Fayat Bomag BW 900-50 Service Manual
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Fayat Bomag BW 900-50 Service Manual

Tandem vibratory roller
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Service Manual
BW 900-50
S-834-0013
S/N 101 834 51 1001> / S/N 861 834 07 2170>
Tandem vibratory roller
www.discount-equipment.com
008 403 18 EN
© 07/2019

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  • Page 1 Service Manual BW 900-50 S-834-0013 S/N 101 834 51 1001> / S/N 861 834 07 2170> Tandem vibratory roller www.discount-equipment.com 008 403 18 EN © 07/2019...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Table Of Contents

    Table of contents Table of contents General information..........................7 1.1 Introduction........................... 8 1.2 Safety regulations........................10 1.2.1 Signage............................18 1.3 Maintenance and repair......................24 1.3.1 Notes on repair........................... 24 1.3.2 General notes on maintenance ....................38 Technical data............................41 2.1 Technical data..........................42 2.2 Additional technical data......................
  • Page 4 Table of contents 5.3.1 Travel pump, PMVO 13S......................107 5.3.2 Travel motor TG405......................... 110 5.3.3 Steering valve........................... 112 5.4 Description of hydraulic circuits..................... 114 5.4.1 Travel circuit..........................114 5.4.2 Vibration circuit......................... 116 5.4.3 Steering circuit.......................... 118 5.5 Tests and adjustments......................121 5.5.1 Checking the rotation speeds....................
  • Page 5 Table of contents 7.3.3 Starting the engine with jump leads..................211 7.4 Trouble shooting, hydraulics....................212 7.4.1 Preliminary remarks......................... 212 7.4.2 Insufficient hydraulic power...................... 213 7.4.3 Troubleshooting axial piston pumps..................216 7.5 Trouble shooting, diesel engine....................219 7.5.1 Starting the engine with jump leads..................219 7.5.2 Engine problems ........................

  • Page 6: General Information

    General information General information BW 900-50...
  • Page 7 General information – Introduction 1.1 Introduction..............8 1.2 Safety regulations............. 10 1.2.1 Signage..............18 1.3 Maintenance and repair..........24 1.3.1 Notes on repair............24 1.3.2 General notes on maintenance ....... 38 1.1 Introduction General This manual: addresses the BOMAG Customer Service and professionally trained personnel.
  • Page 8 General information – Introduction Maintenance/parts service Specialist teams are available for you in Germany, Europe and overseas. This tight network ensures close customer contact all over the world. Parts for maintenance, service and repair are available from our branch offices and dealers at very short notice. BOMAG guarantees long-term availability of all common parts.

  • Page 9: Safety Regulations

    General information – Safety regulations 1.2 Safety regulations General This BOMAG machine has been built in compliance with the latest technical standard and complies with the applicable regulations and technical rules. However, dangers for persons and property may arise from this machine, if: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel, it is changed or converted in an unprofessional way,...
  • Page 10 General information – Safety regulations starting and operation of the machine in explosive environments and in underground mining is prohibited. Remaining dangers, remaining Despite careful work and compliance with standards and regula- risks tions it cannot be ruled out that further dangers may arise when working with and handling the machine.
  • Page 11 General information – Safety regulations Safety installations and switches must neither be removed nor must they be made ineffective. Notes on safety in the operating and maintenance instructions WARNING! Paragraphs marked like this highlight possible dan- gers for persons. NOTICE! Paragraphs marked like this highlight possible dan- gers for machines or parts of the machine.
  • Page 12 General information – Safety regulations Use a tow bar (tobe provided by the operating company). Use a towing vehicle with sufficient traction and braking power for the unbraked towed load. The machine cannot be steered. Tow the machine only after having released the parking brake. Max.
  • Page 13 General information – Safety regulations the seat is correctly adjusted mirrors (if present) are clean and correctly adjusted. Do not start the machine with defective gauges, control lights or control elements. Do not take any loose objects with you or fasten them to the machine.
  • Page 14 General information – Safety regulations Operate the machine only from the operator's seat. Do not adjust the seat while driving. Do not climb onto or off the machine while driving. Change the travel direction only while the machine is standing. Do not use the machine to transport persons.
  • Page 15 General information – Safety regulations Apply appropriate measures (e.g. with metal wheel chocks, to be provided by the operating company) tp secure the machine against rolling away. Refuelling Do not inhale any fuel fumes. Refuel only with the engine shut down. Do not refuel in closed rooms.
  • Page 16 General information – Safety regulations Always catch and dispose of hydraulic oils separately. Do not start the engine after draining the hydraulic oil. Once all work is completed (with the system still depressurized!) check all connections and fittings for leaks. Changing hydraulic hoses Hydraulic hoses must be visually inspected at regular intervals.

  • Page 17: Signage

    General information – Safety regulations Metal objects (e.g. tools, rings, watch straps) must not come in contact with the battery poles – danger of short circuit and burning! When recharging serviceable batteries remove all plugs, to avoid the accumulation of explosive gases. Observe the applicable instructions when starting with an auxiliary battery.
  • Page 18 General information – Safety regulations GASOLINE BENZIN 008 330 05 Hydraulic Oil The engine exhaust of this product contains chemicals known to the state of California to cause cancer, birth defects or other productive harm. B-834-0013 Fig. 1 BW 900-50...
  • Page 19 General information – Safety regulations Warning sticker - Danger of being pulled in by cooling fan, and hot surface Follow operating instructions B-DEC-0197 Fig. 2 Warning sticker - Danger of crushing Fig. 3 Warning sticker - Warning of engine exhaust gases The engine exhaust of this product contains chemicals known to the state of California to cause cancer, birth...
  • Page 20 General information – Safety regulations Instruction sticker - Always wear your seat belt Fig. 6 Information sticker - Lashing point Fig. 7 Information sticker - Filler opening for hydraulic oil Hydraulic Oil B-DEC-0214 Fig. 8 Information sticker - Engine oil drain B-DEC-0211 Fig.
  • Page 21 General information – Safety regulations Information sticker - Lifting point Fig. 10 Information sticker - Choke control B-DEC-0295 Fig. 11 Information sticker - Travel lever control B-DEC-0296 Fig. 12 Operation sticker - Throttle lever Fig. 13 BW 900-50...
  • Page 22 General information – Safety regulations Information sticker - Lubrication nipple B-DEC-0297 Fig. 14 Information sticker - Gasoline GASOLINE BENZIN B-DEC-0298 Fig. 15 Information sticker - Travel lever control B-DEC-0299 Fig. 16 BW 900-50...

