Bomag BW 80 AD-5 User manual

Catalogue No.
008 067 01
Operating instructions
Maintenance instructions
Original operating instructions
05/2012
BW 80 AD-5/BW 90 AD-5/BW 100 ADM-5
BW 90 SC-5 / BW 100 SC-5
BW 100 ACM-5/BW 100 SCC-5
S/N 101 462 00 1139 > / S/N 101 462 01 1053 > / S/N 101 462 03 1065 >
S/N 101 462 05 1027 > / S/N 101 462 07 1013 >
S/N 101 462 04 1028 > / S/N 101 462 06 ....
Tandem Vibratory Roller
Combination Roller

Foreword
BOMAG 3BW 80 AD-5 Fam.
1 Foreword
These BOMAG machines are
products from the wide product
range of BOMAG machines for
earth and asphalt construction,
refuse compaction and stabiliz-
ing/recycling.
BOMAG’s vast experience in con-
nection with state-of-the-art pro-
duction and testing methods,
such as lifetime tests of all impor-
tant components and highest
quality demands guarantee maxi-
mum reliability of your machine.
This manual comprises:
lSafety regulations
lOperating instructions
lmaintenance instructions
lTrouble shooting
Using these instructions will
lhelp you to become familiar with
the machine.
lavoid malfunctions caused by un-
professional operation.
Compliance with the maintenance in-
structions will
lenhance the reliability of the ma-
chine on construction sites,
lprolong the lifetime of the ma-
chine,
lreduce repair costs and down-
times.
BOMAG will not assume liability for
the function of the machine
lif it is handled in a way not comply-
ing with the usual modes of use,
lif it is used for purposes other than
those mentioned in these instruc-
tions.
No warranty claims can be lodged in
case of damage resulting from
loperating errors,
linsufficient maintenance and
lwrong fuels and lubricants.
Please note!
This manual was written for opera-
tors 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 provid-
ed container. These operating and
maintenance instructions are part of
the machine.
You should only operate the machine
after you have been instructed and in
compliance with these instructions.
Strictly observe the safety regula-
tions.
Please observe also the guidelines
of the Civil Engineering Liability As-
sociation ”Safety Rules for the Oper-
ation of Road Rollers and Soil

Foreword
BOMAG4BW80AD-5Fam.
Compactors” and all relevant acci-
dent prevention regulations.
For your own personal safety you
should only use original spare
parts from BOMAG.
For your machine BOMAG offers
service kits to make maintenance
easier.
In the course of technical develop-
ment we reserve the right for tech-
nical modifications without prior
notification.
These operating and maintenance
instructions are also available in oth-
er languages.
Apart from that, the spare parts cata-
logue is available from your BOMAG
dealer against the serial number of
your machine.
Your BOMAG dealer will also supply
you with information about the cor-
rect 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
Copyright by BOMAG

Foreword
BOMAG 5BW 80 AD-5 Fam.
Please fill in
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine type (Fig. 1)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial-number (Fig. 1 and 2)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor type (Fig. 3)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor number (Fig. 3)
Note
i
Supplement the above data together
with the commissioning protocol.
During commissioning our organisa-
tion 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. 1
Fig. 2
Fig. 3
462108

Foreword
BOMAG6BW80AD-5Fam.

Table of Contents
BOMAG 7BW 80 AD-5 Fam.
1 Foreword 3
2 Technical data 11
3 Safety regulations 35
4 Display and control elements 61
4.1 General notes 64
4.2 Description of indicators and control elements 64
5 Operation 77
5.1 General 78
5.2 Tests before taking into operation 78
5.3 Electronic immobilizer 79
5.4 Adjusting the driver’s seat 80
5.5 Starting the engine 81
5.6 Starting with jump wires 84
5.7 Driving the machine 85
5.8 Stopping the machine, operating the parking brake 88
5.9 Shutting down the engine 88
5.10 Switching the vibration on and off 90
5.11 Switching the pressure sprinkling system on and off 94
5.12 Switching the tire sprinkling system on and off 96
5.13 Setting the crabwalk 97
5.14 What to do in events of emergency 98
5.15 Connecting/disconnecting the hydraulic breaker 99
5.16 Towing 102
5.17 Loading/transport 105
6 Maintenance 109
6.1 General notes on maintenance 110
6.2 Fuels and lubricants 113
6.3 Table of fuels and lubricants 118
6.4 Running-in instructions 121
6.5 Maintenance table 122
Every 10 operating hours 127
6.6 Check the engine oil level 127
6.7 Check the fuel level 128

