Bomag BW 100 AD-5 to BW 120 SL-5 Tandem Vibratory Rollers Service Manual 00840124

Description

• Model List:
  • BW 100 AD-5 Tandem Vibratory Roller
  • BW 100 AC-5 Tandem Vibratory Roller
  • BW 100 SL-5 Tandem Vibratory Roller
  • BW 120 AD-5 Tandem Vibratory Roller
  • BW 120 AC-5 Tandem Vibratory Roller
  • BW 120 SL-5 Tandem Vibratory Roller

• 1. Table of contents
• 2. General
• 2.1. Introduction
• 2.2. Concerning your safety
• 2.2.1. General prerequisites
• 2.2.2. Definition of responsible persons
• 2.2.3. Fundamentals for safe operation
• 2.2.4. Handling fuels and lubricants
• 2.2.5. Parking the machine in secured condition
• 2.2.6. What to do in events of emergency
• 2.2.7. Maintenance work
• 2.2.8. Repair
• 2.2.9. Signage, AD/SL
• 2.2.10. Signage, AC
• 2.3. Notes on repair
• 2.3.1. General repair instructions
• 2.3.2. Tightening torques
• 2.4. Maintenance work
• 2.4.1. Preliminary remarks and safety notes
• 2.5. Fuels and lubricants
• 2.5.1. Fuels and lubricants
• 2.6. List of fuels and lubricants
• 2.6.1. List of fuels and lubricants
• 3. Technical data
• 3.1. BW 100 AD5
• 3.1.1. Technical data
• 3.2. BW 100 AC5
• 3.2.1. Technical data
• 3.3. Technical data BW 100 SL5
• 3.3.1. Noise and vibration data
• 3.4. BW 120 AD5
• 3.4.1. Technical data
• 3.5. BW 120 AC5
• 3.5.1. Technical data
• 3.6. Technical data BW 120 SL5
• 3.6.1. Noise and vibration data
• 3.7. Additional technical data
• 4. Overview of machine
• 4.1. Electric systems
• 4.2. Diesel engine
• 4.3. Hydraulic system
• 4.4. Drum
• 4.5. Oscillating articulated joint
• 4.6. Water spraying system
• 5. Electric systems
• 5.1. Overview of electric system
• 5.2. Table of fuels and lubricants
• 5.3. Wiring
• 5.4. CAN BUS overview
• 5.5. Central electrics
• 5.6. Fuse assignment
• 5.6.1. Notes on safety
• 5.6.2. Fuses in engine compartment
• 5.6.3. Central electrics
• 5.7. Control elements
• 5.7.1. AD machine
• 5.7.2. AC machine
• 5.8. Battery service during prolonged machine downtimes
• 5.9. Starting the engine with jump leads
• 5.10. Generator repair
• 5.11. Starter
• 5.11.1. Repair of starter
• 5.11.2. Trouble shooting Starter
• 5.12. Instrument cluster (A15)
• 5.13. Seat contact control
• 5.14. Switching the vibration on
• 5.15. Switching on the pressure sprinkler system
• 5.16. Level sensor in diesel tank, R03
• 5.17. Sensor, water in fuel filter, B124
• 5.18. Charge control lamp and operating hour meter
• 5.19. Engine oil pressure monitoring
• 5.20. Coolant temperature monitoring
• 5.21. Glow plugs, R81, R82 R83
• 5.22. Engine solenoid, Y13
• 5.23. Inductive proximity switch, B63
• 5.24. Angle sensor on travel control lever, B39
• 5.25. Telemecanique switch
• 5.26. Deutsch plug, series DT and DTM
• 5.27. Inspection and maintenance work
• 5.27.1. Maintenance Table
• 5.27.2. Every 250 operating hours
• 6. Diesel engine
• 6.1. Overview of diesel engine
• 6.2. Kubota diesel engine
• 6.3. Checking the compression
• 6.4. Checking the engine oil pressure
• 6.5. Checking the thermostat in disassembled state
• 6.6. Check the injection valves
• 6.7. Checking the start of delivery
• 6.8. Checking the fuel injection pump
• 6.9. Inspection and maintenance work
• 6.9.1. Maintenance Table
• 6.9.2. Checks prior to start up
• 6.9.3. Every 50 operating hours
• 6.9.4. Every 250 operating hours
• 6.9.5. Every 500 operating hours
• 6.9.6. Every 1000 operating hours
• 6.9.7. Every 2000 operating hours
• 6.9.8. Every 3000 operating hours
• 6.9.9. As required
• 7. Hydraulic system
• 7.1. Overview of hydraulics
• 7.2. Open and closed hydraulic circuit
• 7.3. Hydraulic units