  • Page 23: Maintenance And Repair

    General information – Maintenance and repair 1.3 Maintenance and repair 1.3.1 Notes on repair............24 1.3.2 General notes on maintenance ....... 38 1.3.1 Notes on repair 1.3.1.1 General repair instructions NOTICE! Ensure strict cleanliness when performing repair work! – No foreign objects should enter into open sys- tems.
  • Page 24 General information – Maintenance and repair When removing a battery always disconnect the minus pole before the plus pole. When installing the battery connect the minus pole after the plus pole to avoid short circuits. Assemble the battery terminal clamps without force. Always keep battery poles and terminal clams clean to avoid high transition resistances when starting and the related devel- opment of heat.
  • Page 25 General information – Maintenance and repair When replacing the starter the ring gear on the engine flywheel must be checked for damage and its number of teeth - if nec- essary replace the ring gear. Always disconnect the battery before starting assembly work in the starter area of the engine or on the starter itself.
  • Page 26 General information – Maintenance and repair Before commissioning Fill the housings of hydraulic pumps and motors with hydraulic oil. Use only hydraulic oils according to the specification in the maintenance instructions. After changing a component flush the hydraulic system as described in the flushing instructions.
  • Page 27 General information – Maintenance and repair Assembly of radial seals Lubricate sealing lips (2) with clean grease; in case of double seals fill the space between the sealing lips with a generous amount of grease. Slide the seal over the shaft, with the lip facing towards the fluid to be sealed.
  • Page 28 General information – Maintenance and repair 1.3.1.1.4 Repair notes for ball and roller bearings If one bearing of a pair of bearings shows defects, we highly recommend the replacement of both bearings. Remove any lubricant residues from the bearing to be exam- ined by washing it with a suitable degreasing agent.
  • Page 29 General information – Maintenance and repair 1.3.1.1.6 Repair notes for cotter pins Cotter pins In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly. Cotter pins must be assembled as shown in the illustration, unless specified differently.
  • Page 30 General information – Maintenance and repair Example: A screw is marked with 12.9. Fig. 23: Identification of screws Strength classes of metric nuts Nuts are differentiated by three load groups. Each load group has a special designation system for the strength class assigned, so that the load group can be clearly identified.
  • Page 31 General information – Maintenance and repair Nut height below 0,5 d (d = nominal dimension). Identification in clock system For small nuts Ä Fig. 25 the clock system can be used for identifi- cation. The 12 o'clock position is identified by a dot or the manufactur- er's symbol.
  • Page 32 General information – Maintenance and repair Tightening torques for screws with metric unified thread Tightening torques Nm (Coefficient of friction µ tot. = 0.14) Screw dimension 10.9 12.9 1000 1200 1050 1480 1774 1420 2010 2400 Tightening torques for screws with metric unified fine thread Tightening torques Nm (Coefficient of friction µ...
  • Page 33 General information – Maintenance and repair Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste) Tightening torques Nm Screw dimension 10.9 12.9 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 1036 1184 1520...
  • Page 34 General information – Maintenance and repair Tightening torques for screws with UNC thread, UNC Unified Coarse Thread Series, American Unified Coarse Thread Tightening torques Nm (Coefficient of friction µ tot. = 0.14) Screw dimension 10.9 12.9 ² - 20 ² - 18 ²...
  • Page 35 General information – Maintenance and repair Tightening torques Nm (Coefficient of friction µ tot. = 0.14) Screw dimension 10.9 12.9 ² - 12 1350 1900 2300 ² - 12 1900 2700 3200 ² - 12 2600 3700 4400 ² - 12 3300 4600 5600...
  • Page 36 General information – Maintenance and repair Tightening torques for hydraulic fittings with metric thread - series “L” (pressures up to 250 bar) Thread Spanner width Tightening torque [Nm] M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M26 x 1.5 M30 x 2...

  • Page 37: General Notes On Maintenance

    General information – Maintenance and repair Thread Spanner width Tightening torque [Nm] ² - 12 ² - 12 ² - 12 ² - 12 1.3.2 General notes on maintenance When performing maintenance work always comply with the appro- priate safety regulations. Thorough maintenance of the machine guarantees far longer safe functioning of the machine and prolongs the lifetime of important components.
  • Page 38 General information – Maintenance and repair Keep used filters in a separate waste container and dispose of environmentally. The fuel drum must rest for a longer period of time before drawing off fuel. Under no circumstances must the drum be rolled to the tap- ping point just before drawing out fuel.

  • Page 39: Technical Data

    Technical data Technical data BW 900-50...

  • Page 40: Technical Data

    Technical data – Technical data 2.1 Technical data............42 2.2 Additional technical data......... 45 2.3 Terms and basis of calculation........ 47 2.4 Fuels and lubricants..........48 2.5 Table of fuels and lubricants........50 2.1 Technical data Dimensions Fig. 27 1223 1727 2290 1967...
  • Page 41 Technical data – Technical data Weights Max. operating weight 1200 (2646) (lbs) Operating weight (CECE) 1600 (3527) (lbs) Average static linear load (CECE) kg/cm (37.5) (pli) Travel characteristics 0 - 8.7 Travel speed km/h (0 - 5.4) (mph) 0 - 4 Working speed with vibration km/h (0 - 2.5)
  • Page 42 Technical data – Technical data Steering Steering angle +/- 33 ° Oscillation angle +/- 6 ° Inner track radius 1647 (65) (in) Exciter system Vibrating drum front Drive system hydrostatic Frequency (4200) (vpm) Amplitude 0.50 (0.020) (in) Centrifugal force (3372) (lbf) Water sprinkler system Type of sprinkling...

  • Page 43: Additional Technical Data

    Technical data – Additional technical data 2.2 Additional technical data Additional engine data Engine type Four-stroke two-cylinder engine with suspended valves Valve clearance intake 0.0031 in ± 0.0079 in (0.08 ± 0.02 mm) Valve clearance exhaust 0.0039 in ± 0.0079 in (0.10 ± 0.02 mm) Spark plug electrode gap 0.7 to 0.8 Low idle speed...
  • Page 44 Technical data – Additional technical data Type OSPM 80 ON Manufacturer Sauer-Danfoss System Rotary spool valve BW 900-50...

  • Page 45: Terms And Basis Of Calculation

    Technical data – Terms and basis of calculation 2.3 Terms and basis of calculation The following terms and basis of calculation serve as a quick guide to help you understand the technical data provided: Seq. no. Term Units EXPLANATION Dimensions All dimensions given in mm Axle load Specification of the static weight in (kg) affecting each axle...

  • Page 46: Fuels And Lubricants

    Technical data – Fuels and lubricants 2.4 Fuels and lubricants Engine oil Quality The oil is an essential factor for the performance and lifetime of the engine. Use engine oil for four-stroke engines which meets or even exceeds the requirements for API-service class SJ or higher (or equivalent).
  • Page 47 Technical data – Fuels and lubricants Lubrication grease For lubrication purposes use an EP-high pressure grease, lithium saponified (penetration 2), acc. to DIN 51502 KP 2G. BW 900-50...

  • Page 48: Table Of Fuels And Lubricants

    Technical data – Table of fuels and lubricants 2.5 Table of fuels and lubricants Assembly Fuel or lubricant Quantity Summer Winter Attention Observe the level marks motor - Engine oil Engine oil API SJ or higher approx. 0.5 gal (approx. 1.9 l) SAE 5W-30 (-4 °F to +86 °F) (-20 °C to +30 °C)

  • Page 49: Overview Of Machine

    Overview of machine Overview of machine BW 900-50...

  • Page 50: General Information

    Overview of machine – General information 3.1 General information..........52 3.2 Electric systems............53 3.3 Hydraulic system............55 3.4 Machine assemblies..........56 3.4.1 Engine..............56 3.4.2 Oscillating articulated joint........57 3.4.3 Drums..............59 3.1 General information 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.

  • Page 51: Electric Systems

    Overview of machine – Electric systems 3.2 Electric systems S-834-0012 Fig. 30 Battery (G01) and fuse for charge regulator (F148) BW 900-50...
  • Page 52 Overview of machine – Electric systems Charge regulator (A61) Spark plug, right (A62) Starter (M01) Vibration valve (Y22) Spark plug, left (A63) Starter switch (S00) Operating console Push button for vibration (S13) 10 Flashing beacon (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)

  • Page 53: Hydraulic System

    Overview of machine – Hydraulic system 3.3 Hydraulic system S-834-0009 Fig. 31 Hydraulic oil tank Vibration valve (Y22) Pump unit, travel pump with steering / charge / vibration pump Steering valve Rear drum drive motor Steering cylinder Charge circuit filter Front drum drive motor Vibration motor BW 900-50...

  • Page 54: Machine Assemblies

    Overview of machine – Machine assemblies 3.4 Machine assemblies 3.4.1 Engine..............56 3.4.2 Oscillating articulated joint........57 3.4.3 Drums..............59 3.4.1 Engine S-834-0014 Fig. 32 Charge regulator (A61) Engine Exhaust system Oil drain hose BW 900-50...

  • Page 55: Oscillating Articulated Joint

    Overview of machine – Machine assemblies 3.4.2 Oscillating articulated joint Fig. 33 Housing Bearing block, top Bearing block, bottom Bearing housing Bearing journal 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.
  • Page 56 Overview of machine – Machine assemblies Oscillating articulated joints are used to establish a moveable con- nection between the rear and front frames of agricultural and con- struction equipment. The machine can be steered around the ver- tical axis by means of an articulated movement; the rear frame can oscillate on the horizontal axis.

  • Page 57: Drums

    Overview of machine – Machine assemblies 3.4.3 Drums S-834-0016 Fig. 34: Vibratory drum, front Support legs Rubber buffer Exciter shaft Travel motor Drive disc Vibration motor BW 900-50...
  • Page 58 Overview of machine – Machine assemblies S-834-0015 Fig. 35: Rear drum Support legs Brake operation BW 900-50...
  • Page 59 Overview of machine – Machine assemblies Travel motor Drive disc Parking brake BW 900-50...

  • Page 60: Electric Systems

    Electric systems Electric systems BW 900-50...

