Bomag Bw100 120 Service Training
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Service Training
BW 100 AD/AC Series 4
BW 120 AD/AC Series 4
P/N 008 099 86 STATUS: 03/2004
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Service Training
Table of contents
Foreword A1
List of additional documentation A2
General A3
Maintenance A4
List of components B1
Kubota diesel engine C1
View of engine C2
Pump installation on diesel engine C3
View of diesel engine, flywheel side C4
Tests and adjustments C5
Adjusting the valve clearance C6
Trouble Shooting C8
Travel system D1
Travel pump D3
Travel pump control D7
Charge pressure relief valve D9
High pressure relief valves D 10
Drum drive motor D 12
Wheel drive motors on AC-machines D 16
Trouble shooting travel system D 17
Insufficient travel power D 28
The machine moves with the travel lever in “Neutral” D 30
Vibration E1
Vibration pump E3
Vibration control valve E4
Vibration motor E5
Trouble shooting vibration E6
Steering F1
Steering valve F3
Trouble shooting steering F5
Electric circuit diagrams G1
Table of contents G1
Function groups G2
Reference lines, frames G3
Potential cross references G4
Relay cross references G5
List of components G5
Electric system G6
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BW 100/120 AD-3 1
BW 100/120 AC-3
Service Training
Foreword
In 2004 the tandem vibratory rollers of product range BW 100 AD/AC4 and BW 120
AD/AC4 were launched in the market for the first time.
They are a further development of the old BW 100/120AD/AC of generation 3, which
already were a great sales success.
The contents of this training shall enable the service engineer to perform adjustments
and trouble shooting as well as all necessary repair work in a professional manner.
The owner of the machine should recognize that the service engineer is fully familiar
with the machine. He should realize that the service engineer applies the correct
measures to detect a possible fault on a machine and that all repair measures are
performed with skill and knowledge.
Persons participating on this training course should be confident when having to work
on this machine.
Documentation
For the BOMAG machines described in this training manual the following
documentation is additionally available:
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or
the Customer Service page in the BOMAG Intranet or Extranet (BOMAG Secured
Area) in accordance with the serial number of the machine.
1. Operating and maintenance instructions
2. Spare parts catalogue
3. Wiring diagram*
4. Hydraulic diagram*
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.
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BW 100/120 AD-4 A1
BW 100/120 AC-4
Service Training
General
Machines of product range BW 100/120 AD/AC-4 are tandem vibratory rollers or
combination rollers for compaction work in road construction. They are most suitable
for the compaction of bituminous materials as well as light compaction tasks in
earthwork. Compaction is achieved by the vibration of both drums or the vibration of
the drum and the static load of the rubber tires. The power output from the water
cooled Kubota diesel engine is transferred to drums or wheels (travel and vibration
systems) and to the steering via the hydrostatic drive systems of the machine. This
type of power transmission ensures lowest possible efficiency losses.
Both drums of the BW 100/120 AD-4 are fitted with both travel motors as well as
vibration motors. The motors for the respective drive systems are always arranged
on one side of the machine. Since it is beneficial for many applications (e.g. when
laying asphalt layers) to work with one vibrating and one static drum, the machine is
equipped with a vibration shut-off valve for the rear drum.
On machines of type BW 100/120 AC-4 the wheel set is driven by two travel motors.
This roller combines the high compaction power of a vibration drum with the excellent
surface sealing effect of rubber tires in one machine. This machine obviously
achieves considerable savings in costs when compared with a pure vibratory or
pneumatic tired roller.
The standard equipment of the machine includes a gravity sprinkler system. A
pressure sprinkler system is optionally available on request. In connection with the
scrapers the water sprinkler system avoids picking up of material by the drums.
On the AC-machines a pressure sprinkler system prevents sticking of dirt and
bitumen to the rubber tires. For this purpose the tires are sprayed with emulsion.
Front and rear frames of the machine are joined by an oscillating articulated joint.
The amply dimensioned oscillation angle makes sure that the drums always have
ground contact over the entire width.
Both travel motors are fitted with integrated brakes working as parking brakes.
