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  9. Fayat Group BOMAG BW 80 AD-5 User manual

Fayat Group BOMAG BW 80 AD-5 User manual

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Service - Manual
Catalogue number.
008 917 37 12/2013
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 .... > / S/N 101 462 01 .... > / S/N 101 462 03 .... >
S/N 101 462 05 .... > / S/N 101 462 07 .... >
S/N 101 462 04 .... > / S/N 101 462 06 .... >
Tandem Vibratory Roller
Combination Roller
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Table of Contents
BOMAG 3008 917 37
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 13
1.4 Tightening torques 23
The series 5 27
2.1 The series 5 28
Technical data 31
3.1 Technical data 32
Maintenance 49
4.1 General notes on maintenance 50
4.2 Fuels and lubricants 52
4.3 Table of fuels and lubricants 55
4.4 Running-in instructions 56
4.5 Maintenance table 57
Overall view of machine 61
5.1 Overview 62
Electrics 67
6.1 Battery service 68
6.2 Starting with jump wires 69
6.3 Main battery switch 70
6.4 Generator repair 71
6.5 Repair of starter 76
6.6 Instrument cluster (A15), overview 82
6.7 Seat contact switch 84
6.8 Switching the vibration on 85
6.9 Switching on the pressure sprinkler system 86
6.10 Level sensor in diesel tank (R03) 86
6.11 Water in fuel filter, sensor B124 (optional) 87
6.12 Charge control lamp and operating hour meter 88
6.13 Engine oil pressure monitoring 88
6.14 Coolant temperature monitoring 89
6.15 Glow plugs, R81 89
6.16 Engine solenoid, Y13 90
6.17 Inductive proximity switch, B63 91
6.18 Angle sensor on travel control lever, B39 92
6.19 Central electrics 94
6.20 Fuses 100
6.21 Control elements 101
6.22 Machine related electrics 103
Engine 109
7.1 Fuel supply 110
7.2 Kubota diesel engine 111
7.3 Checking the engine oil level 114
7.4 Changing engine oil and oil filter 115
7.5 Checking the coolant level 116
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Table of Contents
BOMAG4008 917 37
7.6 Changing the coolant 117
7.7 Check radiator hoses and hose clamps 118
7.8 Cleaning radiator and hydraulic oil cooler 119
7.9 Checking, tensioning, replacing the V-belt 120
7.10 Checking, cleaning the air filter, replacing if necessary 120
7.11 Check the air intake lines 122
7.12 Checking, cleaning the water separator 122
7.13 Change the fuel filter 123
7.14 Checking fuel lines and clamps 124
7.15 Changing fuel lines 124
7.16 Checking the engine oil pressure 125
7.17 Checking the thermostat in disassembled state 125
7.18 Check the injection valves 126
7.19 Checking the start of commencement 128
7.20 Checking the fuel injection pump 129
7.21 Checking the compression 130
7.22 Checking, adjusting the valve clearance 131
7.23 Engine problems 133
Hydraulics 135
8.1 Hydraulic circuit 136
8.2 Travel pump, A10VG18 HW 138
8.3 Drum drive motor MK04 145
8.4 Wheel motor MSE02 148
8.5 External gear motors 151
8.6 External gear pumps 152
8.7 Pump assembly 154
8.8 Travel circuit 156
8.9 Towing 166
8.10 Vibration circuit 169
8.11 Steering circuit 174
8.12 Checking the hydraulic oil level 180
8.13 Changing the hydraulic oil 181
8.14 Checking the hydraulic oil filter element 182
8.15 Change the hydraulic oil filter 183
Tests and adjustments 185
9.1 Special tools, tests and adjustments 186
9.2 Checking the rotation speeds 190
9.3 Pressure tests in the travel circuit 192
9.4 Checking / adjusting the neutral positions of the travel pump 194
9.5 Pressure test in the vibration circuit 197
9.6 Checking the leakage rate of the vibration motor 199
Trouble shooting 201
10.1 Perform trouble shooting 202
10.2 Trouble shooting chart, diesel engine 203
10.3 Troubleshooting axial piston pumps 205
10.4 Fault detection via instrument cluster, A15 208
10.5 The machine does not drive 208
10.6 Insufficient travel power 210
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Table of Contents
BOMAG 5008 917 37
Flushing and bleeding 213
11.1 Special tools for flushing 214
11.2 Flushing - general 219
11.3 Flushing schematic for travel system, AD/SC-machine 221
11.4 Travel system, flushing AD/SC-machine 222
11.5 Flushing schematic for travel system, AC-machine 226
11.6 Travel system, flushing AC-machine 227
11.7 Bleeding the travel circuit 231
Drum 233
12.1 Repair overview for drums 234
12.2 Removing and installing the AD-drum 240
12.3 Dismantling the AD-drum 242
12.4 Assembling the AD-drum 248
Oscillating articulated joint 255
13.1 Repair overview oscillating articulated joint 256
13.2 Removing and installing the oscillating articulated joint 258
13.3 Repairing the oscillating articulated joint 259
Suppliers documentation 265
14.1 Drum drive 267
14.2 Wheel drive 285
14.3 Steering valve 361
Circuit diagrams 377
15.1 Hydraulic diagram 121 379
15.2 Wiring diagram 76 391
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Table of Contents
BOMAG6008 917 37
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BOMAG 7008 917 37
1 General
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1.1 Introduction
BOMAG8008 917 37
1.1 Introduction
This manual addresses the professionally qualified
personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.
Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
4 Fundamental electrics
Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
!Danger
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
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Safety regulations
BOMAG 9008 917 37
1.2
1.2 Safety regulations
Important notes
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants,
cleaning agents and solvent as well as gases and
chemicals are subject to legal regulations, which
are intended to provide a minimum on safety. It is
obviously your own responsibility to know and
adhere to these regulations.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan-
gers to persons, property and the environment.
i
Note
Paragraphs marked like this contain technical infor-
mation for the optimaleconomical use of the machine.
!
Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
!Danger
Paragraphs marked like this highlight possible
dangers for persons.
Environment
Paragraphs marked like this point out practices
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Observe the regulations for the protection of the
environment.
General
lFor repair and maintenance work move the ma-
chine on a firm base and shut it down.
lAlways secure the machine against unintended roll-
ing.
lSecure the engine reliably against unintentional
starting.
lMark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
the dashboard.
lBlock the articulated joint with the articulation lock.
lUse protective clothes like hard hat, safety boots
and gloves.
lKeep unauthorized persons away from the machine
during repair work.
lTools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
safe condition.
lUse only safe and approved lifting gear of sufficient
load bearing capacity to remove and install parts or
components from and to the machine.
lDo not use easily inflammable or harmful substanc-
es, such as gasoline or paint thinners for cleaning.
lDo not smoke or use open fire and avoid sparks
when cleaning or repairing a tank.
lWhen performing welding work strictly comply with
the respective welding instructions.
Transport work with cranes and lifting
tackle
i
Note
Cranes must only be operated by instructed persons
who had been trained in handling cranes.
lFollow the operating instructions of the manufactur-
er when working with cranes.
lFollow the operating instructions of the operator
when working with cranes.
lAlways comply with the applicable accident preven-
tion instructions when working with cranes and lift-
ing tackle.
Precautions and codes of conduct for
welding work
Welding work must only be carried out by properly
trained personnel.
!Danger
Electric shock!
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
eyes!
Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
lCheck welding equipment and cables for damage
before use (also the validity of inspection stickers).
lEnsure good conductivity between ground cable
and workpiece, avoid joints and bearings.
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1.2 Safety regulations
BOMAG10 008 917 37
lStart the extraction fan before starting work and
guide with the progressing work as required.
lAlways isolate the burner when laying it down (re-
move possible electrode residues).
lProtect cables from being damaged, use cables
with insulated couplings.
lEnsure sufficient fire protection, keep a fire extin-
guisher at hand.
lWelding work in areas where there is a risk of fire or
explosion, must only be carried out with welding
permission.
lRemove any combustible materials from the weld-
ing area or cover such items appropriately.
lName a fire watch during and after welding work.
lPlace welding rod holders and inert gas welding
guns only on properly insulated bases.
lPlace the inert gas bottles in a safe place and se-
cure them against falling over.
lUse a protective screen or hand shield with welding
filter, wear welding gloves and clothes.
lSwitch the welding unit off before connecting weld-
ing cables.
lCheck electrode holders and electric cables at reg-
ular intervals.
Behaviour in case of faults
lIn case of faults on the welding unit switch of the
welding unit immediately and have it repaired by ex-
pert personnel.
lIn case of failure of the extraction system switch the
system off and have it repaired by expert personnel.
Maintenance; waste disposal
lReplace damaged insulating jaws and welding rod
holders immediately.
lReplace the welding wire reels only in de-energized
state.
What to do in case of accidents; First Aid
lKeep calm.
lCall first air helpers.
lReport the accident.
lIn case of an electric accident: Interrupt the power
supply and remove the injured person from the
electric circuit. If breathing and heart have stopped
apply reactivation measures and call for an emer-
gency doctor.
Operation of high-voltage systems
i
Note
The rules and statutory regulations valid in the corre-
sponding do apply in addition to the notes given here.
!
Caution
The high-voltage system must only be operated
and serviced by qualified and authorized person-
nel.
Before starting operation the operator must check
the proper condition of the system.
!Danger
Possibility of injury or even death caused by elec-
tric shock:
lif persons come into contact with live parts,
lin case of faulty insulation of live parts,
linadequate, unsuitable insulation,
lif melted parts flake off in case of short circuits.
Old oils
Prolonged and repetitive contact with mineral oils will
remove the natural greases from the skin and causes
dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
which could cause skin cancer. Appropriate skin pro-
tection agents and washing facilities must therefore
be provided.
lWear protective clothes and safety gloves, if possi-
ble.
lIf there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
full face visor; a facility suitable for rinsing the eyes
should also be available.
lAvoid longer and repetitive contacts with oils. In
case of open incisionsand injuries seek medical ad-
vice immediately.
lApply protective cream before starting work, so that
oil can be easier removed from the skin.
lWash affected skin areas with water and soap (skin
cleansers and nail brushes will help). Lanolin con-
taining agents will replace natural skin oils that were
lost.
lDo not use gasoline, kerosene, diesel, thinner or
solvents to wash the skin.
lDo not put oil soaked cloths into your pockets.
lAvoid clothes getting soiled by oil.
lOveralls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
lIf possible degrease components before handling.
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