  • Page 61: Basic Principles

    Electric systems – Basic principles 4.1 Basic principles............64 4.1.1 Measuring technology..........64 4.1.2 Understanding circuit diagrams....... 69 4.1.3 Telemecanique switch..........80 4.2 Starting the engine with jump leads....... 82 4.3 Overview of electric system........83 4.3.1 Control elements............85 4.4 Central electrics............
  • Page 62 Electric systems – Basic principles Voltage tester It is used to perform simple voltage measurements. The tester con- sists of two probes. The negative measuring line is connected to ground; the positive measuring line is connected to the relevant measuring point. When voltage is applied, the corresponding LED lights up.

  • Page 63: Basic Principles

    Electric systems – Basic principles The following information should be observed when measuring resistance and continuity: The component to be measured must not be connected to the power supply during the measurement. At least one side of the component to be measured must be disconnected from the circuitry, as otherwise the measuring result may be influenced by parallel components.
  • Page 64 Electric systems – Basic principles Current measurement with the multimeter The meter is connected in series with the consumer. During the measurement the current must be able to flow through the meter, i.e. the electric circuit must be opened. Fig. 43: Measuring current Advice If the electric circuit is difficult to access and the internal resistance of the consumer is known, the voltage may also be measured at...
  • Page 65 Electric systems – Basic principles For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact. Fig. 46 Magnet tester The magnet tester is used to test solenoid valves and magnetic coils.

  • Page 66: Understanding Circuit Diagrams

    Electric systems – Basic principles 4.1.2 Understanding circuit diagrams 4.1.2.1 Circuit diagrams Circuit diagrams provide information on the logical, electrical func- tions of BOMAG machines and currently do not provide any infor- mation on how and in which order electrical components are wired together, even if some directional wiring symbols are occasionally used.
  • Page 67 Electric systems – Basic principles S-ELE-0026 Fig. 49: Cover sheet Table of contents The table of contents lists the individual functions. S-ELE-0027 Fig. 50: Table of contents Overview of structural symbols Overview of structural symbols (only if the struc- tural view is used). The overview of structural symbols represents the structure of the machine with respect to equipment, functions and installation loca- tions as a summary.
  • Page 68 Electric systems – Basic principles S-ELE-0028 Fig. 51: Overview of structural symbols +BAT Battery box +EBOX Electrics box +MOT Engine and attachment parts +SEAT Driver’s seat +FRFR Front frame +REFR Rear frame +CONV Conveyor belt +MIBO Milling box +PUMP Pump module +DRUM Drum +DPL Driver’s stand...
  • Page 69 Electric systems – Basic principles +FRFR +REFR +DRUM +PLA +CAB +ROPS +DPL +SEAT +MOT +ARC +PUMP +BAT +EBOX Function Page from Created Layout mounting locations Funktion Blatt Erstellt S-ELE-0025 Higher-level function Anlage Checked Übersicht Einbauorte Mounting location VIEW EPE 000 Geprüft Einbauort Fig.
  • Page 70 Electric systems – Basic principles S15:11/=OPT/41.0 S-ELE-0029 Fig. 53: Functional diagrams Relay cross references are used to track signals, which need to be tracked for components with outgoing contacts. A contact overview with information about the contact types of a relay and their positions in the circuit diagram is additionally attached to the bottom of each relay coil.
  • Page 71 Electric systems – Basic principles S-ELE-0030 Fig. 54: List of components An electric component is a part, assembly or device in an electrical installation. Components are marked with a combination of letters and numbers. The identification with letters follows the standard DIN - EN 61346 T1-T2.
  • Page 72 Electric systems – Basic principles Terminal strip overview Klemmleistenübersicht WAGO WAGO WAGO WAGO WAGO WAGO WAGO WAGO Mounting location Mounting location Mounting location Mounting location Einbauort Einbauort Einbauort Einbauort Device tag Device tag Device tag Device tag Page Page Page Page Path Path Path...
  • Page 73 Electric systems – Basic principles Plug overview Steckerübersicht Plug Plug Plug Plug Mounting location Mounting location Mounting location Mounting location -X0.A +EBOX -X0.C +EBOX -X1.B +EBOX -X2.A +EBOX Stecker Einbauort Stecker Einbauort Stecker Einbauort Stecker Einbauort Function text Plug, supply potential 30 Function text Plug, supply potential 30 before battery disconnect switch Function text...
  • Page 74 Electric systems – Basic principles 10 Fuse 11 Terminal strip 12 Plugs Different symbols are used to simplify the differentiation of terminal strips 11 Ä Fig. 58 and plugs (12) in a wiring diagram. Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable connection and mating plug.
  • Page 75 Electric systems – Basic principles Identification of externally supplied documentation Fig. 60: Example: Identification of externally supplied documenta- tion In industrial technology of today it is quite common to integrate externally supplied electric sub-systems into the projecting of machines. These systems may be composed of various compo- nents and wirings.
  • Page 76 Electric systems – Basic principles For example:-X0 36 and -X0 37. In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right plug symbol. 4.1.2.3 Identification of switch blocks Switches of modular design Fig.

  • Page 77: Telemecanique Switch

    Electric systems – Basic principles 4.1.3 Telemecanique switch Dismantling Fig. 63 Lift up the interlock (5). Fold down the switch block (4). Loosen the screw (1). Fig. 64: Folding down the switch block Lift up the interlock (2) and pull out the front element (3). Fig.
  • Page 78 Electric systems – Basic principles Assembly Fig. 66: Assembly Insert the front element (3) into the bore in the control panel. Clip the fastening adapter (6) onto the front element (3). Watch the marks on front element and fas- tening flange. Tighten the screw (1) with a tightening torque of 0.6 Nm.

  • Page 79: Starting The Engine With Jump Leads

    Electric systems – Starting the engine with jump leads 4.2 Starting the engine with jump leads NOTICE! A wrong connection will cause severe damage in the electric system. – Bridge the machine only with a 12 Volt auxiliary battery. Connect the plus pole of the external battery first with the plus pole of the vehicle battery using the first jump lead.

  • Page 80: Overview Of Electric System

    Electric systems – Overview of electric system 4.3 Overview of electric system S-834-0012 Fig. 70 Battery (G01) and fuse for charge regulator (F148) BW 900-50...
  • Page 81 Electric systems – Overview of electric system Charge regulator (A61) Spark plug, right (A62) Starter (M01) Vibration valve (Y22) Spark plug, left (A63) Starter switch (S00) Operating console Push button for vibration (S13) 10 Flashing beacon (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)

  • Page 82: Control Elements

    Electric systems – Overview of electric system 4.3.1 Control elements Fig. 71 [S53] Rotary switch for working lights [H08] Charge control light [P00] Operating hour meter [H38] Fuel level warning light [S05] Rotary switch for spraying system BW 900-50...
  • Page 83 Electric systems – Overview of electric system [S00] Ignition switch Choke lever [S01] Emergency stop switch [A01] Rotary switch for interval spraying 10 [S03] Push button for warning horn 11 [S38] Rotary switch for flashing beacon 12 [S13] Push button for vibration 13 Travel lever 14 Throttle lever 15 Parking brake lever...

  • Page 84: Central Electrics

    Electric systems – Central electrics 4.4 Central electrics Fig. 72 K136 Timer relay seat contact (5 sec. delayed release) Relay for start current Relay for engine oil pressure Relay for engine shut-down Relay for start current Relay for reverse alarm system Relay for spraying pump Relay for vibration Stepping relay for vibration...
  • Page 85 Electric systems – Central electrics If the operating voltage (15/54) is switched off, the output will remain dead when switching on again. BW 900-50...

  • Page 86: Fuse Assignment

    Electric systems – Fuse assignment 4.5 Fuse assignment 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.

  • Page 87: Engine Oil Pressure Monitoring

    Electric systems – Engine oil pressure monitoring 4.6 Engine oil pressure monitoring If the oil pressure drops below 0.5 bar, the engine is shut down. Fig. 75: Oil pressure switch, B06 BW 900-50...

  • Page 88: Proximity Switches, B08 And B38

    Electric systems – Proximity switches, B08 and B38 4.7 Proximity switches, B08 and B38 B08 Proximity switch for travel lever “0” position B38 Proximity switch for vibration lock Fig. 76: Proximity switches on travel lever Working principle The working principle is based on the principle of the dampened LC-oscillator.
  • Page 89 Electric systems – Proximity switches, B08 and B38 Breaking and making contacts Proximity switches are used as breaking or making contacts. Depending on the design the switching distances 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.

