Fayat Group BOMAG BW 80/90 AD-5 User manual

BW 80/90 AD-5 / BW 100 ADM/ACM-5 /
BW 90/100 SC-5 / BW 100 SCC-5
Tandem vibratory roller
Combination roller
Service Manual
S-462-0018
S/N 101 462 00 1797> S/N 101 462 01 1323> S/N 101 462 03 1443> /
S/N 101 462 05 1087> S/N 101 462 07 1054> / S/N 101 462 04 1104> S/N 101 462 06 1015>
© 05/2018008 925 60

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Table of contents
1 General................................................................................................................................................... 7
1.1 Introduction................................................................................................................................... 8
1.2 Safety regulations....................................................................................................................... 10
1.3 Maintenance and repair.............................................................................................................. 29
1.3.1 Notes on repair........................................................................................................................... 29
1.3.2 General notes on maintenance.................................................................................................. 43
2 Technical data...................................................................................................................................... 45
2.1 BW 80 AD-5.................................................................................................................................. 47
2.1.1 Noise and vibration data............................................................................................................ 49
2.2 BW 90 AD-5.................................................................................................................................. 51
2.2.1 Noise and vibration data............................................................................................................ 53
2.3 BW 90 AC-5.................................................................................................................................. 55
2.3.1 Noise and vibration data............................................................................................................ 57
2.4 BW 100 ADM-5............................................................................................................................. 59
2.4.1 Noise and vibration data............................................................................................................ 61
2.5 BW 90 SC-5.................................................................................................................................. 63
2.5.1 Noise and vibration data............................................................................................................ 65
2.6 BW 100 SC-5................................................................................................................................ 67
2.6.1 Noise and vibration data............................................................................................................ 69
2.7 BW 100 ACM-5............................................................................................................................. 71
2.7.1 Noise and vibration data............................................................................................................ 74
2.8 BW 100 SCC-5............................................................................................................................. 75
2.8.1 Noise and vibration data............................................................................................................ 78
2.9 Additional technical data............................................................................................................ 79
2.10 Terms and basis of calculation................................................................................................ 81
2.11 Fuels and lubricants................................................................................................................. 82
2.11.1 Engine oil.................................................................................................................................. 82
2.11.2 Fuel.......................................................................................................................................... 83
2.11.3 Coolant..................................................................................................................................... 84
2.11.4 Hydraulic oil.............................................................................................................................. 85
2.12 List of fuels and lubricants...................................................................................................... 86
3 Overview of machine.......................................................................................................................... 87
3.1 General information.................................................................................................................... 88
3.2 Overviews.................................................................................................................................... 92
3.3 Electric systems.......................................................................................................................... 99
3.4 Hydraulic system...................................................................................................................... 101
3.5 Machine assemblies................................................................................................................. 104
3.5.1 Diesel engine........................................................................................................................... 104
3.5.2 Oscillating articulated joint....................................................................................................... 105
3.5.3 Drum........................................................................................................................................ 107
4 Electric systems................................................................................................................................ 111
4.1 Basic principles......................................................................................................................... 113
4.1.1 Measuring method.................................................................................................................... 113
4.1.2 Understanding circuit diagrams................................................................................................ 118
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4.1.3 Telemecanique switch.............................................................................................................. 129
4.1.4 Deutsch plug, series DT and DTM........................................................................................... 131
4.1.5 Magnetic coil plug.................................................................................................................... 135
4.2 Overview of electric system..................................................................................................... 138
4.2.1 Driver’s stand, old version........................................................................................................ 141
4.2.2 Driver’s stand, new version...................................................................................................... 144
4.2.3 Wiring....................................................................................................................................... 147
4.2.4 CAN BUS overview.................................................................................................................. 158
4.2.5 Table of fuels and lubricants..................................................................................................... 160
4.3 Starting with jump wires........................................................................................................... 166
4.4 Central electrics........................................................................................................................ 167
4.5 Fuse assignment....................................................................................................................... 172
4.5.1 Central electrics....................................................................................................................... 173
4.5.2 Main battery fuse...................................................................................................................... 174
4.6 Description of electrical components..................................................................................... 175
