Bomag BW 161 ADO-50 Tandem vibratory roller Service Training Manual – PDF DOWNLOAD

Description

Bomag BW 161 ADO-50 Tandem vibratory roller Service Training Manual – PDF DOWNLOAD

FILE DETAILS:

Bomag BW 161 ADO-50 Tandem vibratory roller Service Training Manual – PDF DOWNLOAD

Language : English
Pages : 698
Downloadable : Yes
File Type : PDF
Size: 193 MB

DESCRIPTION:

Bomag BW 161 ADO-50 Tandem vibratory roller Service Training Manual – PDF DOWNLOAD

General
This manual:
n addresses the BOMAG customer service or professionally
trained personnel.
n explains the design of the machine and its functions.
n serves as
– document to be used during the training course
– reference book for the purpose of repeating or deepening
the training contents you have learned.
This manual describes components, assemblies and the essential
functions of the machine. (As far as required for the BOMAG After
Sales Service)

Documentation
For the BOMAG machines described in this manual the following
documentation is additionally available:
n Operating and maintenance instructions
n Spare parts catalogue
n Service information (if necessary)

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Bomag BW 161 ADO-50 Tandem vibratory roller Service Training Manual – PDF DOWNLOAD

Table of contents 3
1 ​​General​​ 9
1 1 ​​General​​ 10
1 2 ​​Concerning your safety​​ 11
1 2 1 ​​General prerequisites​​ 11
1 2 1 1 ​​General​​ 11
1 2 1 2 ​​Explanations to signal words used:​​ 11
1 2 1 3 ​​Personal protective outfit​​ 12
1 2 1 4 ​​Intended use​​ 13
1 2 1 5 ​​Unintended use​​ 13
1 2 1 6 ​​Unintended use​​ 14
1 2 2 ​​Terminological definition of the responsible persons​​ 14
1 2 2 1 ​​Operating company​​ 14
1 2 2 2 ​​Expert / qualified person​​ 15
1 2 2 3 ​​Driver / operator​​ 15
1 2 3 ​​Fundamentals for safe operation​​ 15
1 2 3 1 ​​Remaining dangers, remaining risks​​ 15
1 2 3 2 ​​Regular safety inspections​​ 16
1 2 3 3 ​​Changes and conversions to the machine​​ 16
1 2 3 4 ​​Damage, deficiencies, misuse of safety installations​​ 16
1 2 3 5 ​​Roll Over Protective Structure (ROPS)​​ 16
1 2 4 ​​Handling fuels and lubricants​​ 17
1 2 4 1 ​​Preliminary remarks​​ 17
1 2 4 2 ​​Safety regulations and environmental protection regulations for handling diesel fuel​​ 18
1 2 4 3 ​​Safety regulations and environmental protection regulations for handling oil​​ 19
1 2 4 4 ​​Safety regulations and environmental protection regulations for handling hydraulic oil​​ 20
1 2 4 5 ​​Safety regulations and environmental protection regulations for handling coolants​​ 21
1 2 4 6 ​​Safety regulations and environmental protection regulations for handling battery acid​​ 22
1 2 5 ​​What to do in events of emergency​​ 22
1 2 5 1 ​​Actuating the emergency stop switch​​ 22
1 2 5 2 ​​Disconnect the battery​​ 23
1 2 5 3 ​​Towing the machine​​ 23
1 2 6 ​​Park the machine in secured condition ​​ 23
1 2 7 ​​Maintenance and repair​​ 24