• 7.3.1. Travel pump, A10VG28 HW
• 7.3.2. Swash plate principle, pump
• 7.3.3. Drum drive motor MK 04
• 7.3.4. Wheel drive motor, MS/MSE
• 7.3.5. External gear pumps
• 7.3.6. Outer gear motors nonreversible
• 7.3.7. Steering valve
• 7.4. Charge circuit
• 7.5. Travel circuit
• 7.6. Vibration circuit
• 7.7. Steering circuit
• 7.8. Chip spreader
• 7.8.1. Mounting / removing the chip spreader
• 7.9. Edge cutter
• 7.9.1. Mounting the tool
• 7.10. Flow divider
• 7.11. Tests and adjustments
• 7.11.1. Checking the rotation speeds
• 7.11.2. Pressure tests in the travel circuit
• 7.11.3. Checking / adjusting the neutral positions of the travel pump
• 7.11.4. Pressure test in the vibration circuit
• 7.11.5. Checking the leakage rate of the vibration motor
• 7.11.6. Pressure test in steering circuit
• 7.12. Flushing and bleeding
• 7.12.1. Flushing general
• 7.12.2. Flushing diagram for front drum drive
• 7.12.3. Flushing the front drum drive
• 7.12.4. Flushing diagram for rear drum drive
• 7.12.5. Flushing the rear drum drive
• 7.12.6. Flushing diagram, rear wheel drive motors
• 7.12.7. Flushing the rear wheel drive
• 7.12.8. Flushing diagram for vibration drive on AD/SL machine
• 7.12.9. Flushing the vibration circuit
• 7.12.10. Bleeding the travel circuit
• 7.13. Inspection and maintenance work
• 7.13.1. Maintenance Table
• 7.13.2. Checks prior to start up
• 7.13.3. Every 500 operating hours
• 7.13.4. Every 1000 operating hours
• 7.13.5. Every 2000 operating hours
• 8. Drum
• 8.1. Edge cutter
• 8.1.1. Edge cutter
• 8.2. Overview drum
• 8.3. Removing and installing the drum
• 8.4. Dismantling the drum
• 8.5. Assembling the drum
• 9. Rubber tires
• 9.1. Inspection and maintenance work
• 9.1.1. Maintenance Table
• 9.1.2. Checks prior to start up
• 10. Scrapers
• 10.1. Inspection and maintenance work
• 10.1.1. Scrapers
• 10.1.2. Checks prior to start up
• 11. Oscillating articulated joint
• 11.1. Overview oscillating articulated joint
• 11.2. Disassembling the oscillating articulated joint
• 11.3. Repairing the oscillating articulated joint
• 11.4. Installing the oscillating articulated joint
• 12. Troubleshooting
• 12.1. Preliminary remarks
• 12.2. What to do in events of emergency
• 12.2.1. Actuating the emergency stop switch
• 12.2.2. Disconnecting the battery
• 12.2.3. Towing the machine
• 12.2.4. After towing, ADmachine
• 12.2.5. After towing, ACmachine
• 12.3. Troubleshooting, electrical systems
• 12.3.1. Preliminary remarks
• 12.3.2. Starting the engine with jump leads
• 12.3.3. Fuse assignment
• 12.3.4. Trouble shooting Starter
• 12.3.5. Instrument cluster (A15)
• 12.3.6. Trouble shooting ECONOMIZER
• 12.3.7. The machine does not drive
• 12.3.8. Seat contact control
• 12.3.9. Check the parking brake
• 12.3.10. Understanding electric circuit diagrams
• 12.3.11. Measuring method
• 12.4. Trouble shooting, hydraulics
• 12.4.1. Insufficient hydraulic power
• 12.4.2. Trouble shooting axial piston pumps
• 12.4.3. The machine does not drive
• 12.4.4. Insufficient travel power
• 12.4.5. Check the parking brake
• 12.5. Trouble shooting, diesel engine
• 12.5.1. Engine faults
• 13. Disposal
• 13.1. Final shutdown of machine
• 14. Special tools
• 14.1. Special tools, hydraulic system
• 14.1.1. Special tools, tests and adjustments
• 14.1.2. Special tools for flushing
• 14.2. Special tools, electrics
• 15. Index
• 16. Appendix
• 16.1. A Supplier documentation
• 16.1.1. Travel pump
• 16.1.2. Drum drive
• 16.1.3. Wheel drive
• 16.1.4. Steering valve
• 16.2. B Circuit diagrams
• 16.2.1. Hydraulic diagram 287
• 16.2.2. Hydraulic diagram 363
• 16.2.3. Circuit diagram 368