4.6.1 Angle sensor on travel lever, B39............................................................................................ 175
4.6.2 Inductive proximity switch, B63................................................................................................ 177
4.6.3 Switching the vibration on, old version..................................................................................... 178
4.6.4 Switching the vibration on, new version................................................................................... 179
4.6.5 Switching the pressurized spraying system on, old version..................................................... 180
4.6.6 Switching the pressurized spraying system on, new version................................................... 181
4.6.7 Sensor, water in fuel filter, B124............................................................................................... 182
4.6.8 Engine oil pressure monitoring................................................................................................. 182
4.6.9 Coolant temperature monitoring............................................................................................... 182
4.6.10 Level sensor in diesel tank, R03............................................................................................ 183
4.6.11 Charge control light and operating hour meter....................................................................... 183
4.6.12 Glow plugs, R81, R82 & R83................................................................................................. 185
4.6.13 Engine solenoid, Y13............................................................................................................. 186
4.6.14 Instrument cluster, old version............................................................................................... 187
4.6.15 Instrument cluster, new version.............................................................................................. 189
4.6.16 Seat contact control............................................................................................................... 191
4.7 Repairs....................................................................................................................................... 192
4.7.1 Generator repair....................................................................................................................... 192
4.7.2 Repair of starter....................................................................................................................... 196
4.8 Inspection and maintenance work.......................................................................................... 202
4.8.1 Maintenance Table................................................................................................................... 202
4.8.2 Every 250 operating hours....................................................................................................... 202
4.8.3 As required............................................................................................................................... 204
5 Hydraulic system.............................................................................................................................. 207
5.1 Basic principles......................................................................................................................... 209
5.1.1 Open and closed hydraulic circuit............................................................................................ 209
5.1.2 Swash plate principle, pump.................................................................................................... 211
5.1.3 External gear pumps................................................................................................................ 212
5.1.4 Reversible external gear motor................................................................................................ 215
5.2 Overview of hydraulics............................................................................................................. 217
5.2.1 Pump overview......................................................................................................................... 219
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5.3 Description of hydraulic components..................................................................................... 221
5.3.1 Travel pump, A10VG18 HW..................................................................................................... 221
5.3.2 Drum drive motor MK 04.......................................................................................................... 227
5.3.3 Wheel drive motor, MS/MSE.................................................................................................... 232
5.3.4 Steering valve.......................................................................................................................... 236
5.4 Description of hydraulic circuits............................................................................................. 238
5.4.1 Travel circuit............................................................................................................................. 238
5.4.2 Vibration circuit......................................................................................................................... 247
5.4.3 Steering circuit......................................................................................................................... 252
5.4.4 Edge cutter............................................................................................................................... 259
5.4.5 Hydraulic cutting tool................................................................................................................ 260
5.5 Tests and adjustments............................................................................................................. 262
5.5.1 Pump overview......................................................................................................................... 263
5.5.2 Checking the rotation speeds................................................................................................... 264
5.5.3 Pressure tests in the travel circuit............................................................................................ 265
5.5.4 Checking / adjusting the neutral positions of the travel pump.................................................. 267
5.5.5 Pressure test in the vibration circuit......................................................................................... 270
5.5.6 Checking the leakage rate of the vibration motor..................................................................... 271
5.6 Flushing and bleeding.............................................................................................................. 273
5.6.1 Flushing - general.................................................................................................................... 273
5.6.2 Flushing schematic for travel system, AD/SC-machine........................................................... 276
5.6.3 Travel system, flushing AD/SC-machine.................................................................................. 276
5.6.4 Flushing schematic for travel system, AC-machine................................................................. 281
5.6.5 Travel system, flushing AC-machine........................................................................................ 282
5.6.6 Bleeding the travel circuit......................................................................................................... 286
5.7 Inspection and maintenance work.......................................................................................... 288
5.7.1 Maintenance Table................................................................................................................... 288
5.7.2 Checks prior to start up............................................................................................................ 288
5.7.3 Every 500 operating hours....................................................................................................... 289
5.7.4 Every 2000 operating hours..................................................................................................... 290
6 Machine assemblies......................................................................................................................... 295
6.1 Diesel engine............................................................................................................................. 296
6.1.1 Overview of diesel engine........................................................................................................ 296
6.1.2 Kubota diesel engine................................................................................................................ 300