1 2 7 1 ​​Preliminary remarks and safety notes​​ 24
1 2 7 2 ​​Preparations / concluding work​​ 25
1 2 7 2 1 ​​Open and secure the engine hood​​ 26
1 2 7 2 2 ​​Engaging / releasing the articulation lock​​ 26
Engaging the articulation lock 26
Disengaging the articulation lock 27
1 2 7 2 3 ​​Lifting the machine with a jack​​ 28
1 2 7 3 ​​Work on hydraulic lines​​ 30
1 2 7 4 ​​Working on the engine​​ 30
1 2 7 5 ​​Maintenance work on electric components and battery​​ 31
1 2 7 6 ​​Working on the air conditioning​​ 31
1 2 7 7 ​​Cleaning work​​ 31
1 3 ​​Fuels and lubricants​​ 33
1 3 1 ​​Engine oil​​ 33
1 3 1 1 ​​Oil quality​​ 33
1 3 1 2 ​​Oil viscosity​​ 34
1 3 1 3 ​​Oil change intervals​​ 34
1 3 2 ​​Fuel​​ 34
1 3 2 1 ​​Fuel quality​​ 34
1 3 2 2 ​​Winter fuel​​ 35
1 3 2 3 ​​Storage​​ 35
1 3 3 ​​Coolant​​ 35
1 3 3 1 ​​General​​ 35
1 3 3 2 ​​Water quality​​ 36
1 3 3 3 ​​Cooling system protection agent​​ 36
1 3 4 ​​Hydraulic oil​​ 38
1 3 4 1 ​​Mineral oil based hydraulic oil​​ 38
1 3 4 2 ​​Bio-degradable hydraulic oil​​ 38
1 3 5 ​​Exciter system​​ 38
1 4 ​​Table of fuels and lubricants​​ 39
2 ​​Technical data​​ 41
2 1 ​​Technical data​​ 42
2 2 ​​Additional technical data​​ 45
3 ​​Overview of machine​​ 47
3 1 ​​Overview of electric system​​ 50
3 2 ​​Overview of diesel engine​​ 52
3 3 ​​Overview of hydraulics​​ 54
3 3 1 ​​Pump overview​​ 55
3 4 ​​Overview of water sprinkling system​​ 57
3 4 1 ​​AD, ADO & AM​​ 57
3 4 2 ​​Pump overview​​ 57
3 5 ​​Overview of air conditioning system​​ 60
3 6 ​​Overview, AD drum​​ 62
3 7 ​​Overview, ADO drum​​ 63
3 8 ​​Information and safety stickers/decals on the machine​​ 64
4 ​​Electric systems​​ 67
4 1 ​​Overview of electric system​​ 68
4 1 1 ​​CAN BUS overview​​ 75
4 2 ​​Telemecanique switch​​ 77
4 3 ​​Magnetic coil plug​​ 79
4 4 ​​Deutsch plug, series DT and DTM​​ 82
4 5 ​​Servicing the battery, checking the main battery switch​​ 86
4 5 1 ​​Battery service​​ 86
4 5 2 ​​Checking the main battery switch​​ 87
4 6 ​​Starting the engine with jump leads​​ 88
4 7 ​​Asphalt temperature sensor, B106​​ 90
4 8 ​​Acceleration transducer, B84 & B85​​ 91
4 9 ​​Switching on the pressure sprinkler system​​ 93
4 10 ​​Data collector, A80​​ 95
4 11 ​​Differential pressure switch for hydraulic oil filter, B21​​ 101
4 12 ​​Air filter vacuum switch, B03​​ 102
4 13 ​​Sensor, water in fuel filter, B124​​ 103
4 14 ​​Float switch in coolant compensation tank, B55​​ 104
4 15 ​​Oil pressure switch, B06​​ 105
4 16 ​​Coolant temperature switch, B53​​ 106
4 17 ​​Removing and assembling the coolant temperature switch​​ 107
4 18 ​​Boost fuel solenoid valve​​ 108
4 19 ​​Engine solenoid to shut down the engine, Y58​​ 109
4 20 ​​Electric throttle control, Y120​​ 110
4 21 ​​Heating flange on engine​​ 113
4 22 ​​Checking the heating flange control​​ 115
4 23 ​​Charge control lamp​​ 116
4 24 ​​Fuse assignment​​ 117
4 24 1 ​​Notes on safety​​ 117
4 24 2 ​​Central electrics​​ 117
