BOMAG Roller BW202AD-4 Operation Manual [PDF]

Zitiervorschau

Operating instructions Maintenance instructions

BW 161 AD-4 / BW 202 AD-4 BW 161 ADH-4 / BW 203 AD-4 S/N 101 920 02 ....> S/N 101 920 03 ....> S/N 101 920 04 ....> S/N 101 920 05 ....>

Tandem Vibratory Roller

Catalogue number

008 111 81

11/2004

Foreword BOMAG machines are products from the wide range of BOMAG compaction equipment. F oreword

BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your machine.

You should only operate the machine after you have been instructed and in compliance with these instructions. Strictly observe the safety regulations. Please observe also the guidelines of the Civil Engineering Liability Association ”Safety Rules for the Operation of Road Rollers and Soil Compactors” and all relevant accident prevention regulations.

This manual comprises: l

Safety regulations

l

Operating instructions

l

Maintenance instructions

l

Trouble shooting

For your own personal safety you should only use original spare parts from BOMAG. In the course of technical development we reserve the right for technical modifications without prior notification. These operating and maintenance instructions are also available in other languages.

Using these instructions will l

help you to become familiar with the machine.

l

avoid malfunctions caused by unprofessional operation.

Compliance with the maintenance instructions will l

enhance the reliability of the machine on construction sites,

l

prolong the lifetime of the machine,

l

reduce repair costs and downtimes.

BOMAG will not assume liability for the function of the machine l

if it is handled in a way not complying with the usual modes of use,

l

if it is used for purposes other than those mentioned in these instructions.

Apart from that, the spare parts catalogue is available from your BOMAG dealer against the serial number of your machine. Your BOMAG dealer will also supply you with information about the correct use of our machines in soil and asphalt construction. The above notes do not constitute an extension of the warranty and liability conditions specified in the general terms of business of BOMAG. We wish you successful work with your BOMAG machine. BOMAG GmbH Printed in Germany Copyright by BOMAG

No warranty claims can be lodged in case of damage resulting from l

operating errors,

l

insufficient maintenance and

l

wrong fuels and lubricants.

Please note! This manual was written for operators and maintenance personnel on construction sites. Always keep this manual close at hand, e.g. in the tool compartment of the machine or in a specially provided container. These operating and maintenance instructions are part of the machine.

BW 161/202/203 AD-4

BOMAG

3

Foreword Please fill in ............................ Machine type (Fig. 1) ............................ Serial-number (Fig. 1 and 2) ............................ Engine type (Fig. 3) ............................ Engine number (Fig. 3)

i

Note

Fig. 1

Supplement the above data together with the commissioning protocol. During commissioning our organisation will instruct you in the operation and maintenance of the machine. Please observe strictly the safety regulations and all notes on risks and dangers!

Fig. 2

Fig. 3

4

BOMAG

BW 161/202/203 AD-4

Table of Contents

Technical Data Safety regulations Indicators and Controls Operation

Maintenance

BW 161/202/203 AD-4

7 13 21

3.1 General notes 3.2 Description of indicators and control elements

24 24

4.1 General notes 4.2 Tests before taking into operation 4.3 Starting the engine 4.4 Starting with jump wires 4.5 Driving the machine 4.6 Stopping the machine, operating the parking brake 4.7 Shutting the engine down 4.8 Switching the vibration on and off 4.9 Operating the crabwalk 4.10 Switching the pressure sprinkling system on and off 4.11 Sprinkling of edge cutter 4.12 Actuating the emergency stop switch 4.13 Adjusting the rotation stop for travel lever movement 4.14 Adjusting the driver’s seat 4.15 Opening or closing the cabin window 4.16 Towing 4.17 Transport

40 40 41 45 46 48 49 50 53 54 55 55 56 56 57 57 59

5.1 General notes on maintenance 5.2 Fuels and lubricants 5.3 Fuels, lubricants and filling capacities 5.4 Running-in instructions 5.5 Maintenance chart 5.6 Check the engine oil level 5.7 Check the fuel level 5.8 Check the hydraulic oil level 5.9 Check the coolant level 5.10 Check / empty the fuel pre-cleaner (water separator) / bleed 5.11 Check the water level 5.12 Check, clean radiator, fuel cooler, hydraulic oil cooler and intercooler 5.13 Checking the oil level in vibrator shaft tube 5.14 Change the engine oil 5.15 Change the engine oil filter cartridge 5.16 Checking the anti-freeze concentration 5.17 Servicing the air conditioning (summer operation)

62 63 66 67 68 70 70 71 72 72 74 75 76 77 78 78 79

BOMAG

39

61

5

Table of Contents

Trouble shooting

6

5.18 5.19 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34 5.35 5.36 5.37 5.38 5.39

Service the battery Cleaning the fuel pre-cleaner, replacing, bleeding the filter if necessary Change the fuel filter cartridge Changing the oil in the drum drive gear Checking, tensioning, lubricating the steering chain Check the engine mounts Checking the V-belt, tighten, if necessary replace the V-belt Changing the oil in the vibrator shaft tube Check, adjust the valve clearance Changing hydraulic oil and breather filter Changing the hydraulic oil filter Grease the articulated joint Change the coolant Replace the injection valve Check, clean, change the combustion air filter Clean the water tank Clean the water filter Water sprinkler system, maintenance in the event of frost Fill the provision tank for the windscreen washer system Adjust the scrapers Tightening torques Engine conservation