6.1.3 Check the injection valves........................................................................................................ 302
6.1.4 Checking the fuel injection pump............................................................................................. 305
6.1.5 Inspection and maintenance work............................................................................................ 306
6.2 Oscillating articulated joint...................................................................................................... 331
6.2.1 Overview oscillating articulated joint........................................................................................ 331
6.2.2 Removing and installing the oscillating articulated joint........................................................... 334
6.2.3 Repairing the oscillating articulated joint.................................................................................. 334
6.3 Drum........................................................................................................................................... 341
6.3.1 Overview drum......................................................................................................................... 341
6.3.2 Removing and installing the AD-drum...................................................................................... 345
6.3.3 Dismantling the AD-drum......................................................................................................... 348
6.3.4 Assembling the AD-drum......................................................................................................... 353
Table of contents
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7 Troubleshooting................................................................................................................................ 359
7.1 Preliminary remarks.................................................................................................................. 360
7.2 Emergency procedures............................................................................................................ 361
7.2.1 Actuating the emergency stop switch....................................................................................... 361
7.2.2 Disconnecting the battery......................................................................................................... 361
7.2.3 Towing the machine................................................................................................................. 361
7.3 Towing - tandem vibratory roller............................................................................................. 362
7.4 Towing - combination roller..................................................................................................... 365
7.5 Troubleshooting, electrical systems....................................................................................... 367
7.5.1 Preliminary remarks................................................................................................................. 367
7.5.2 Starting with jump wires........................................................................................................... 370
7.5.3 Fuse assignment...................................................................................................................... 371
7.5.4 Trouble shooting "Starter"........................................................................................................ 374
7.5.5 Fault detection via instrument cluster, A15.............................................................................. 376
7.5.6 Trouble shooting ECONOMIZER............................................................................................. 377
7.5.7 The machine does not drive..................................................................................................... 378
7.5.8 Seat contact control................................................................................................................. 380
7.5.9 Check the parking brake.......................................................................................................... 381
7.6 Trouble shooting, hydraulics................................................................................................... 383
7.6.1 Insufficient hydraulic power...................................................................................................... 383
7.6.2 Troubleshooting axial piston pumps......................................................................................... 386
7.6.3 The machine does not drive..................................................................................................... 388
7.6.4 Insufficient travel power........................................................................................................... 389
7.6.5 Check the parking brake.......................................................................................................... 391
7.7 Trouble shooting, diesel engine.............................................................................................. 393
7.7.1 Engine problems ..................................................................................................................... 393
8 Special tools...................................................................................................................................... 395
8.1 Special tools, hydraulic system............................................................................................... 396
8.1.1 Special tools, tests and adjustments........................................................................................ 396
8.1.2 Special tools for flushing.......................................................................................................... 398
8.2 Special tools, electrics............................................................................................................. 399
9 Index................................................................................................................................................... 401
Appendix............................................................................................................................................ 411
A Circuit diagrams............................................................................................ 413
A.1 Circuit diagram 368................................................................................... 413
A.2 Hydraulic diagram 289............................................................................... 446
Table of contents
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1 General
General
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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1.1 Introduction................................................................. 8
1.2 Safety regulations..................................................... 10
1.3 Maintenance and repair............................................ 29
1.3.1 Notes on repair........................................................ 29
1.3.2 General notes on maintenance................................ 43
1.1 Introduction
This manual:
naddresses the BOMAG Customer Service and professionally
trained personnel.
nprovides support for repair work or maintenance procedures on
the machine.
This manual described the deinstallation, dismantling , assembly,
installation as well as the repair of components and assembly
groups as far as this makes sense with respect to tools and spare
parts supply.
The index is a reference register that will help you to find informa-
tion in this Service Manual. The index lists keywords in alphabet-
ical order. Cross references (keywords related to page numbers)
enable quick and convenient search/navigation.
Keywords concerning the following subjects are listed in the index:
nElectrical operating means
nPlug designations
nOverviews
nFault codes
nTroubleshooting
n...
For the BOMAG machines described in this manual the following
documentation is additionally available:
nOperating and maintenance instructions
nSpare parts catalogue
nService information (if necessary)
General
Index
Documentation
General – Introduction
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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nSpecialist teams are available for you in Germany, Europe and
overseas. This tight network ensures close customer contact
all over the world.
nParts for maintenance, service and repair are available from
our branch offices and dealers at very short notice.
nBOMAG guarantees long-term availability of all common parts.
nWell-designed catalogues provide an easy guide to finding and
ordering the required parts.
nOnly use genuine BOMAG parts. These have been specially
adapted to the corresponding machine. In this way, you will
prevent any problems arising and unnecessary downtimes of
your machine.
