Bomag BW 80 AD-5 Operating Instructions Manual
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Bomag BW 80 AD-5 Operating Instructions Manual

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

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Summary of Contents for Bomag BW 80 AD-5

  • Page 1 Operating instructions Maintenance instructions Original operating instructions BW 80 AD-5/BW 90 AD-5/BW 100 ADM-5 BW 90 SC-5 / BW 100 SC-5 BW 100 ACM-5/BW 100 SCC-5 S/N 101 462 00 1139 > / S/N 101 462 01 1053 > / S/N 101 462 03 1065 >...

  • Page 3: Foreword

    Foreword reduce repair costs and down- 1 Foreword times. BOMAG will not assume liability for These BOMAG machines are the function of the machine products from the wide product range of BOMAG machines for if it is handled in a way not comply-...
  • Page 4 These operating and maintenance instructions are also available in oth- er languages. Apart from that, the spare parts cata- logue is available from your BOMAG dealer against the serial number of your machine. Your BOMAG dealer will also supply you with information about the cor- rect use of our machines in soil and asphalt construction.
  • Page 5 During commissioning our organisa- tion will instruct you in the operation and maintenance of the machine. Please observe strictly the safety regulations and all notes on risks and Fig. 2 dangers! 462108 Fig. 3 BW 80 AD-5 Fam. BOMAG...
  • Page 6 Foreword BOMAG BW 80 AD-5 Fam.

  • Page 7: Table Of Contents

    Connecting/disconnecting the hydraulic breaker 5.16 Towing 5.17 Loading/transport Maintenance General notes on maintenance Fuels and lubricants Table of fuels and lubricants Running-in instructions Maintenance table Every 10 operating hours Check the engine oil level Check the fuel level BW 80 AD-5 Fam. BOMAG...
  • Page 8 Change the hydraulic oil filter 6.31 Changing the coolant 6.32 Changing the fuel lines 6.33 Check the injection nozzles Every 3000 operating hours 6.34 Check the fuel injection pump As required 6.35 Check the tire pressure BOMAG BW 80 AD-5 Fam.
  • Page 9 Water sprinkler system, maintenance in case of frost 6.37 Tightening torques for screws with metric unified thread 6.38 Measures to be applied for longer periods of rest Trouble shooting General notes Engine problems Disposal Final shut-down of machine BW 80 AD-5 Fam. BOMAG...
  • Page 10 Table of Contents BOMAG BW 80 AD-5 Fam.