6.1 General notes 6.2 Engine

81 83 85 86 87 88 88 92 93 95 96 97 98 99 101 103 104 105 106 107 107 108

109

110 111

BOMAG

BW 161/202/203 AD-4

1 Technical Data

BW 161/202/203 AD-4

BOMAG

7

Technical Data

Fig. 4

Dimensions in mm

A

B

C

D

H

H2

K

L

O

W

BW 161 AD-4

3300

1840

715

1220

2320

3000

400

4520

80

1680

BW 202 AD-4

3300

2295

715

1220

2320

3000

400

4520

80

2135

*

BW 161 AD-4

BW 202 AD-4

kg kg

9600 10100

11300 11800

kg kg kg/cm

5050 5050 30,1

5900 5900 27,6

kg/cm

30,1

27,6

Dimensions Oscillation angle Inner track radius

+/-° mm

6 4400

6 4170

8

BOMAG

Weights Operating weight (CECE) Operating weight (CECE) with ROPS-cabin Front axle load (CECE) Rear axle load (CECE) Static linear load front (CECE) Static linear load rear (CECE)

BW 161/202/203 AD-4

Technical Data *

Travel characteristics Travel speed (1) Travel speed (2) Max. gradability without/ with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Electrical equipment Battery Drive system Driven drum

km/h km/h %

kW (PS) 1 rpm V V/AH

Brakes Service brake Parking brake Steering Type of steering Steering operation Steering angle Crabwalk, lateral offsetting of drum (right/left)

+/- degree mm

Vibration system Drive system Frequency 1/2 Amplitude 1/2 Vibrating drum

Hz mm

Water sprinkler system Type Interval control Filling capacities Fuel (diesel) Water Hydraulic oil Engine oil *

l l l l

BW 161 AD-4

BW 202 AD-4

0-6 0-11 40/35

0-6 0-11 40/35

Deutz BF4M 2012 Water 4 74,9 2300 12 12/100 hydrost. front + rear

Deutz BF4M 2012 C Water 4 98 2300 12 12/100 hydrost. front + rear

hydrost. mechanical

hydrost. mechanical

Oscill.-articul. hydrost. 30 170

Oscill.-articul. hydrost. 30 170

hydrost. 40/50 0,91/0,39 front + rear

hydrost. 40/50 0,83/0,35 front + rear

Pressure (+)

Pressure (+)

200 1000 60 13,5

200 1000 60 13,5

The right for technical modifications remains reserved

BW 161/202/203 AD-4

BOMAG

9

Technical Data

Fig. 5

Dimensions in mm

A

B

C

D

H

H2

K

L

O

W

BW 161 ADH-4

3300

1840

715

1220

2320

3000

400

4520

80

1680

BW 203 AD-4

3300

2300

715

1220

2320

3000

400

4520

80

2135

*

BW 161 ADH-4

BW 203 AD-4

kg kg

10200 10700

12700 13200

kg kg kg/cm kg/cm

5300 5400 31,5 32,1

6600 6600 30,9 30,9

Dimensions Oscillation angle Inner track radius

+/-° mm

6 4400

6 4170

10

BOMAG

Weights Operating weight (CECE) Operating weight (CECE) with ROPS-cabin Front axle load (CECE) Rear axle load (CECE) Static linear load front (CECE) Static linear load rear (CECE)

BW 161/202/203 AD-4

Technical Data *

Travel characteristics Travel speed (1) Travel speed (2) Max. gradability without/with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Electrical equipment Battery Drive system Driven drum

km/h km/h %

kW (PS) rpm V V/AH

Brakes Service brake Parking brake Steering Type of steering Steering operation Steering/oscillation angle Crabwalk, lateral offsetting of drum (right/left)

+/- degree mm

Vibration system Drive system Frequency 1/2 Amplitude 1/2 Frequency 1/2 (US-version) Amplitude 1/2 (US-version) Vibrating drum

Hz mm Hz mm

Water sprinkler system Type Interval control Filling capacities Fuel (diesel) Water Hydraulic oil Engine oil *

l l l l

BW 161 ADH-4

BW 203 AD-4

0-6,0 0-11,0 40/35

0-6,0 0-11,0 40/35

Deutz BF4M 2012 C Water 4 98 2300 12 12/100 hydrost. front + rear

Deutz BF4M 2012 C Water 4 98 2300 12 12/100 hydrost. front + rear

hydrost. mechanical

hydrost. mechanical

Oscill.-articul. hydrost. 30/6 170

Oscill.-articul. hydrost. 30/6 170

hydrost. 40/50 0,91/0,39 45/60 0,91/0,39 front + rear

hydrost. 40/50 0,70/0,30

front + rear

Pressure (+)

Pressure (+)

200 1000 60 13,5

200 1000 60 13,5

The right for technical modifications remains reserved

BW 161/202/203 AD-4

BOMAG

11

Technical Data The following noise and vibration values according to the EC-directive for machines, edition (98/37/ EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with the vibration switched on. The machine was standing on an elastic base. During operation these values may vary because of the existing operating conditions.

Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level at the work place of the operator (with cabin): LpA =79,7 dB(A) The nose emission value for the machine according to the noise emission regulation 2000/14/EG is guaranteed sound capacity level of the machine: LWA = 103,3 dB(A) These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO 11204 for sound pressure level (LpA) at the place of the operator.

Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire boy (driver’s seat) The weighted effective acceleration value determined according to ISO 7096 is