This manual is not subject of an updating service. For this reason
we would like to draw your attention to the additionally published
service informations.
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 notification.
Information and illustrations in this manual must not be reproduced
and distributed, nor must they be used for the purpose of competi-
tion without the consent of BOMAG. All rights according to the
copyright law remain expressly reserved.
Maintenance/parts service
Updating service
Copyright
General – Introduction
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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1.2 Safety regulations
This BOMAG machine has been built in compliance with the
latest technical standard and complies with the applicable
regulations and technical rules. However, dangers for persons
and property may arise from this machine, if:
nit is used for purposes other than the ones it is intended for,
nit is operated by untrained personnel,
nit is changed or converted in an unprofessional way,
nthe safety instructions are not observed.
Each person involved in the operation, maintenance and
repair of the machine must therefore read and comply with
these safety regulations. If necessary, this must be confirmed
by obtaining the signature of the customer.
Furthermore, the following obviously also applies:
napplicable accident prevention instructions,
ngenerally accepted safety and road traffic regulations,
ncountry specific safety regulations. It is the duty of the operator
to be acquainted with these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.
This machine must only be used for:
nCompaction of bituminous material, e.g. road surface layers,
nlight to medium compaction work in earth construction or road
sub-bases.
Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
Examples for improper use are:
nwork with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
ncleaning the drums while driving or changing nozzles during
travel.
ndriving on subsoils with too low load bearing capacity
ndriving on slippery subsoils (e.g. ice and snow)
ndriving on surfaces of insufficient size (danger of turning over)
nPassing over too high borders (e.g. curbstones, embankments,
trenches, potholes)
nunauthorized use of public roads
nUsing the machine for towing
transporting persons, except the machine driver, is prohibited.
General
Intended use
Improper use
General – Safety regulations
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starting and operation of the machine in explosive environments
and in underground mining is prohibited.
Despite careful work and compliance with standards and regula-
tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
Both the machine as well as all other system components comply
with the currently valid safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even when using the machine
for the purpose it is intended for and following all information given
in the operating instructions.
A remaining risk can also not be excluded beyond the actual
danger zone of the machine. Persons remaining in this area must
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
All persons remaining ion the area of the machine must be
informed about the dangers that arise from the operation of the
machine.
Have the machine inspected by an expert (capable person) as
required for the conditiosn the machine is working under, but at
least once every year.
Only trained, instructed and authorized persons of at least 18 years
of age are permitted to drive and operate this machine. For opera-
tion of the machine the responsibilities must be clearly specified
and complied with.
Persons under the influence of alcohol, medicine or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
Unauthorized changes to the machine are prohibited for safety rea-
sons.
Original parts and accessories have been specially designed for
this machine.
We wish to make explicitly clear that we have not tested or
approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse
effect on the active and/or passive safety.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.
Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Remaining dangers, remaining
risks
Regular safety inspections
Who is allowed to operate the
machine?
Changes and conversions to the
machine
Damage, deficiencies, misuse of
safety installations
General – Safety regulations
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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Safety installations and switches must neither be removed nor
must they be made ineffective.
WARNING!
Paragraphs marked like this highlight possible dan-
gers for persons.
NOTICE!
Paragraphs marked like this highlight possible dan-
gers for machines or parts of the machine.
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the
machine.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubri-
cants as well as replacement parts.
Observe the regulations for the protection of the
environment.
Loading with loading ramp
Use only stable loading ramps of sufficient load bearing capacity.
The ramp inclination must be less than the gradability of the
machine.
The ramp must be free of grease, oil, snow and ice.
Make sure that persons are not endangered by the machine tipping
or sliding off.
During demonstration and when loading the machine do not
remain in the danger zone of the machine.
Secure the machine with the articulation lock after driving it on the
transport vehicle.
Loading by crane
Lifting tackle must only be attached to loads by expert personnel
(qualified person).
Engage the articulation lock.
Always use suitable lifting tackle on the lifting points to lift the
machine.
Notes on safety in the operating
and maintenance instructions
Loading / transporting the machine
General – Safety regulations
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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Check all lifting points and fastening elements for damage before
lifting the machine. Do not use damaged or in any other way
impaired lifting points.
Lift the machine only with suitable lifting gear. Use only safe lifting
gear of sufficient load bearing capacity Minimum lifting capacity of
lifting gear: see operating weight in chapter "Technical Data".
Do not lift or lower the machine jerkily.