  • Page 90: Inspection And Maintenance Work

    Electric systems – Inspection and maintenance work 4.8 Inspection and maintenance work 4.8.1 Maintenance Table Maintenance works Page Every 250 operating hours 4.8.2.1 Battery service 4.8.2 Every 250 operating hours 4.8.2.1 Battery 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.
  • Page 91 Electric systems – Inspection and maintenance work Reference values: 12.6 V = fully charged; 12.3 V = 50% dis- charged. Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging. The open-circuit voltage of the battery occurs approx.

  • Page 92: Hydraulic System

    Hydraulic system Hydraulic system BW 900-50...
  • Page 93 Hydraulic system 5.1 Basic principles............97 5.1.1 Open and closed hydraulic circuit......97 5.1.2 Swash plate principle, pump........99 5.1.3 External gear pumps..........101 5.1.4 Outer gear motors non-reversible......103 5.2 Overview of hydraulics.......... 104 5.3 Description of hydraulic components....107 5.3.1 Travel pump, PMVO 13S........

  • Page 94: Basic Principles

    Hydraulic system – Basic principles 5.1 Basic principles 5.1.1 Open and closed hydraulic circuit Open circuit Fig. 80: Open circuit Open in this case means that the suction line of a pump (1) nor- mally is situated below the fluid level, the surface of which is in open contact with atmospheric pressure.
  • Page 95 Hydraulic system – Basic principles Closed circuit Fig. 81: Closed circuit One talks about a closed hydraulic system, when the hydraulic oil flows from the consumer (3) directly back to the pump (2). The closed circuit consists of a high and a low pressure side, depending on the load direction (take-off moment on the con- sumer).

  • Page 96: Swash Plate Principle, Pump

    Hydraulic system – Basic principles 5.1.2 Swash plate principle, pump Fig. 82 The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive shaft. The pistons are thereby supported by the swash plate. Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic pumps or hydraulic motors.
  • Page 97 Hydraulic system – Basic principles Through drive Valve plate 10 Top dead centre TDC 11 Bottom dead centre BTC 12 Control slots in suction side of swash plate (for sense of rota- tion shown) 13 Control slot on pressure side Driven by the engine, the drive shaft rotates and drives the cylinder via a splined connection.

  • Page 98: External Gear Pumps

    Hydraulic system – Basic principles 5.1.3 External gear pumps External gear pumps mainly consist of the friction bearing mounted gear pair and the housing with front and rear covers. The drive shaft, which is sealed with a radial seal, protrudes from the front cover.
  • Page 99 Hydraulic system – Basic principles Function Fig. 85 The increasing volume caused by a tooth exiting a tooth gap results in a vacuum in the suction chamber. The pressure fluid is transported into the pressure chamber. There the meshing of teeth and tooth gaps displaces the pressure fluid into the upper supply line.

  • Page 100: Outer Gear Motors Non-Reversible

    Hydraulic system – Basic principles Multiple gear pumps Gear pumps are suited for multiple pump arrangements, in which the drive shaft of pump 1 is extended to drive a second or third pump. The shafts are connected by drivers in between. The indi- vidual pump stages are sealed to each other, i.e.

  • Page 101: Overview Of Hydraulics

    Hydraulic system – Overview of hydraulics 5.2 Overview of hydraulics S-834-0009 Fig. 89 Hydraulic oil tank Vibration valve (Y22) Pump unit, travel pump with steering / charge / vibration pump Steering valve Rear drum drive motor Steering cylinder Charge circuit filter Front drum drive motor Vibration motor The travel pump is directly driven by the crankshaft of the engine...
  • Page 102 Hydraulic system – Overview of hydraulics S-834-0010 Fig. 90: Pump assembly Steering / charge / vibration pump Travel pump Pump flange with flexible coupling Working port, travel pump forward Pressure test port, pressure A OUT Pressure side steering / charge / vibration pump Pressure port for charge circuit Leak oil connection S-834-0011...
  • Page 103 Hydraulic system – Overview of hydraulics Pressure test port, pressure B Pressure port for charge circuit Leak oil connection BW 900-50...

  • Page 104: Description Of Hydraulic Components

    Hydraulic system – Description of hydraulic components 5.3 Description of hydraulic components 5.3.1 Travel pump, PMVO 13S........107 5.3.2 Travel motor TG405..........110 5.3.3 Steering valve............112 5.3.1 Travel pump, PMVO 13S Axial piston variable displacement pump PMVO 13S1M Control, mechanical The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow.
  • Page 105 Hydraulic system – Description of hydraulic components Fig. 92 Designation Designation Drive shaft Piston Retracting plate Slipper pad Charge pressure relief valve Slipping disc Cylinder Swashing shaft Valve plate BW 900-50...
  • Page 106 Hydraulic system – Description of hydraulic components Hydraulic diagram Fig. 93 Designation Designation mechanical control Work connection High pressure relief valves Work connection Charge pressure relief valve Motor Pressure test port, pressure A Pressure test port, pressure B Control pressure inlet Ventilation Pressure port for charge circuit BW 900-50...

  • Page 107: Travel Motor Tg405

    Hydraulic system – Description of hydraulic components Designation Designation Leak oil Leak oil Port for control pressures, pressure in front of nozzle High pressure relief and charge High pressure relief valves with integrated boost check valves pressure valve Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safeguarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and relieve oil into the low pressure side.
  • Page 108 Hydraulic system – Description of hydraulic components Fig. 94 The drive sets of the hydraulic motors consist of a housing section with internal gearing and a gear wheel, the centre of which during rotation orbits around the centre of the ring gear. BW 900-50...

  • Page 109: Steering Valve

    Hydraulic system – Description of hydraulic components Notes on repair Fig. 95 1) 61 to 75 Nm tightening torque alternately on 7 screws. 2) Insert commutator completely with new seal. The flat side of the seal faces towards the outside. 3) Before assembling the drive shaft thoroughly grease the space between the dashed lines.
  • Page 110 Hydraulic system – Description of hydraulic components When the steering wheel is operated, the steering unit measures the exact oil quantity proportional to the rotation of the steering wheel. This oil quantity is directed to the steering cylinders. The steering unit mainly consists of a rotary spool valve and a metering pump (gear set).

  • Page 111: Description Of Hydraulic Circuits

    Hydraulic system – Description of hydraulic circuits 5.4 Description of hydraulic circuits 5.4.1 Travel circuit............114 5.4.2 Vibration circuit............116 5.4.3 Steering circuit............118 5.4.1 Travel circuit The travel circuit is a closed hydraulic circuit, it consists mainly of the travel pump PMVO13S with the integrated safety elements, the travel motors and the check valve.
  • Page 112 Hydraulic system – Description of hydraulic circuits S-834-0003 Fig. 98 Vibration valve (Y22) with pressure test port Hydraulic oil tank Steering valve Check valve, 1 bar Travel pump BW 900-50...

  • Page 113: Vibration Circuit

    Hydraulic system – Description of hydraulic circuits Charge oil filter with pressure test port Rear drum drive motor Front drum drive motor Steering / charge / vibration pump M Pressure test ports Brake Hydrostatic braking During travel operation the machine is braked by the closed hydraulic circuit.
  • Page 114 Hydraulic system – Description of hydraulic circuits S-834-0004 Fig. 99 Hydraulic oil tank Steering / charge / vibration pump Vibration motor Vibration valve (Y22) with pressure test port M Pressure test port Vibration drive The vibration pump delivers the hydraulic oil from the tank to the vibration valve (Y22).

  • Page 115: Steering Circuit

    Hydraulic system – Description of hydraulic circuits S-834-0005 Fig. 100 Exciter shaft Rubber buffer Vibration motor Weights 5.4.3 Steering circuit The steering circuit is an open hydraulic circuit. BW 900-50...
  • Page 116 Hydraulic system – Description of hydraulic circuits S-834-0006 Fig. 101 Vibration valve (Y22) with pressure test port Hydraulic oil tank Steering valve Check valve, 1 bar Travel pump BW 900-50...
  • Page 117 Hydraulic system – Description of hydraulic circuits Charge oil filter with pressure test port Rear drum drive motor Front drum drive motor Steering / charge / vibration pump 10 Steering cylinder 11 Pressure test port The steering pump delivers the hydraulic oil from the tank through the vibration valve to the steering orbitrol and to the steering cyl- inder.