4 24 3 ​​Main fuses​​ 118
4 24 4 ​​Fuse, cabin​​ 119
4 24 5 ​​Fuses ROPS​​ 120
4 25 ​​Power board​​ 121
4 26 ​​Operator’s stand​​ 125
4 26 1 ​​Instrument cluster​​ 127
4 27 ​​Electric system, old version​​ 130
4 27 1 ​​CAN BUS overview​​ 133
4 27 2 ​​Switching on the pressure sprinkler system​​ 134
4 27 3 ​​Level sensor in diesel tank, R03​​ 136
4 27 4 ​​Immersion pipe sensor in water tank, R14​​ 137
4 27 5 ​​Float switch in water tank, B33​​ 138
4 27 6 ​​Float switch in coolant compensation tank, B55​​ 139
4 27 7 ​​Differential pressure switch for hydraulic oil filter, B21​​ 140
4 27 8 ​​Air filter vacuum switch, B03​​ 141
4 27 9 ​​Sensor, water in fuel filter, B124​​ 142
4 27 10 ​​Oil pressure switch, B06​​ 143
4 27 11 ​​Coolant temperature switch, B53​​ 144
4 27 12 ​​Heating flange on engine​​ 145
4 27 13 ​​Checking the heating flange control​​ 147
4 27 14 ​​Charge control lamp​​ 148
4 27 15 ​​Operator’s stand​​ 150
4 27 15 1 ​​Instrument cluster​​ 151
5 ​​Diesel engine​​ 155
5 1 ​​Overview of diesel engine​​ 156
5 2 ​​Service side​​ 158
5 3 ​​Starter side​​ 159
5 4 ​​Lubrication oil circuit​​ 160
5 5 ​​Coolant circuit​​ 162
5 6 ​​Replacing the thermostat​​ 164
5 7 ​​Fuel supply​​ 166
5 8 ​​Injection system​​ 168
5 9 ​​Injection pump replacement during service​​ 170
5 9 1 ​​Disassembling the injection pump​​ 170
5 9 2 ​​Determining the start of injection​​ 172
5 9 3 ​​Installing the injection pump​​ 175
5 10 ​​Injection valve replacement during service​​ 180
5 11 ​​Checking / repairing injection valves​​ 183
5 12 ​​Inspection and maintenance work​​ 189
5 12 1 ​​Checking the engine oil level​​ 189
5 12 2 ​​Change engine oil and oil filter cartridge​​ 189
5 12 3 ​​Check the coolant level​​ 191
5 12 4 ​​Check the anti-freeze concentration and the condition of the coolant​​ 192
5 12 5 ​​Change the coolant​​ 192
5 12 6 ​​Cleaning the radiator module​​ 194
5 12 7 ​​Replacing the fuel filter, bleeding the fuel system​​ 195
5 12 7 1 ​​Preliminary remarks​​ 195
5 12 7 2 ​​Replacing the fuel filter and the fuel pre-cleaner​​ 196
5 12 7 3 ​​Bleed the fuel system​​ 198
5 12 8 ​​Checking, cleaning the water separator​​ 199
5 12 9 ​​Service the belt drive​​ 199
5 12 9 1 ​​Checking the condition of the V-belt​​ 200
5 12 9 2 ​​Checking the V-belt tension​​ 200
5 12 9 3 ​​Tensioning the generator V-belt​​ 201
5 12 9 4 ​​Tensioning the fuel pump V-belt​​ 202
5 12 9 5 ​​Tensioning the air conditioning compressor V-belt​​ 202
5 12 9 6 ​​Replacing the V-belt​​ 203
5 12 10 ​​Air filter maintenance​​ 204
5 12 10 1 ​​Replace the safety element​​ 206
5 12 11 ​​Adjusting the valve clearance​​ 206
5 12 12 ​​Checking the compression​​ 208
6 ​​Hydraulic system​​ 211
6 1 ​​Overview of hydraulics​​ 212
6 1 1 ​​Pump overview​​ 213
6 2 ​​Open and closed hydraulic circuit​​ 215
6 3 ​​Hydraulic units​​ 217
6 3 1 ​​Travel pump, A4VG71 EP​​ 217
6 3 1 1 ​​Variable displacement pumps, A4VG28EP to 180EP​​ 217