The tension must always be effective in vertical direction.
The machine must not swing about when being lifted.
Do not step or stand under suspended loads.
Lashing
Always use suitable lashing gear on the lifting points to lash down
the machine.
Check all lashing points for damage before lashing down the
machine. Do not use a damaged or in any other way impaired
lashing points.
Always apply the articulation lock for transportation.
Lash the machine down, so that it is secured against rolling, sliding
and turning over.
After transport
Operate the machine only with the foldable ROPS properly fas-
tened and the fastening screws tightened with the correct tight-
ening torque.Optional equipment
After transport release the articulation lock again and store it in the
receptacle.
Apply appropriate measures (e.g. with metal wheel chocks, to be
provided by the operating company) to secure the machine against
rolling away before releasing the parking brake.
Use a tow bar (tobe provided by the operating company).
Use a towing vehicle with sufficient traction and braking power for
the unbraked towed load.
The machine cannot be steered.
Tow the machine only after having released the parking brake.
Max. towing speed 1 km/h (0.6 mph), max. towing distance 500 m
(0.3 mi).
The frame of the machine must not be warped, bent or cracked in
the area of the ROPS fastening.
The ROPS must not show any rust, damage, hairline cracks or
open fractures.
The real machine weight must never exceed the testing weight for
the ROPS.
Towing the machine
Checking the Roll Over Protective
Structure (ROPS)
General – Safety regulations
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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The ROPS must not rattle about when driving. This indicates that it
is not properly fastened. All bolted connections must comply with
the specifications and should be absolutely tight (observe the tight-
ening torques). Screw and nuts must not be damaged, bent or
deformed.
No accessories may be welded or bolted on and no additional
holes must be drilled without the consent of the manufacturer,
since this will impair the strength of the unit.
The ROPS must therefore also not be straightened or repaired if it
is damaged.
A defect ROPS must generally be replaced with an original spare
part in close coordination with the manufacturer.
Before starting
Use only machines which are serviced at regular intervals.
Become acquainted with the equipment, the control elements, the
working principle of the machine and the working area.
Wear your personal protective outfit (hard hat, safety boots, etc.).
Wear ear defenders.
Before mounting the machine check whether:
npersons or obstructions are beside or under the machine.
nthe machine is free of oily and combustible material.
nall grips, steps and platforms are free of grease, oils, fuel, dirt,
snow and ice.
nthe engine hood is closed and locked.
Use steps and grips to mount the machine.
Before starting the machine check whether:
nthe machine shows any obvious faults.
nall guards and safety elements are in place.
nsteering, brakes, control elements, light system and warning
horn work correctly.
nthe seat is correctly adjusted
nmirrors (if present) are clean and correctly adjusted.
Do not start the machine with defective gauges, control lights or
control elements.
Do not take any loose objects with you or fasten them to the
machine.
On machines with roll over protection system you must always
wear your seat belt!
Starting
Start and operate the machine only from the driver’s seat.
For starting set all control levers to 'neutral position'.
Do not use any starting aids like start pilot or ether.
After starting check all display instruments.
Starting with jump wires
Starting the machine
General – Safety regulations
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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Connect plus to plus and minus to minus (ground cable) – always
connect the ground strap last and disconnect it first! A wrong con-
nection will cause severe damage in the electric system.
Do not start the engine by shorting the electric terminals on the
starter motor, because the machine may start to drive immediately.
Starting and operation of the machine is closed rooms and
trenches
Exhaust gases are extremely dangerous! Always ensure an ade-
quate supply of fresh air when starting and operating in closed
rooms and trenches!
Persons in the danger area
Before taking up work, also after breaks, you should always con-
vince yourself that the danger zone is free of persons or obstruc-
tions, especially when driving in reverse.
Give warning signals, if necessary. Stop work immediately if per-
sons remain in the danger zone, despite the warning.
Do not step or stand in the articulation area of the machine when
the engine is running. Danger of squashing!
Driving
Always wear the seat belt when driving.
Do not drive on bases with insufficient load bearing capacity.
Do not drive on ice and snow.
In events of emergency and in case of danger actuate the emer-
gency stop switch immediately. Do not use the emergency stop
switch as service brake.
Restart the machine only after the danger that caused the actua-
tion of the emergency stop switch has been eliminated.
