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
Table of contents
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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
Table of contents
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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
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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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
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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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
BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5
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