 96 Fig 97 Maintenance Every 250 operating hour...

Page 77: ... area round hydraulic oil tank filler opening and breather filter Do not start the engine after draining the hydraulic oil Do not use any detergents 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 m...

Page 78: ...ystem Fill in new hydraulic oil Check the hydraulic oil level in the inspection glass Ä Fig 100 NOTICE The breather filter for the hydraulic oil tank is inte grated in the filler cap you must therefore replace the complete filler cap Close the tank with a new cover Perform a test run and check the system for leaks 6 9 2 Change the hydraulic oil filter WARNING Danger of scalding Danger of scalding ...

Page 79: ...ent must also be changed after major repairs in the hydraulic system ENVIRONMENT Catch running out oil dispose of oil and filter ele ment environmentally Remove filter bowl 4 Ä Fig 101 with filter element 3 Examine the surface of the filter element thoroughly for any visible dirt Take out the old filter element and clean filter bowl and thread Reassemble the filter bowl with a new filter element a...

Page 80: ...must be closed with clean cloths on both ends to make sure that no dirt will enter into the fuel system Dirt particles can destroy the injection pump Check the condition and tight fit of all fuel lines 1 Ä Fig 102 and hose clamps Replace damaged parts immediately with original spare parts Fig 102 Maintenance Every 2000 operating hours 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 ...

Page 81: ...ill 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 that comply with the specification MIL L 21260 B or TL 9150 037 2 resp Nato Code C 640 642 If the engine is to be shut down for a longer period of time...

Page 82: ...w both spark plugs and spray anti corrosion oil through the spark plug openings Crank the engine several times and install the spark plugs again Close air intake on air filter and exhaust opening tightly Maintenance As required 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 83: ...7 Troubleshooting Troubleshooting 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 84: ...refore thoroughly read these instructions on correct operation and maintenance If you cannot locate the cause of a fault or rectify it yourself by fol lowing the trouble shooting chart you should contact our customer service department Troubleshooting Preliminary remarks 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 85: ...sis ground as far away from the battery as possible 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 Once the engine is running switch on a powerful consumer working light etc After starting disconnect the nega...

Page 86: ...ized causing the starter to turn too slow Clean the pole clamps tighten and cover them with acid free grease Especially in winter use of too viscous engine oil Use an engine oil complying with the ambient temperatures 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 v...

Page 87: ...e shut down immediately Cooling air inlets heavily soiled Clean the cooling air inlets Air filter dirty Clean air filter change if necessary Troubleshooting Engine problems 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 88: ...8 Disposal Disposal BW 900 50 91 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 89: ...p into the ground and dispose of in compliance with legal regulations Remove the battery and dispose off according to legal regu lations Empty the fuel tank Drain the hydraulic oil tank Drain the lubrication oil from the engine WARNING Danger of explosion Parts that previously contained combustible fluids must not be cut with a cutting torch Disposal Final shut down of machine BW 900 50 92 G o t o...

Page 90: ...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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