Do not drive the machine with the hydraulic breaker con-
nected.Optional equipment
Do not switch on the rotary switch for hydraulic breaker1 while
driving. The machine would be abruptly braked without braking
delay. In case of frequent use the wear on the multi-discs brakes
will be very high.
If the machine has contacted high-voltage power lines:
ndo not leave the operator’s stand.
nwarn others from coming close to or touching the machine.
nif possible drive the machine out of the danger zone.
nhave the power switched off.
Operate the machine only from the driver's seat.
Do not adjust the driver’s seat while driving.
Do not climb onto or off the machine while the machine is driving.
Change the travel direction only at standstill.
Do not use the machine to transport persons.
Driving the machine
General – Safety regulations
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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In case of unusual noises and development of smoke perform
trouble shooting and have the fault corrected.
Always keep a sufficient distance to excavation walls and embank-
ments and do not use working methods that could impair the sta-
bility of the machine.
Always keep a sufficient distance when passing through subways,
under bridges, tunnels, electric power lines etc.
Driving on inclinations and slopes
Do not drive on gradients exceeding the maximum gradability of
the machine.
On slopes drive extremely careful and always directly up or down
the slope. Change to a lower gear before starting to drive.
Wet and loose soils considerably reduce the ground adhesion of
the machine on inclinations and slopes. Higher risk of accident!
Inclination
Fig. 1
The tipping angle was measured in static condition on level, hard
ground with the machine stopped, no steering and without vibra-
tion.
The maximum permissible inclination of the machine may be
limited by the permissible inclination of the engine.
The specified angle Ä Fig. 1 must not be exceeded.
With loose soil, acceleration/deceleration, running vibration,
steering or attached accessoriies the tipping angle may be consid-
erably lower.
Driving across slopes should therefore be strictly avoided, because
of the high risk of tipping over and the related risk of severe or
even fatal accidents.
You should therefore always drive straight up or down a slope.
General – Safety regulations
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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For rollers with a drum width of 1 m (3.3 ft) or less there is a con-
siderable risk of tipping over near edges (e.g. curbstones, embank-
ments, trenches, potholes) when driving over these edges.
Behaviour in traffic
Match the speed to the working conditions. Do not make extreme
steering movements when driving with high speed, danger of tip-
ping over!
Always give way to loaded transport vehicles.
Switch the lights on if the visibility is poor.
Keep away from edges and embankments.
Checking the effect of vibration
When compacting with vibration you must check the effect on
nearby buildings and underground supply lines (gas, water,
sewage, electric power), if necessary stop compaction work with
vibration.
Do not work with vibration on hard concrete, cured bitumen layers
or extremely frozen ground. Danger of bearing damage!
Park the machine on horizontal, level, firm ground.
Before leaving the machine:
nShift the travel lever to neutral position and lock it in parking
brake position. The parking brake is applied.
nShut down the engine, pull off the ignition key
Mark machines, which could be in the way, with a clearly visible
sign.
Parking on slopes and inclinations
Apply appropriate measures (e.g. with metal wheel chocks, to be
provided by the operating company) tp secure the machine against
rolling away.
Do not inhale any fuel fumes.
Refuel only with the engine shut down.
Always use access steps.
Do not refuel in closed rooms.
No open fire, do not smoke.
Static charges may be generated in the fuel as it passes through
the filling system. A discharge of such charges in the presence of
combustible vapours may cause fire or an explosion.
Ultra-low sulphur diesel fuel poses a higher risk of ignition caused
by static charges than a diesel fuel with a higher sulphur content.
You should therefore always make sure that the filling system is
properly earthed and that there is equipotential bonding to the
machine. If necessary install a connecting cable between filling
system and vehicle ground.
Monitor the entire refuelling process.
Parking the machine
Refuelling
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Do not spill any fuel. Catch running out fuel, do not let it seep into
the ground.
Wipe off spilled fuel. Keep dirt and water away from the fuel.
A leaking fuel tank can cause an explosion. Ensure tight fit of the
fuel tank cover, if necessary replace immediately.
Fire protection measures
Familiarise yourself with the location and the operation of fire
fighting equipment. Observe all fire reporting and fire fighting possi-
bilities.
Comply with the maintenance work described in the operating and
maintenance instructions, including the information concerning the
replacement of parts.
Maintenance work must only be performed by qualified and author-
ized persons.
Do not touch hot engine parts.
For overhead maintenance and assembly work use the access
steps and working platforms provided or other secure means. Do
not use machine parts as access steps.
