PDF Service Training Manual Bomag BW 100 AD AC Series 4 BW 120 AD AC Series 4 - 898 KB
This service training manual is a comprehensive resource for the Bomag BW 100 and BW 120 Series 4 tandem rollers.
It is designed to provide technicians with a deep understanding of the machine's systems, including hydraulics, electrics, and engine.
The manual covers principles of operation, troubleshooting procedures, and detailed repair instructions.
Use this guide to enhance your technical skills and perform effective maintenance.
It is an essential document for any professional servicing these compactors.
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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
Pump installation on diesel engine
3
1
2
Pos. 1 Charge pump
Pos. 2 Vibration pump
Pos. 3 Oil pressure switch 0.6 bar
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BW 100/120 AD Series 4 C3
BW 100/120 AC Series 4
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Service Training
Besides its function of supplying the closed circuit with cool and filtered oil as replacement for
leakage and flushing losses, the oil from the charge circuit is also used to release the travel
motor integrated brakes:
All safety and control elements needed for the operation in a closed hydraulic circuit are
integrated in the travel pump. These are:
High pressure relief valves (380 bar) with integrated boost check valves
Charge pressure relief valve (24 bar)
Servo control
The travel motors (on AD-machines) are hydraulically connected parallel to each other. On
AC-machines all three motors are arranged parallel to each other.
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BW 100/120 AD Series 4 D2
BW 100/120 AC Series 4
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Service Training
Drum drive motor:
Poclain travel motor type MK04
Both drums are driven by Poclain travel motors type MK04. These are radial piston motors.
These drive motors consist of the outer housing, the flat distributor, the cylinder block with
the working pistons, the output shaft and the brake. The brake is designed as a Hirth-
toothing.
The housing consists of
Ø bearing section (bearings for output shaft)
Ø torque module (cam race)
Ø oil distributor and
Ø Hirth brake
The function of the radial piston motor is described hereunder. The piston positions
mentioned in the description are shown in the corresponding illustration.
The movement of a piston along the cam race must be examined during various phases of
the rotation.
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BW 100/120 AD Series 4 D 12
BW 100/120 AC Series 4
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Service Training
If the charge pressure is correct check the high pressure of the travel pump.
Attention! The following test must not exceed 5 seconds !
> Close high pressure ports A and B.
> Connect 600 bar pressure gauges to the high pressure test ports
> Run the engine in idle speed and actuate the travel pump quickly to both
directions.
> Read the pressure gauges.
Nominal value: approx. 400 bar
Close the ports
Install 600 bar pressure
gauges
Fig 6:
________________________________________________________________________________________
BW 100/120 AD Series 4 D 22
BW 100/120 AC Series 4
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Service Training
If the bores are in line check the mechanical neutral position.
> Join both control chambers of the travel pump (X1 and X2)
Note: The resulting condition of equilibrium must bring the machine to standstill.
If the neutral position is reached by this measure replace or repair the servo control
on the machine.
Connect ports X1 and X2 with a
hose
Fig 16:
________________________________________________________________________________________
BW 100/120 AD Series 4 D 32
BW 100/120 AC Series 4
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Service Training
If the pressure value is not reached subject the vibration pump to a high pressure check.
> Install a 200 bar pressure relief valve with a 600 bar pressure gauge between vibration
pump and vibration valve.
> Start the engine and switch on the vibration
Nominal value : approx. 200 bar
If the pressure is reached replace the vibration valve block.
If the pressure value is not reached replace the vibration pump.
________________________________________________________________________________________
BW 100/120 AD Series 4 E9
BW 100/120 AC Series 4
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Service Training
Electric circuit diagrams
Electric circuit diagrams are graphic presentations of control logical conditions in the electric
system. They do not contain any information on the type of wiring, their purpose is solely the
clarification of control logics. Circuit diagrams are of help when performing trouble shooting
and enable the fault free connection during modifications or changes to the electric
equipment of the machine.
Structure:
1. Table of contents
2. Function groups
3. List of components
1. Table of contents
The table of contents lists all function groups and component lists of the machine.
The arrangement of all sheets in a sequence results in the total wiring diagram.
Example:
Function group ”brake”, drawing number 880,100 51 is found on sheet 4
Components list on sheet 101
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BW 100/120 AD Series 4 G1
BW 100/120 AC Series 4
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Service Training
Neutral position of angle sensor
The zero point of the angle sensor is automatically adjusted via the module. Once the travel
lever is in neutral position the brake initiator (on the travel lever) (Pin 12) is actuated. The
zero position is thereby recognized. Should the brake initiator be defective or a cable is
broken the last value is set as default for the zero point.
If LED2 (on the module) flashes in intervals of one second and LED3 lights permanently, the
zero point is reached.
In it iator fo r Brake
LED lights with trav el lev er in zero posit ion
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BW 100/120 AD Series 4 G 11
BW 100/120 AC Series 4
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Inhaltsverzeichnis: BW 100 AD/AC−4, BW 120 AD/AC−4
table of contents: BW 100 AD/AC−4, BW 120 AD/AC−4
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 880 100 51 Stromlaufplan Circuit Diagram
002 880 100 51 Versorgung, Motor, Starten, Not−Aus supply, engine, starting unit, emergancy shut off
003 880 100 51 Vibration, Berieselung vibration, sprinkler system
004 880 100 51 Bremse, Mengenteiler, Rundumkennleuchte, Kantenschneidg. brake, flow divider, rotary beacon, edge cutter
005 880 100 51 Sitzkontakt switch seat contact
006 880 100 51 Arbeitsbeleuchtung, Blinkbegrenzung, Arbeitsbeleuchtung working head lights, flash and position illum., working head lights
007 880 100 51 Wetterschutzkabine cabin, weather protection
009 880 100 51 Zentralelektrik cross − bonding − box
101 880 100 51 Bauteilliste component listing
4.2.2004
Kneip Stromlaufplan 001 001 880 100 51
4.2.2004 circuit diagram
Nallin 001