Table of Contents
BOMAG8BW80AD-5Fam.
6.8 Checking the hydraulic oil level 129
6.9 Checking the hydraulic oil filter element 130
6.10 Checking the coolant level 130
6.11 Checking the water level 131
6.12 Check the emulsion level 132
Every 50 operating hours 133
6.13 Checking, cleaning the air filter, replacing if necessary 133
6.14 Check fuel lines and clamps 135
6.15 Checking, cleaning the water separator 136
Every 250 operating hours 137
6.16 Changing engine oil and oil filter 137
6.17 Checking, tensioning, replacing the V-belt 139
6.18 Checking the air intake lines 140
6.19 Cleaning radiator and hydraulic oil cooler 140
6.20 Battery service 142
6.21 Checking radiator hoses and hose clamps 143
6.22 Check the scrapers, adjust if necessary 144
Every 500 operating hours 145
6.23 Drain the fuel tank sludge 145
6.24 Change the fuel filter 146
6.25 Check the anti-freeze concentration and the condition of the coolant 147
Every 1000 operating hours 149
6.26 Checking, adjusting the valve clearance 149
6.27 Check the engine mounts 150
6.28 Check the travel control 151
Every 2000 operating hours 153
6.29 Changing hydraulic oil and breather filter 153
6.30 Change the hydraulic oil filter 156
6.31 Changing the coolant 157
6.32 Changing the fuel lines 159
6.33 Check the injection nozzles 159
Every 3000 operating hours 161
6.34 Check the fuel injection pump 161
As required 163
6.35 Check the tire pressure 163

Table of Contents
BOMAG 9BW 80 AD-5 Fam.
6.36 Water sprinkler system, maintenance in case of frost 163
6.37 Tightening torques for screws with metric unified thread 165
6.38 Measures to be applied for longer periods of rest 166
7 Trouble shooting 167
7.1 General notes 168
7.2 Engine problems 169
8 Disposal 173
8.1 Final shut-down of machine 174

Table of Contents
BOMAG10 BW 80 AD-5 Fam.

BOMAG 11BW 80 AD-5 Fam.
2 Technical data

Technical data
BOMAG12 BW 80 AD-5 Fam.
Fig. 4
BW 80 AD-5
Dimen-
sions
A B C D H H2K L O S W
in mm 1483 856 433 580 1627 2304 255 2194 28 13 800
in in 58.4 33.7 17.0 22.8 64.1 90.7 10.0 86.4 1.1 0.51 31.5

Technical data
BOMAG 13BW 80 AD-5 Fam.
1BW 80 AD-5
Weights
Operating weight (CECE) kg (lbs) 1550 (3417)
Mean static linear load (CECE) kg/cm (pli) 9,7 (54.3)
Max. operating weight kg (lbs) 1800 (3968)
Travel characteristics
Max. travel speed km/h (mph) 10,0 (6.2)
Max. working speed with vibration km/h (mph) 4,5 (2.8)
Max. gradability without/with vibration
(soil dependent)
% 40/30
Drive
Engine manufacturer Kubota
Type D902
Cooling Water
Number of cylinders 3
Rated power ISO 14396 kW 15.1
Rated power SAE J 1995 hp 20.2
Fixed engine speed (1) min-1 3000
Fixed engine speed (2) min-1 2100
Electrical equipment V 12
Drive system hydrostatic
Driven drum front + rear
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering/oscillation angle +/-° 33/8
Inner track radius mm (in) 2080 (81.9)
Vibration system

Technical data
BOMAG14 BW 80 AD-5 Fam.
Vibrating drum front + rear
Drive system hydrostatic
Frequency (1) Hz (vpm) 63 (3780)
Frequency (2) Hz (vpm) 42 (2520)
Amplitude mm (in) 0,50 (0,020)
Centrifugal force (1) kN (lbf) 17 (3822)
Centrifugal force (2) kN (lbf) 8 (1798)
Water sprinkler system
Type Pressure
Filling capacities
Fuel (diesel) l (gal us) approx. 30 (7.9)
Water (sprinkling system) l (gal us) approx. 100 (26.4)
Hydraulic oil l (gal us) approx. 14 (3.7)
Engine oil l (gal us) approx. 3.9 (1.0)
Coolant l (gal us) approx. 9 (2.4)
1 The right for technical modifications remains reserved
1BW 80 AD-5