Keep unauthorized persons away from the machine.
Do not perform maintenance work while the machine is driving or
the engine is running.
Park the machine on horizontal, level, firm ground.
Remove the key from the ignition switch.
Secure the articulated joint with the articulation lock.
Work on hydraulic lines
Relieve hydraulic pressures before working on hydraulic lines.
Hydraulic oil escaping under pressure can penetrate the skin and
cause severe injury. When being injured by hydraulic oil consult a
medical doctor immediately, as otherwise this may cause severe
infections.
Do not step in front of or behind the drums/wheels when per-
forming adjustment work in the hydraulic system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature – danger of
scalding!
Any hydraulic oil must be caught and disposed of in an environ-
mentally friendly manner.
Always catch and dispose of hydraulic oils separately.
Do not start the engine after draining the hydraulic oil.
Once all work is completed (with the system still depressurized!)
check all connections and fittings for leaks.
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at regular intervals.
Hydraulic hoses must be immediately replaced if:
Maintenance work
General – Safety regulations
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nthe outer layer is damaged down to the inlay (e.g. chafing,
cuts, cracks).
nthe outer layer is brittle (formation of cracks in the hose mate-
rial).
nthe hose shows deformations in pressurized and depressurized
condition, which do not comply with the genuine shape of the
hydraulic hose.
nthe hose shows deformations in bends, e.g. squeezing, buck-
ling, layer separation, formation of blisters,
nparts of the hose are leaking.
nhoses are not correctly installed
nthe hydraulic hose has separated from the fitting
nthe fitting shows corrosion that impairs both function and
strength.
nfittings are damaged or deformed, whereby the function and
strength of the hose - hose connection is impaired.
hoses are mixed up by mistake.
Only genuine BOMAG replacement hydraulic hoses ensure that
the correct hose type (pressure range) is used at the right location.
Working on the engine
Shut down the engine before opening the engine hood.
Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, catch running out oil and dispose of environ-
mentally.
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of environmentally.
Do not leave any tools or other objects, that could cause damage,
in the engine compartment.
Check and change coolant only when the engine is cold.
Catch coolant and dispose of environmentally.
Working on electric parts of the machine
Before starting to work on electric parts of the machine disconnect
the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not bridge
fuses. Fire hazard!
Working on the battery
When working on the battery do not smoke, do not use open fire!
Do not let acid come in contact with hands or clothes! When
injured by acid flush off with clear water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must not come in
contact with the battery poles – danger of short circuit and burning!
When recharging non-serviceable batteries remove all plugs, to
avoid the accumulation of explosive gases.
Observe the applicable instructions when starting with an auxiliary
battery.
Switch off the charging current before removing the charging
clamps.
General – Safety regulations
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Ensure sufficient ventilation, especially if the battery is to be
charged in a closed room.
Dispose of old batteries according to regulations.
Working on the fuel system
Do not inhale any fuel fumes.
Avoid open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the ground and dis-
pose off environmentally.
Working on wheels and tires
Explosion-like bursting of tires or parts of tires and rims can cause
most severe or even deadly injuries.
Install the tires only if are sufficiently experienced and with the right
tools at hand. If necessary have the tires assembled in a qualified
workshop.
Always ensure the correct tire pressure and do not exceed the
specified maximum pressure.
Check tires and wheels every day for pressure, cuts, bulges, dam-
aged rims, missing wheel studs or nuts. Do not drive with damaged
tires or wheels.
Ant-sticking emulsions for tires must only consist of water and anti-
sticking agent, in a concentration in accordance with the specifica-
tions of the manufacturer of the anti-sticking agent. Observe appli-
cable environmental regulations.
Cleaning work
Do not perform cleaning work while the motor is running.
Do not use gasoline or other easily inflammable substances for
cleaning.
When cleaning with steam cleaning equipment do not subject elec-
trical parts and insulation material to the direct jet of water, or cover
it beforehand.
nDo not guide the water jet into the exhaust and into the air filter.
After maintenance work
After all maintenance work is completed reinstall all guards and
safety installations.
Mark a defective machine by attaching a warning tag to the
steering wheel.
Repair work must only be performed by qualified and authorized
persons. Use our repair instructions for this work.
Exhaust gases are extremely dangerous! Always ensure an ade-
quate supply of fresh air when starting in closed rooms!
Disconnect the battery before starting welding work on the
machine.
Repair
General – Safety regulations
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