  • Page 11: Technical Data

    2 Technical data BW 80 AD-5 Fam. BOMAG...
  • Page 12 Technical data Fig. 4 BW 80 AD-5 Dimen- sions in mm 1483 856 433 580 1627 2304 255 2194 28 13 in in 58.4 33.7 17.0 22.8 64.1 90.7 10.0 86.4 1.1 0.51 31.5 BOMAG BW 80 AD-5 Fam.
  • Page 13 Drive system hydrostatic Driven drum front + rear Brakes Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Oscill.-articul. Steering operation hydrostatic Steering/oscillation angle +/-° 33/8 Inner track radius mm (in) 2080 (81.9) Vibration system BW 80 AD-5 Fam. BOMAG...
  • Page 14 (gal us) approx. 100 (26.4) Hydraulic oil l (gal us) approx. 14 (3.7) Engine oil l (gal us) approx. 3.9 (1.0) Coolant l (gal us) approx. 9 (2.4) The right for technical modifications remains reserved BOMAG BW 80 AD-5 Fam.
  • Page 15 Technical data Fig. 5 BW 90 AD-5 Dimen- sions in mm 1483 956 433 580 1627 2304 255 2194 28 12 in in 58.4 37.6 17.0 22.8 64.1 90.7 10.0 86.4 1.1 0.47 35.4 BW 80 AD-5 Fam. BOMAG...
  • Page 16 Drive system hydrostatic Driven drum front + rear Brakes Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Oscill.-articul. Steering operation hydrostatic Steering/oscillation angle +/-° 33/8 Inner track radius mm (in) 2030 (79.9) Vibration system BOMAG BW 80 AD-5 Fam.
  • Page 17 (gal us) approx. 100 (26.4) Hydraulic oil l (gal us) approx. 14 (3.7) Engine oil l (gal us) approx. 3.9 (1.0) Coolant l (gal us) approx. 9 (2.4) The right for technical modifications remains reserved BW 80 AD-5 Fam. BOMAG...
  • Page 18 Technical data Fig. 6 BW 100 ADM-5 Dimen- sions in mm 1483 1056 433 580 1627 2304 255 2194 28 12 1000 in in 58.4 41.6 17.0 22.8 64.1 90.7 10.0 86.4 1.1 0.47 39.4 BOMAG BW 80 AD-5 Fam.
  • Page 19 Drive system hydrostatic Driven drum front + rear Brakes Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Oscill.-articul. Steering operation hydrostatic Steering/oscillation angle +/-° 33/8 Inner track radius mm (in) 1980 (78.0) Vibration system BW 80 AD-5 Fam. BOMAG...
  • Page 20 (gal us) approx. 100 (26.4) Hydraulic oil l (gal us) approx. 14 (3.7) Engine oil l (gal us) approx. 3.9 (1.0) Coolant l (gal us) approx. 9 (2.4) The right for technical modifications remains reserved BOMAG BW 80 AD-5 Fam.
  • Page 21 Technical data Fig. 7 BW 90 SC-5 Dimen- sions in mm 1483 960 435 580 1627 2304 255 2194 52 12 in in 58.4 37.8 17.1 22.8 64.1 90.7 10.0 86.4 2.0 0.47 37.8 BW 80 AD-5 Fam. BOMAG...
  • Page 22 Drive system hydrostatic Driven drum front + rear Brakes Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Oscill.-articul. Steering operation hydrostatic Steering/oscillation angle +/-° 33/8 Inner track radius mm (in) 2000 (78.7) Vibration system BOMAG BW 80 AD-5 Fam.
  • Page 23 (gal us) approx. 100 (26.4) Hydraulic oil l (gal us) approx. 14 (3.7) Engine oil l (gal us) approx. 3.9 (1.0) Coolant l (gal us) approx. 9 (2.4) The right for technical modifications remains reserved BW 80 AD-5 Fam. BOMAG...
  • Page 24 Technical data Fig. 8 BW 100 SC-5 Dimen- sions in mm 1483 1060 435 580 1627 2304 255 2194 52 12 1060 in in 58.4 41.7 17.1 22.8 64.1 90.7 10.0 86.4 2.0 0.47 41.7 BOMAG BW 80 AD-5 Fam.
  • Page 25 Drive system hydrostatic Driven drum front + rear Brakes Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Oscill.-articul. Steering operation hydrostatic Steering/oscillation angle +/-° 33/8 Inner track radius mm (in) 1950 (76.8) Vibration system BW 80 AD-5 Fam. BOMAG...
  • Page 26 (gal us) approx. 100 (26.4) Hydraulic oil l (gal us) approx. 14 (3.7) Engine oil l (gal us) approx. 3.9 (1.0) Coolant l (gal us) approx. 9 (2.4) The right for technical modifications remains reserved BOMAG BW 80 AD-5 Fam.
  • Page 27 Technical data Fig. 9 BW 100 ACM-5 Dimen- sions in mm 1483 1056 435 580 1663 2340 240 2194 28 12 1000 in in 58.4 41.6 17.1 22.8 65.5 92.1 9.4 86.4 1.1 0.47 39.4 BW 80 AD-5 Fam. BOMAG...
  • Page 28 3000 Fixed engine speed (2) 2100 Electrical equipment Drive system hydrostatic Wheels driven Driven drum front Tires Tire size 205/60-15 Brakes Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Oscill.-articul. Steering operation hydrostatic BOMAG BW 80 AD-5 Fam.
  • Page 29 (gal us) approx. 11 (2.9) Hydraulic oil l (gal us) approx. 14 (3.7) Engine oil l (gal us) approx. 3.9 (1.0) Coolant l (gal us) approx. 9 (2.4) The right for technical modifications remains reserved BW 80 AD-5 Fam. BOMAG...
  • Page 30 Technical data Fig. 10 BW 100 SCC-5 Dimen- sions in mm 1483 1056 435 580 1663 2340 240 2194 52 12 1030 in in 58.4 41.6 17.1 22.8 65.5 92.1 9.4 86.4 2.0 0.47 40.6 BOMAG BW 80 AD-5 Fam.
  • Page 31 3000 Fixed engine speed (2) 2100 Electrical equipment Drive system hydrostatic Wheels driven Driven drum front Tires Tire size 205/60-15 Brakes Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Oscill.-articul. Steering operation hydrostatic BW 80 AD-5 Fam. BOMAG...
  • Page 32 (gal us) approx. 11 (2.9) Hydraulic oil l (gal us) approx. 14 (3.7) Engine oil l (gal us) approx. 3.9 (1.0) Coolant l (gal us) approx. 9 (2.4) The right for technical modifications remains reserved BOMAG BW 80 AD-5 Fam.
  • Page 33 Vibration of the entire body (driver’s seat) The weighted effective acceleration value determined according to ISO 7096 is ≤ 0.5 m/s Hand-arm vibration values The weighted effective acceleration value determined according to EN 500/ ISO 5349 is ≤ 2.5 m/s BW 80 AD-5 Fam. BOMAG...
  • Page 34 Technical data BOMAG BW 80 AD-5 Fam.