Depending on the position of the brake solenoid valve these brakes are released by
charge pressure when starting the engine and applied when shutting the engine
down.
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BW 100/120 AD-4 A2
BW 100/120 AC-4
Service Training
Maintenance
The tandem/combination rollers of series BW 100/120 AD/AC-4 are high
performance machines for the extremely difficult use in asphalt compaction and earth
work. To be able to meet these demands the machine must always be ready to be
loaded up to its limits. Apart from that, all safety installations must always be fully
functional when working under the partly very dangerous conditions on a construction
site.
Thorough maintenance of the machine is therefore mandatory. This not only
guarantees a remarkably higher functional safety, but also prolongs the lifetime of the
machine and of important components.
The time required for thorough maintenance is only minor when being compared with
the malfunctions and faults that may occur if these instructions are not observed.
The maintenance intervals are given in operating hours. It is quite obvious that with
each maintenance interval all the work for shorter preceding intervals must also be
performed. During the 2000 hour interval you must also perform the maintenance
work for the 500 and 1000 hour intervals.
It should also be clear, that with the 2500 hours interval only the work for the 10 and
500 hour intervals must be performed.
For maintenance work you must only use the fuels and lubricants mentioned in the
table of fuels and lubricants (oils, fuels, grease etc.).
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BW 100/120 AD-4 A3
BW 100/120 AC-4
Service Training
List of components
BW 100/120 AD/AC-4
Engine
Manufacturer Kubota
Type D 1703 MDI
Cooling Water
Working cycles 4
Number of cylinders 3
Power DIN 6271 IFN/SAE
at 2700 rpm kW 25,2
Fixed engine speed rpm 2250
Stage 1
Fixed engine speed rpm 2700
Stage 2
Valve clearance I/E mm 0,20/0,20
Travel pump
Manufacturer Hydromatik
Type A10 VG 28
System Axial piston
Displacement cm³/rev. 28
High pressure limitation bar 380
Charge pressure bar 24
Speed rpm 2700
Max. flow capacity l/min 73
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BW 100/120 AD Series 4 B1
BW 100/120 AC Series 4
Service Training
BW 100/120 AD/AC-4
Travel motor (drums)
Manufacturer Poclain
Type MK 04
Number 2
System Radial piston motor
Displacement cm³/rev. 408
Brake yes
BW 100/120 AC-4
Travel motor (wheels)
Manufacturer Poclain
Type MSE 02
Number 2
System Radial piston motor
Displacement cm³/rev. 255
Brake yes
BW 100/120 AD/AC-4
Vibration pump
Manufacturer Bosch
Type HYZ 11
System Gear
Displacement cm³/rev. 11
Starting pressure bar 210
Operating pressure bar 100 +/-60 bar (soil dependent)
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BW 100/120 AD Series 4 B2
BW 100/120 AC Series 4
Service Training
Vibration motor
Manufacturer Bosch
Type HYZ 8
System Gear
Displacement cm³/rev. 8
Frequency stage 1 Hz 55
Frequency stage 2 Hz 70
Amplitude mm 0.5
Steering pump
Manufacturer Bosch
Type HYZ 8
System Gear
Displacement cm³/rev. 8
max. steering pressure bar 140 +/-30 bar
Steering valve
Manufacturer Danfoss
Type OSPC 80 ON
System Rotary valve
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BW 100/120 AD Series 4 B3
BW 100/120 AC Series 4
Service Training
Kubota diesel engine 1703 MDI
The tandem vibratory rollers of series BW 100/120 AD/AC-4 are powered by a water
cooled 3-cylinder Kubota diesel engine type 1703 MDI.
The engine is an upright water-cooled four-stroke diesel engine.
Cross-section of diesel engine
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BW 100/120 AD Series 4 C1
BW 100/120 AC Series 4
Bomag Bw100 120 Service Training
Full download: http://manualplace.com/download/bomag-bw100-120-service-training/
Service Training
View of engine:
4 3
Pos. 1 Engine temperature switch
Pos. 2 Connection glow plug
Pos. 3 Oil dipstick
Pos. 4 Injection nozzles
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BW 100/120 AD Series 4 C2
BW 100/120 AC Series 4
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