  • Page 118: Tests And Adjustments

    Hydraulic system – Tests and adjustments 5.5 Tests and adjustments 5.5.1 Checking the rotation speeds........ 121 5.5.2 Pressure tests in the travel circuit......123 5.5.3 Adjusting the neutral positions of the travel pump. 124 5.5.4 Travel pump high pressure test......125 5.5.5 Pressure tests in the vibration circuit.....
  • Page 119 Hydraulic system – Tests and adjustments Start the engine and shift the throttle lever to max. speed position Ä Fig. 104. Fig. 104 Checking the engine speed Measure the speed, rest the measuring instrument on your thumb Ä Fig. 105. ð...

  • Page 120: Pressure Tests In The Travel Circuit

    Hydraulic system – Tests and adjustments 5.5.2 Pressure tests in the travel circuit Special tools Hydraulic test case NOTICE! Perform measurements at operating temperature of the hydraulic oil (40 °C). Block the drums with suitable chocks Ä Fig. 107. Fig. 107 Pull up the parking brake lever.

  • Page 121: Adjusting The Neutral Positions Of The Travel Pump

    Hydraulic system – Tests and adjustments Read charge and high pressure gauges. ð Nominal value Charge pressure gauge: See technical data. High pressure gauge: Both identical pres- sure (charge pressure). Evaluation of test If the nominal value is not reached, check the steering/charge pump.

  • Page 122: Travel Pump High Pressure Test

    Hydraulic system – Tests and adjustments Raise the machine Ä Fig. 110, so that both drums can turn freely. Fig. 110 Shift the travel lever to position “0” Ä Fig. 111. Fig. 111 Start the engine and run it with maximum speed. Adjust the travel control cable Ä...
  • Page 123 Hydraulic system – Tests and adjustments Block the drums with suitable chocks Ä Fig. 113. Fig. 113 Pull up the parking brake lever Ä Fig. 114. Fig. 114 Connect 600 bar pressure gauges Ä Fig. 115 to high pres- sure test ports M and M Close high pressure ports M and M...

  • Page 124: Pressure Tests In The Vibration Circuit

    Hydraulic system – Tests and adjustments NOTICE! Run the following pressure test for max. 3 seconds. Move the travel lever quickly to both travel directions Ä Fig. 116 and read the high pressure gauges. ð Nominal value approx. 320 bar Fig.

  • Page 125: Vibration Pump High Pressure Test

    Hydraulic system – Tests and adjustments Connect a 600 bar pressure gauge to the pressure test port on the vibration valve Ä Fig. 118. Start the engine and shift the throttle lever to max. speed position. Fig. 118 Switch the vibration on Ä Fig. 119. ð...
  • Page 126 Hydraulic system – Tests and adjustments Block the drums with suitable chocks Ä Fig. 120. Fig. 120 Pull up the parking brake lever. Ä Fig. 121. Fig. 121 NOTICE! Run the following pressure test for max. 3 seconds. Close the pump outlet Ä Fig. 122 with a 200 bar pressure limiting valve.

  • Page 127: Checking The Leakage Rate Of The Vibration Motor

    Hydraulic system – Tests and adjustments 5.5.7 Checking the leakage rate of the vibration motor NOTICE! Perform measurements at operating temperature of the hydraulic oil (40 °C). Drive the drum of the machine onto an elastic base (rubber buffers) Ä Fig. 123 and block the rear drum additionally with suitable chocks.

  • Page 128: Pressure Tests In The Steering Circuit

    Hydraulic system – Tests and adjustments 5.5.8 Pressure tests in the steering circuit NOTICE! Perform measurements at operating temperature of the hydraulic oil (40 °C). Pull up the parking brake lever. Ä Fig. 126. Fig. 126 Connect a 600 bar pressure gauge to the steering pressure test port Ä...
  • Page 129 Hydraulic system – Tests and adjustments Disconnect the hydraulic hoses Ä Fig. 129 from ports L and R on the steering cylinder and close them with plugs. Repeat the pressure test. Nominal value approx. 10 bar Evaluation of test If the nominal value is reached, replace the Fig.

  • Page 130: Flushing And Bleeding

    Hydraulic system – Flushing and bleeding 5.6 Flushing and bleeding 5.6.1 Flushing in general..........133 5.6.2 Flushing schematic for travel system..... 136 5.6.3 Flushing the travel system........137 5.6.4 Bleeding the travel circuit........141 5.6.1 Flushing in general NOTICE! Changing a component –...
  • Page 131 Hydraulic system – Flushing and bleeding Water in oil – Increased wear, accelerated ageing of oil. Chips (abrasion) in the oil – Open and clean all components in the oil circuit; replace if necessary. – Clean all high pressure hoses in the oil circuit; replace if necessary.
  • Page 132 Hydraulic system – Flushing and bleeding Bleeding Always bleed closed hydraulic circuits if lines had been removed or connected. Fig. 134 Servicing the flushing filter kit Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the flushing process.

  • Page 133: Flushing Schematic For Travel System

    Hydraulic system – Flushing and bleeding 5.6.2 Flushing schematic for travel system Travel pump Bulkhead fitting (tool) Elbow union (tool) Screw socket 1" - 25S (tool) Flushing hose 25S - 20S (tool) Flushing hose 25S - 20S (tool) Flushing filter with filter element 1μ (tool) BW 900-50...

  • Page 134: Flushing The Travel System

    Hydraulic system – Flushing and bleeding Hose connection, travel pump B - drum drive motor, front Front drum drive motor 10 Rear drum drive motor 5.6.3 Flushing the travel system Observe the chapter "Flushing - General" Installing the flushing filter NOTICE! Before the installation of the filters check hoses and connections for cleanliness.
  • Page 135 Hydraulic system – Flushing and bleeding Bleeding the travel circuit Bleeding the travel circuit, see chapter "Bleeding the travel circuit". Fig. 137 Flushing the hoses Block the drums with suitable chocks. Fig. 138 Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.
  • Page 136 Hydraulic system – Flushing and bleeding Reconnect the high pressure hoses to the drum drive motors. Flushing the drum drive motor WARNING! Danger of accident! The drums must be able to rotate freely. Jack or lift up the machine. Fig. 141 Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.
  • Page 137 Hydraulic system – Flushing and bleeding Bleeding the travel circuit Bleeding the travel circuit, see chapter "Bleeding the travel circuit". Fig. 144 Circulating the tank content After completing the bleeding process circulate the tank con- tent with the filling and filtering unit for another 15 minutes. Fig.

  • Page 138: Bleeding The Travel Circuit

    Hydraulic system – Flushing and bleeding 5.6.4 Bleeding the travel circuit Secure the drums with chocks. Fig. 147 Actuate the emergency stop switch. ð WARNING! The engine must not start. Fig. 148 Install a pressure test hose to the charge pressure test port. Install a pressure test hose each to the high pressure test ports.
  • Page 139 Hydraulic system – Flushing and bleeding Connect a 60 bar pressure gauge Ä Fig. 151 to the charge pressure test port and run the engine max. 15 seconds at idle speed. Wait for approx. 30 seconds and keep repeating this proce- dure until the gauge shows a constant charge pressure reading.

  • Page 140: Inspection And Maintenance Work

    Hydraulic system – Inspection and maintenance work 5.7 Inspection and maintenance work 5.7.1 Maintenance Table Maintenance works Page Checks prior to start up 5.7.2.1 Checking the hydraulic oil level 5.7.2.2 Checking the hydraulic oil filter element Every 2000 operating hours 5.7.3.1 Changing the hydraulic oil 5.7.3.2...

  • Page 141: Every 2000 Operating Hours

    Hydraulic system – Inspection and maintenance work 5.7.2.2 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...
  • Page 142 Hydraulic system – Inspection and maintenance work NOTICE! The hydraulic oil must also be changed after major repairs in the hydraulic system. Perform the oil change when the hydraulic oil is warm. Replace the hydraulic oil filter elements with every hydraulic oil change.
  • Page 143 Hydraulic system – Inspection and maintenance work Unscrew the plug from the hydraulic oil tank Ä Fig. 156, drain off and collect all hydraulic oil. Turn the plug tightly back in. We recommend to use our filling and filtering unit with fine filter to fill the system.
  • Page 144 Hydraulic system – Inspection and maintenance work NOTICE! If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the oil change and after the test run. Do not use the oil in the filter bowl again. Visible dirt may be an early sign for the failure of system components and indicate the possible failure of components.