6 3 2 ​​Vibration pump, A10VG28 EP​​ 222
6 3 2 1 ​​Variable displacement pump, A10VG28/45 EP​​ 222
6 3 3 ​​Swash plate principle, pump​​ 227
6 3 4 ​​Drum drive motor​​ 229
6 3 4 1 ​​Functional principle radial piston motors, MS/MSE​​ 229
6 3 5 ​​Vibration motor​​ 231
6 3 5 1 ​​Vibration motor A10FE/FM​​ 231
6 3 6 ​​External gear pumps​​ 233
6 3 7 ​​Outer gear motors non-reversible​​ 235
6 3 8 ​​Steering valve​​ 236
6 4 ​​Charge circuit and fan circuit​​ 238
6 5 ​​Travel circuit​​ 240
6 6 ​​Vibration circuit​​ 245
6 7 ​​Steering and crabwalk​​ 253
6 8 ​​Edge cutter​​ 257
6 9 ​​Inspection and maintenance work​​ 259
6 9 1 ​​Check the hydraulic lines​​ 259
6 9 2 ​​Checking the hydraulic oil level​​ 259
6 9 3 ​​Changing the hydraulic oil​​ 260
6 9 4 ​​Replacing the hydraulic oil filter​​ 262
6 10 ​​Tests and adjustments​​ 265
6 10 1 ​​Pump overview​​ 265
6 10 2 ​​Activate service mode​​ 266
6 10 3 ​​Driving against the closed brake​​ 268
6 10 4 ​​Pressure tests in the travel circuit​​ 270
6 10 5 ​​Checking / adjusting the neutral positions of the travel pump​​ 272
6 10 6 ​​Checking the setting of the high pressure relief valves in the travel circuit​​ 275
6 10 7 ​​Pressure tests in the front vibration circuit​​ 277
6 10 8 ​​Pressure tests in the rear vibration circuit​​ 278
6 10 9 ​​Checking the high pressure relief valves in the front vibration circuit​​ 280
6 10 10 ​​Checking the high pressure relief valves in the rear vibration circuit​​ 282
6 11 ​​Flushing and bleeding​​ 285
6 11 1 ​​Flushing – general​​ 285
6 11 2 ​​Flushing schematic for front drum drive​​ 288
6 11 3 ​​Flushing the front drum drive​​ 289
6 11 4 ​​Flushing schematic for rear drum drive system​​ 293
6 11 5 ​​Flushing the rear drum drive​​ 294
6 11 6 ​​Flushing schematic for front vibration drive​​ 299
6 11 7 ​​Flushing the front vibration circuit ​​ 300
6 11 8 ​​Flushing schematic for rear vibration circuit​​ 305
6 11 9 ​​Flushing the rear vibration circuit ​​ 306
6 11 10 ​​Bleeding the travel circuit​​ 310
6 11 11 ​​Bleeding the vibration circuit​​ 312
7 ​​Water spraying system​​ 315
7 1 ​​Overview of water sprinkling system​​ 316
7 1 1 ​​AD, ADO & AM​​ 316
7 1 2 ​​Pump overview​​ 316
7 2 ​​Inspection and maintenance work​​ 319
7 2 1 ​​Checking the water level, topping up​​ 319
7 2 2 ​​Cleaning water tank and water filter​​ 320
7 2 3 ​​Water spraying system, maintenance in case of frost​​ 321
8 ​​Air conditioning​​ 327
8 1 ​​Overview of air conditioning system​​ 328
8 2 ​​Physical principles​​ 330
8 3 ​​Refrigerant R134a​​ 333
8 4 ​​Compressor oil / refrigeration oil​​ 336
8 5 ​​Working principle of the air conditioning system​​ 339
8 6 ​​Monitoring devices​​ 340
8 7 ​​Description of components​​ 341
8 8 ​​Compressor​​ 347
8 9 ​​Emptying in case of repair​​ 349
8 10 ​​Drying and evacuation​​ 350
8 11 ​​Filling instructions​​ 351
8 12 ​​Steam table for R134a​​ 356