Technical data
BOMAG 15BW 80 AD-5 Fam.
Fig. 5
BW 90 AD-5
Dimen-
sions
A B C D H H2K L O S W
in mm 1483 956 433 580 1627 2304 255 2194 28 12 900
in in 58.4 37.6 17.0 22.8 64.1 90.7 10.0 86.4 1.1 0.47 35.4

Technical data
BOMAG16 BW 80 AD-5 Fam.
1BW 90 AD-5
Weights
Operating weight (CECE) kg (lbs) 1600 (3527)
Mean static linear load (CECE) kg/cm (pli) 8,9 (49.8)
Max. operating weight kg (lbs) 1800 (3968)
Travel characteristics
Max. travel speed km/h (mph) 10,0 (6.2)
Max. working speed with vibration km/h (mph) 4,5 (2.8)
Max. gradability without/with vibration
(soil dependent)
% 40/30
Drive
Engine manufacturer Kubota
Type D902
Cooling Water
Number of cylinders 3
Rated power ISO 14396 kW 15.1
Rated power SAE J 1995 hp 20.2
Fixed engine speed (1) min-1 3000
Fixed engine speed (2) min-1 2100
Electrical equipment V 12
Drive system hydrostatic
Driven drum front + rear
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering/oscillation angle +/-° 33/8
Inner track radius mm (in) 2030 (79.9)
Vibration system

Technical data
BOMAG 17BW 80 AD-5 Fam.
Vibrating drum front + rear
Drive system hydrostatic
Frequency (1) Hz (vpm) 63 (3780)
Frequency (2) Hz (vpm) 42 (2520)
Amplitude mm (in) 0,50 (0,020)
Centrifugal force (1) kN (lbf) 17 (3822)
Centrifugal force (2) kN (lbf) 8 (1798)
Water sprinkler system
Type Pressure
Filling capacities
Fuel (diesel) l (gal us) approx. 30 (7.9)
Water (sprinkling system) l (gal us) approx. 100 (26.4)
Hydraulic oil l (gal us) approx. 14 (3.7)
Engine oil l (gal us) approx. 3.9 (1.0)
Coolant l (gal us) approx. 9 (2.4)
1 The right for technical modifications remains reserved
1BW 90 AD-5

Technical data
BOMAG18 BW 80 AD-5 Fam.
Fig. 6
BW 100 ADM-5
Dimen-
sions
A B C D H H2K L O S W
in mm 1483 1056 433 580 1627 2304 255 2194 28 12 1000
in in 58.4 41.6 17.0 22.8 64.1 90.7 10.0 86.4 1.1 0.47 39.4

Technical data
BOMAG 19BW 80 AD-5 Fam.
1BW 100 ADM-5
Weights
Operating weight (CECE) kg (lbs) 1650 (3638)
Mean static linear load (CECE) kg/cm (pli) 8,3 (46.2)
Max. operating weight kg (lbs) 1800 (3968)
Travel characteristics
Max. travel speed km/h (mph) 10,0 (6.2)
Max. working speed with vibration km/h (mph) 4,5 (2.8)
Max. gradability without/with vibration
(soil dependent)
% 40/30
Drive
Engine manufacturer Kubota
Type D902
Cooling Water
Number of cylinders 3
Rated power ISO 14396 kW 15.1
Rated power SAE J 1995 hp 20.2
Fixed engine speed (1) min-1 3000
Fixed engine speed (2) min-1 2100
Electrical equipment V 12
Drive system hydrostatic
Driven drum front + rear
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering/oscillation angle +/-° 33/8
Inner track radius mm (in) 1980 (78.0)
Vibration system

Technical data
BOMAG20 BW 80 AD-5 Fam.
Vibrating drum front + rear
Drive system hydrostatic
Frequency (1) Hz (vpm) 63 (3780)
Frequency (2) Hz (vpm) 42 (2520)
Amplitude mm (in) 0,40 (0,016)
Centrifugal force (1) kN (lbf) 17 (3822)
Centrifugal force (2) kN (lbf) 8 (1798)
Water sprinkler system
Type Pressure
Filling capacities
Fuel (diesel) l (gal us) approx. 30 (7.9)
Water (sprinkling system) l (gal us) approx. 100 (26.4)
Hydraulic oil l (gal us) approx. 14 (3.7)
Engine oil l (gal us) approx. 3.9 (1.0)
Coolant l (gal us) approx. 9 (2.4)
1 The right for technical modifications remains reserved
1BW 100 ADM-5