  • Page 145: Machine Assemblies

    Machine assemblies Machine assemblies BW 900-50...
  • Page 146 Machine assemblies 6.1 Engine..............151 6.1.1 Engine overview............ 151 6.1.2 Carburettor inspection........... 153 6.1.3 Inspection and maintenance work......155 6.2 Oscillating articulated joint........166 6.2.1 Repair overview for oscillating articulated joint..167 6.2.2 Removing and installing the oscillating articulated joint................ 169 6.2.3 Repairing the oscillating articulated joint....

  • Page 147: Engine

    Machine assemblies – Engine 6.1 Engine 6.1.1 Engine overview S-834-0014 Fig. 159 Charge regulator (A61) Engine Exhaust system 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.
  • Page 148 Machine assemblies – Engine The engine is equipped with an electric fuel shut- down solenoid (Y58), which interrupts the fuel supply to the main carburettor nozzle when ener- gized. 90° B201 S-834-008 Fig. 160: Engine Float switch for fuel (B201) Oil dipstick Oil filler neck Charge regulator (A61)

  • Page 149: Carburettor Inspection

    Machine assemblies – Engine Fig. 161 Valve cover Rocker arm Exhaust valve Combustion chamber Push rod Plunger Camshaft Spark plug 6.1.2 Carburettor inspection BW 900-50...
  • Page 150 Machine assemblies – Engine BW 900-50...

  • Page 151: Inspection And Maintenance Work

    Machine assemblies – Engine 6.1.3 Inspection and maintenance work 6.1.3.1 Maintenance Table Maintenance works Page Every 10 operating hours 6.1.3.2.1 Checking the engine oil level 6.1.3.2.2 Cleaning the cooling air intake openings Every 125 operating hours 6.1.3.3.1 Check, clean the air filter, replace if necessary 6.1.3.3.2 Clean, check the spark plugs, replace if necessary 6.1.3.3.3...
  • Page 152 Machine assemblies – Engine Pull the dipstick Ä Fig. 162 out, wipe it off with a lint-free, clean cloth and reinsert it until it bottoms. Pull the dipstick back out. The oil level must always be between the "MIN"- and "MAX"- marks.
  • Page 153 Machine assemblies – Engine 6.1.3.3 Every 125 operating hours 6.1.3.3.1 Check, clean the air filter, replace if necessary NOTICE! A dirty oil filter obstructs the air flow to the carbu- rettor, which then reduces the engine power. In a dusty environment you should clean the air filter every day.
  • Page 154 Machine assemblies – Engine WARNING! Eye injury! Wear safety goggles. NOTICE! Do not hold the compressed air nozzle closer to the filter than 1 in (3 cm) Fig. 166 Bang the paper filter element several times against a hard surface. Blow out the paper filter element with clean compressed air and a maximum air pressure (max.
  • Page 155 Machine assemblies – Engine NOTICE! Renew the spark plugs at the latest after 250 oper- ating hours or once every year. Pull off the spark plug socket (1) Ä Fig. 168 and clean off any dirt in the spark plug area. Unscrew the spark plug with a spark plug spanner (2).
  • Page 156 Machine assemblies – Engine 6.1.3.3.3 Changing engine oil and oil filter WARNING! Danger of scalding! When draining off hot oil. By hot oil when unscrewing the engine oil filter. NOTICE! Drain the engine oil only when the engine is warm. For quality and quantity of oil refer to the "table of fuels and lubricants".
  • Page 157 Machine assemblies – Engine Fill in new engine oil Ä Fig. 172. Screw the oil filler cover back on again. After a short test run check the oil level once again , if neces- sary top up to the top mark (Max). Fig.
  • Page 158 Machine assemblies – Engine 6.1.3.4.2 Checking, adjusting the valve clearance NOTICE! We recommend to have this work carried out by trained personnel or our after sales service. Check and adjust only when the engine is cold. Adjusting values intake valves: 0.0031 in ± 0.0079 in (0.08 ±...
  • Page 159 Machine assemblies – Engine Turn the flywheel clockwise further Ä Fig. 177, until the marks (2, 3) are in line. Check and , if necessary, adjust the valve clearance of the 2nd cylinder. After checking and adjusting reassemble the cylinder head covers with new gaskets.
  • Page 160 Machine assemblies – Engine NOTICE! If fuel lines or hose clamps are found to be dam- aged, the corresponding parts must be immedi- ately repaired or replaced. After replacing lines or hose clamps the fuel system needs to be bled. Disassembled or new fuel lines must be closed with clean cloths on both ends, to make sure that no dirt will enter into the fuel system.
  • Page 161 Machine assemblies – Engine Clean engine and cooling system: With cold cleansing agent and water jet or, even better, with steam cleaning equipment. Run the engine warm and shut it down. Drain the still warm engine oil and fill in anti-corrosion engine oil.

  • Page 162: Oscillating Articulated Joint

    Machine assemblies – Oscillating articulated joint 6.2 Oscillating articulated joint 6.2.1 Repair overview for oscillating articulated joint..167 6.2.2 Removing and installing the oscillating articulated joint................ 169 6.2.3 Repairing the oscillating articulated joint....170 Oscillating articulated joints are used to establish a moveable con- nection between the rear and front frames of agricultural and con- struction equipment.

  • Page 163: Repair Overview For Oscillating Articulated Joint

    Machine assemblies – Oscillating articulated joint 6.2.1 Repair overview for oscillating articulated joint Fig. 180 Housing Bearing block, top Bearing block, bottom Bearing housing Bearing journal 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.
  • Page 164 Machine assemblies – Oscillating articulated joint S-462-0035 Fig. 181 Bearing journal Bearing block, top Bearing block, bottom Bearing housing Tapered roller bearing Rocker bearing 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.

  • Page 165: Removing And Installing The Oscillating Articulated Joint

    Machine assemblies – Oscillating articulated joint 6.2.2 Removing and installing the oscillating articulated joint Engage the articulation lock Ä Fig. 182. Fig. 182 WARNING! Danger of accident! Block front and rear drums with wedges against rolling! Do not work in the articulation area of the roller while the engine is running.

  • Page 166: Repairing The Oscillating Articulated Joint

    Machine assemblies – Oscillating articulated joint 6.2.3 Repairing the oscillating articulated joint Dismantling the oscillating articu- lated joint Pull bearing blocks 1 Ä Fig. 186 off both sides. Fig. 186 Remove supporting discs 1 Ä Fig. 187, shims (2) and seal rings (3) from both sides.
  • Page 167 Machine assemblies – Oscillating articulated joint Hexagon nut secured with LOCTITE. Unscrew hexagon nut 1 Ä Fig. 189. Fig. 189 Pull bearing housing 1 Ä Fig. 190 off bearing journal (2). Fig. 190 Take disc 1 Ä Fig. 191 out of the bearing housing and remove O-ring (2).
  • Page 168 Machine assemblies – Oscillating articulated joint Remove outer bearing race 1 Ä Fig. 193. Fig. 193 Turn the bearing housing upside down and take out seal ring 1 Ä Fig. 194. Fig. 194 Knock the outer bearing race 1 Ä Fig. 195 out of the bearing housing.
  • Page 169 Machine assemblies – Oscillating articulated joint Assembling the oscillating articu- lated joint Press taper roller bearing 1 Ä Fig. 197 onto the bearing journal. Fig. 197 Press outer bearing race 1 Ä Fig. 198 into the bearing housing and fill to 2/3 with lithium saponified high pressure grease.
  • Page 170 Machine assemblies – Oscillating articulated joint Mount bearing housing 1 Ä Fig. 201 to bearing journal (2). Fig. 201 Knock taper roller bearing 1 Ä Fig. 202 into the bearing housing. Fig. 202 Insert Belleville springs 3 Ä Fig. 203 with the curvature pointing down.
  • Page 171 Machine assemblies – Oscillating articulated joint NOTICE! The assembly mandrel should only contact the outer race of the rocker bearing, as other- wise the bearing will be destroyed! Knock the new rocker bearings Ä Fig. 205 in until they bottom. Fig.

  • Page 172: Drum

    Machine assemblies – Drum 6.3 Drum 6.3.1 Vibratory drum, front..........176 6.3.2 Rear drum.............. 192 6.3.3 Inspection and maintenance work......200 6.3.1 Vibratory 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......