8 13 ​​Inspection and maintenance work​​ 360
8 13 1 ​​Checking the compressor oil level / refrigeration oil level​​ 360
8 13 2 ​​Service the air conditioning​​ 360
8 13 2 1 ​​Air conditioning function test​​ 360
8 13 2 2 ​​Checking the condition of the drier/collector unit​​ 360
8 13 3 ​​Cleaning the circulation air filter for the heating​​ 362
8 13 4 ​​Changing the fresh air filter in the cabin​​ 362
9 ​​Drum​​ 365
9 1 ​​Overview, AD drum​​ 367
9 2 ​​Overview, ADO drum​​ 368
9 3 ​​Inspection and maintenance work​​ 369
9 3 1 ​​Checking, adjusting the scrapers​​ 369
9 3 2 ​​Checking the oil level in the front exciter housing​​ 369
9 3 3 ​​Change the oil in the front exciter housing​​ 370
9 3 4 ​​Rear exciter housing, check for leaks​​ 371
9 3 5 ​​Change the oil in the rear exciter housing​​ 371
9 3 6 ​​Checking, tensioning the toothed belt for the rear drum​​ 373
10 ​​Troubleshooting​​ 379
10 1 ​​Preliminary remarks​​ 380
10 2 ​​What to do in events of emergency​​ 381
10 2 1 ​​Actuate the emergency stop switch​​ 381
10 2 2 ​​Disconnecting the battery​​ 381
10 2 3 ​​Towing the machine​​ 381
10 2 4 ​​After towing​​ 384
10 3 ​​Troubleshooting, electrical systems​​ 386
10 3 1 ​​Preliminary remarks​​ 386
10 3 2 ​​Starting the engine with jump leads​​ 386
10 3 3 ​​Checking the main battery switch​​ 387
10 3 4 ​​Fuse assignment​​ 387
10 3 4 1 ​​Notes on safety​​ 387
10 3 4 2 ​​Central electrics​​ 388
10 3 4 3 ​​Main fuses​​ 389
10 3 4 4 ​​Fuse, cabin​​ 390
10 3 4 5 ​​Fuses ROPS​​ 391
10 3 5 ​​Understanding electric circuit diagrams​​ 391
10 3 5 1 ​​Electric circuit diagrams​​ 391
10 3 5 2 ​​Circuit symbols in E-Plan​​ 399
10 3 5 3 ​​Identification of switch blocks​​ 403
10 3 6 ​​Metrology​​ 404
10 3 7 ​​ESX, checking the electric power supply​​ 408
10 3 8 ​​Diagnostics concept​​ 416
10 3 9 ​​Machine control, ESX​​ 418
10 4 ​​Trouble shooting, diesel engine​​ 518
10 4 1 ​​Starting the engine with jump leads​​ 518
10 4 2 ​​Fault – Cause – Remedy​​ 519
10 5 ​​Trouble shooting, hydraulics​​ 521
10 5 1 ​​Insufficient hydraulic power​​ 521
10 5 2 ​​Trouble shooting axial piston pumps​​ 524
10 5 3 ​​Trouble shooting axial piston motors​​ 526
10 6 ​​Trouble shooting, air conditioning system​​ 528
10 6 1 ​​Trouble shooting in refrigerant circuit, basic principles​​ 528
10 6 2 ​​Trouble shooting procedure​​ 535
10 6 3 ​​Leak test​​ 544
10 6 4 ​​Checking the magnetic clutch ​​ 545
11 ​​Special tools​​ 547
11 1 ​​Special tools, electrics​​ 548
11 2 ​​Special tools, hydraulic system​​ 549
11 2 1 ​​Special tools, tests and adjustments​​ 549
11 2 2 ​​Special tools for flushing​​ 551
11 3 ​​Special tools for drum​​ 556
11 3 1 ​​ADO drum​​ 556
11 4 ​​List of special tools​​ 558
Appendix 559
A Circuit diagrams 561
A A Hydraulic diagram 921 125 11a 561
A B Wiring diagram 282 563
A C Wiring diagram 337 624

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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