Fayat Group BOMAG BW 80 AD-5 User manual

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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