  • Page 173: Vibratory Drum, Front

    Machine assemblies – Drum 6.3.1.1 Repair overview of vibratory drum S-834-0016 Fig. 208: Vibratory drum, front Support legs Rubber buffer Exciter shaft Travel motor Drive disc Vibration motor BW 900-50...
  • Page 174 Machine assemblies – Drum S-834-0017 Fig. 209 Drum Vibration motor Rubber buffer Exciter shaft Clutch Vibration bearings Travel bearings 6.3.1.2 Removing and installing the vibratory drum Removing the vibratory drum Park the machine on level and firm ground. Always secure the machine against unintended rolling. BW 900-50...
  • Page 175 Machine assemblies – Drum Lift the front frame up Ä Fig. 210 and support it safely. Unhook the springs to relieve the scrapers (1). Unscrew the fastening screws (2) and remove the vibration motor with its flange. Fig. 210 Check coupling hub 2 Ä Fig. 211 for wear. If necessary, unscrew the hexagon nut (1) and pull off the coupling hub (2) with a puller.
  • Page 176 Machine assemblies – Drum Examine all rubber buffers 1 Ä Fig. 213 for wear, replace if necessary. Fig. 213 Adjusting the pre-load of the rubber buffers NOTICE! Install the support legs under pre-load. The preload of the rubber buffers is achieved by a gap "X"...
  • Page 177 Machine assemblies – Drum 6.3.1.3 Dismantling the vibratory drum WARNING! Secure the drum against unintended rolling. Removing the travel motor Attach the lifting tackle to support leg 2 Ä Fig. 216. Unscrew the four hexagon nuts (1). Remove support leg (2) with travel motor and drive disc from the drum.
  • Page 178 Machine assemblies – Drum Disassemble fastening screws 1 Ä Fig. 218, washers and nuts (2). Remove the travel motor (3) from the support leg (4). Disassemble the feather key (5). S-834-0027 Fig. 218 Check the rubber buffers 1 Ä Fig. 219, unscrew and replace if necessary.
  • Page 179 Machine assemblies – Drum Take off V-ring 1 Ä Fig. 221. Fig. 221 Remove circlip 1 Ä Fig. 222. Fig. 222 Press flange 1 Ä Fig. 223 off the bearing flange with forcing screws (2). Fig. 223 Knock ball bearing 1 Ä Fig. 224 out of the flange. Fig.
  • Page 180 Machine assemblies – Drum Take shim 1 Ä Fig. 225 and V-ring (2) off the bearing flange. Fig. 225 Remove coupling element 1 Ä Fig. 226. Fig. 226 Removing / dismantling the exciter shaft Unscrew fastening screws 1 Ä Fig. 227. Force the bearing flange off the drum using forcing screws (2).
  • Page 181 Machine assemblies – Drum Remove cylinder roller bearing 1 Ä Fig. 229 from the bearing flange. Fig. 229 Pull coupling hub 1 Ä Fig. 230 off the exciter shaft. Fig. 230 Pull inner bearing race 1 Ä Fig. 231 off both sides of the exciter shaft.
  • Page 182 Machine assemblies – Drum Unscrew hexagon screws 1 Ä Fig. 232. Remove the flange (2). S-834-0028 Fig. 232 Remove cylinder roller bearing 1 Ä Fig. 233 from the flange. S-834-0029 Fig. 233 6.3.1.4 Assembling the vibratory drum Assembling / installing the exciter shaft Fill approx.
  • Page 183 Machine assemblies – Drum Fill approx. 15 g of lithium saponified high pressure grease into the gap between the rolling elements and approx. 15 g into the Grease grease chamber of the flange. Fett Graise Grasa Cool the new cylinder roller bearing 1 Ä Fig. 235 down to -25°C and press it into the flange until it bottoms and fill it with high pressure grease.
  • Page 184 Machine assemblies – Drum Install coupling hub 1 Ä Fig. 238. Fig. 238 NOTICE! Danger of squashing! Insert the exciter shaft into the opposite cylinder roller bearing Ä Fig. 239. Fig. 239 Slide the bearing flange over the exciter shaft and fasten it with hexagon screws 1 Ä...
  • Page 185 Machine assemblies – Drum Measure the distance between coupling and front face once again. Subtract the second measurement from the first measurement to calculate the end float. Nominal value: min. 0.65 mm max. 1.89 mm Insert coupling element 1 Ä Fig. 242 into the coupling hub. Fig.
  • Page 186 Machine assemblies – Drum Knock flange 1 Ä Fig. 245 onto the bearing flange using a drift punch. Fig. 245 Insert circlip 1 Ä Fig. 246 into the groove in the bearing flange and check the correct fit. Fig. 246 Install the new V-ring 1 Ä...
  • Page 187 Machine assemblies – Drum Installing the travel motor Tighten rubber buffer 1 Ä Fig. 249 with a matching rubber buffer mounting bell. Tightening torque for rubber buffers: 211 Nm Fig. 249 Mount travel motor 3 Ä Fig. 250 with hexagon screws (1), washers and nuts (2) to the support leg (4).

  • Page 188: Rear Drum

    Machine assemblies – Drum Mount support leg 2 Ä Fig. 252 with travel motor and drive disc to the drum. Tightening torques for rubber buffers (1): 211 Nm S-834-0019 Fig. 252 6.3.2 Rear drum 6.3.2.1 Repair overview of rear drum......193 6.3.2.2 Removing and installing the rear drum....
  • Page 189 Machine assemblies – Drum 6.3.2.1 Repair overview of rear drum S-834-0015 Fig. 253: Rear drum Support legs BW 900-50...
  • Page 190 Machine assemblies – Drum Brake operation Travel motor Drive disc Parking brake 6.3.2.2 Removing and installing the rear drum Removing the drum Park the machine on level and firm ground. Always secure the machine against unintended rolling. Lift the rear frame up Ä Fig. 254 and support it safely. Unhook the springs to relieve the scrapers (1).
  • Page 191 Machine assemblies – Drum Starting up the machine NOTICE! Bleed the travel circuit before starting opera- tion. Check the hydraulic oil level Ä Fig. 256, top up if necessary. Perform a test drive, check function of travel system, parking brake and spraying system. Check all connections and fittings for leak tightness.
  • Page 192 Machine assemblies – Drum Removing the travel motor Attach the lifting tackle to support leg 2 Ä Fig. 258. Unscrew the four hexagon nuts (1). Remove support leg (2) with travel motor, lift the drive disc and parking brake from the drum. LOCTITE S-834-0025 Fig.
  • Page 193 Machine assemblies – Drum Unscrew hexagon nut 1 Ä Fig. 260 and pull the drive disc 407 Nm - 542 Nm (2) off the travel motor. S-834-0032 Fig. 260 Disassemble fastening screws 1 Ä Fig. 261, washers and nuts (2). Remove the travel motor (3) from the support leg (4).
  • Page 194 Machine assemblies – Drum 6.3.2.4 Assembling the rear drum Assembling the travel bearing Slide the travel bearing 1 Ä Fig. 262 onto the shaft. S-834-0024 Fig. 262 Installing the travel motor Mount travel motor 3 Ä Fig. 263 with hexagon screws (1), washers and nuts (2) to the support leg (4).
  • Page 195 Machine assemblies – Drum Mount drive disc 2 Ä Fig. 264 with fastening nuts (1) to the 407 Nm - 542 Nm travel motor (3). Tightening torque: 407 to 542 Nm S-834-0032 Fig. 264 Mount parking brake 1 Ä Fig. 264 with screws (2) and washers to the support leg.

  • Page 196: Inspection And Maintenance Work

    Machine assemblies – Drum Mount support leg 2 Ä Fig. 266 with travel motor, drive disc and parking brake to the drum. Tightening torques for hexagon screws (1): 270 Nm ð Insert the hexagon screws (1) with LOCTITE 243. LOCTITE S-834-0025 Fig.
  • Page 197 Machine assemblies – Drum 6.3.3.3 Every 125 operating hours 6.3.3.3.1 Lubricating the 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. 268. Lubricate the grease nipple with a grease gun, until grease starts to run out of the bearing.

  • Page 198: Troubleshooting

    Troubleshooting Troubleshooting BW 900-50...

  • Page 199: Preliminary Remarks

    Troubleshooting – Preliminary remarks 7.1 Preliminary remarks..........204 7.2 Emergency procedures.......... 205 7.2.1 Actuating the emergency stop switch....205 7.2.2 Towing..............205 7.3 Troubleshooting, electrical systems..... 207 7.3.1 Preliminary remarks..........207 7.3.2 Fuse assignment........... 210 7.3.3 Starting the engine with jump leads....... 211 7.4 Trouble shooting, hydraulics.........

  • Page 200: Emergency Procedures

    Troubleshooting – Emergency procedures 7.2 Emergency procedures 7.2.1 Actuating the emergency stop switch In events of emergency and in case of danger actuate the emergency stop switch immediately. ð The engine is shut down and the parking brake is closed. Fig.
  • Page 201 Troubleshooting – Emergency procedures Release the parking brake Ä Fig. 271. Fig. 271 NOTICE! Tow the machine only after having released the parking brake. Towing speed 1 km/h, max. towing distance 500 m. Fig. 272 After towing WARNING! Danger of accident! Before loosening the drawbar secure the machine against unintended rolling by using appropriate means (e.g.

  • Page 202: Troubleshooting, Electrical Systems

    Troubleshooting – Troubleshooting, electrical systems 7.3 Troubleshooting, electrical systems 7.3.1 Preliminary remarks..........207 7.3.2 Fuse assignment........... 210 7.3.3 Starting the engine with jump leads....... 211 7.3.1 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.
  • Page 203 Troubleshooting – Troubleshooting, electrical systems Do not operate the main battery switch under load. Do not use jump leads after the battery has been removed. Sensors and electric actuators on control units must never be con- nected individually or between external power sources for the pur- pose of testing, but only in connection with the control unit in ques- tion.
  • Page 204 Troubleshooting – Troubleshooting, electrical systems Measuring fault Whenever the electrical system of the vehicle behaves in an unex- pected way, one should first consider that there may be a ground problem! The older the electrical system and the lower the voltage, the more likely this will be the cause.

  • Page 205: Fuse Assignment

    Troubleshooting – Troubleshooting, electrical systems If the battery is empty If the battery is empty, the fault is normally quite quickly identified. There are the following possibilities: because it is no longer charged by the generator because one of the consumers (light, radio, etc.) has not been switched off because a hidden consumer “surreptitiously”...

  • Page 206: Starting The Engine With Jump Leads

    Troubleshooting – Troubleshooting, electrical systems 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. 274 7.3.3 Starting the engine with jump leads NOTICE! A wrong connection will cause severe damage in the electric system.

  • Page 207: Trouble Shooting, Hydraulics

    Troubleshooting – Trouble shooting, hydraulics 7.4 Trouble shooting, hydraulics 7.4.1 Preliminary remarks..........212 7.4.2 Insufficient hydraulic power........213 7.4.3 Troubleshooting axial piston pumps...... 216 7.4.1 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.

  • Page 208: Insufficient Hydraulic Power

    Troubleshooting – Trouble shooting, hydraulics Too little or no pressure – this is how a hydraulic system may stop working. There is often incorrect air in the system because there are one or more leaks. The correct viscosity of the liquid used and sufficient cooling are also important for the pressure to be correct.
  • Page 209 Troubleshooting – Trouble shooting, hydraulics Diesel engine running, travel lever position "0" Fig. 276: Charge pressure (6S) present Charge pump Variable displacement pump Hydraulic motor Charge pressure relief valve (example 30 bar) Pressure limiting valves (example 300 bar) Pressure gauge, (6S) charge pressure, (6H) high pressure Cooler (optional) Filter Connection for pump control...
  • Page 210 Troubleshooting – Trouble shooting, hydraulics Troubleshooting closed circuit using the example of a travel circuit Fig. 277 10 Pressure resistance plugs Connect pressure gauges (6) for high pressure and charge pressure. Disconnect hydraulic motor/s (3) and close the ports with pressure resistant plugs (10).

  • Page 211: Troubleshooting Axial Piston Pumps

    Troubleshooting – Trouble shooting, hydraulics 7.4.3 Troubleshooting axial piston pumps The following table should be of help when performing trouble- shooting. This table is by no means complete. In practice, other problems may occur that have not been listed here. Procedure: Always proceed systematically, even under time pressure.
  • Page 212 Troubleshooting – Trouble shooting, hydraulics Fault description Cause Remedy No or insufficient Faulty mechanical drive (e.g. defective cou- Check and repair the drive. volumetric flow pling). Drive speed too low. Consult the service department Insufficient suction conditions, e.g. air in the Completely purge the axial piston suction line, inadequate diameter of the suc- unit, fill the suction line with pres-...
  • Page 213 Troubleshooting – Trouble shooting, hydraulics Fault description Cause Remedy Fluctuations in pres- Insufficient suction conditions, e.g. air in the Remove foreign bodies from sure/volumetric flow suction line, inadequate diameter of the suc- inside the suction line. tion line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line.

  • Page 214: Trouble Shooting, Diesel Engine

    Troubleshooting – Trouble shooting, diesel engine 7.5 Trouble shooting, diesel engine 7.5.1 Starting the engine with jump leads....... 219 7.5.2 Engine problems ........... 219 7.5.1 Starting the engine with jump leads NOTICE! A wrong connection will cause severe damage in the electric system. –...
  • Page 215 Troubleshooting – Trouble shooting, diesel engine Fault description Cause Remedy Engine does not start Driver not seated (seat con- Occupy the driver's seat when tact switch) starting. Travel lever not in neutral Return the travel levers to neutral position position. Battery not charged or not Charge the battery, check the pole connected...

  • Page 216: Special Tools

    Special tools Special tools BW 900-50...

  • Page 217: Special Tools For Hydraulic System

    Special tools – Special tools for hydraulic system 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 8.1 Special tools for hydraulic system 8.1.1 Special tools, tests and adjustments Hydraulic test case, large BOMAG part no.: 007 610 03...
  • Page 218 Special tools – Special tools for hydraulic system Pressure gauge 60 bar BOMAG part no.: 059 721 07 600 bar BOMAG part no.: 059 721 04 Fig. 282 Adapter for pressure test hose BOMAG part no.: 055 439 02 Fig. 283 Gear pump testing device BOMAG part no.: 007 610 05 Fig.

  • Page 219: Special Tools For Flushing

    Special tools – Special tools for hydraulic system Vacuum pump for hydraulic oil tank BOMAG part no.: 007 610 04 (12 Volt) BOMAG part no.: 007 610 24 (24 Volt) Fig. 285 8.1.2 Special tools for flushing The following list informs about special tools for flushing.

  • Page 220: Special Tools, Electrics

    Special tools – Special tools, electrics 8.2 Special tools, electrics Special pliers tool kit The contacts are not included in the kit. Depending on the contact to be crimped, the matching tool head must be attached to the handle. BOMAG part-no.: 079 950 03 Comprising: –...

  • Page 221: Special Tools For Drum

    Special tools – Special tools for drum 8.3 Special tools for drum Bell to change the rubber buffers Fig. 292 BW 900-50...

  • Page 222: Index

    Index Index BW 900-50...
  • Page 223 Index Description Hydraulic units ..............107 Maintenance intervals Drum .
  • Page 224 Index K31 ................87 K96 .

  • Page 225: Appendix

    Appendix Appendix BW 900-50...
  • Page 226 Appendix Circuit diagrams............233 BW 900-50...

  • Page 227: A Circuit Diagrams

    Circuit diagrams Circuit diagrams A.1 Circuit diagram 78..........233 A.2 Hydraulic diagram 138........... 243 Circuit diagram 78 BW 900-50...
  • Page 228 Circuit diagrams BW 900-50...
  • Page 229 Circuit diagrams BW 900-50...
  • Page 230 Circuit diagrams BW 900-50...
  • Page 231 Circuit diagrams BW 900-50...
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  • Page 233 Circuit diagrams BW 900-50...
  • Page 234 Circuit diagrams BW 900-50...
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  • Page 236 Circuit diagrams BW 900-50...
  • Page 237 Circuit diagrams Hydraulic diagram 138 BW 900-50...
  • Page 238 Circuit diagrams BW 900-50...
  • Page 239 Circuit diagrams BW 900-50...
  • Page 240 Circuit diagrams BW 900-50...
  • Page 241 Circuit diagrams BW 900-50...
  • Page 242 Circuit diagrams BW 900-50...
  • Page 243 Circuit diagrams BW 900-50...
  • Page 244 Circuit diagrams BW 900-50...
  • Page 245 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

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