  • Page 35: Safety Regulations

    3 Safety regulations BW 80 AD-5 Fam. BOMAG...
  • Page 36 Safety regulations General This BOMAG machine has been built in compliance with the latest tech- nical standard and complies with the applicable regulations and techni- cal rules. However, dangers for persons and property may arise from this machine, if: it is used for purposes other than the ones it is intended for,...
  • Page 37 Regular safety inspections 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. BW 80 AD-5 Fam. BOMAG...
  • Page 38 Safety installations and switches must neither be removed nor must they be made ineffective. Notes on safety in the operating and maintenance instruc- tions Danger Paragraphs marked like this highlight possible dangers for persons. BOMAG BW 80 AD-5 Fam.
  • Page 39 Always use suitable lifting tackle on the lifting points to lift the machine. 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. BW 80 AD-5 Fam. BOMAG...
  • Page 40 Use a towing vehicle with sufficient traction and braking power for the un- braked 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). Optional equipment BOMAG BW 80 AD-5 Fam.
  • Page 41 Use steps and grips to mount the machine. Before starting the machine check whether: the machine shows any obvious faults BW 80 AD-5 Fam. BOMAG...
  • Page 42 Driving the machine Persons in the danger area Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions, especially when driving in reverse. BOMAG BW 80 AD-5 Fam.
  • Page 43 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 embankments and do not use working methods that could impair the stability of the machine. Optional equipment BW 80 AD-5 Fam. BOMAG...
  • Page 44 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. BOMAG BW 80 AD-5 Fam.
  • Page 45 Refuelling Do not inhale any fuel fumes. Refuel only with the engine stopped and the auxiliary heater switched off. Always use access steps. Do not refuel in closed rooms. BW 80 AD-5 Fam. BOMAG...
  • Page 46 Do not step in front of or behind the drums/wheels when performing adjust- ment work in the hydraulic system. Do not change the setting of pressure relief valves. Drain the hydraulic oil at operating temperature – danger of scalding! BOMAG BW 80 AD-5 Fam.
  • Page 47 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.
  • Page 48 Catch running out fuel, do not let it seep into the ground and dispose off envi- ronmentally. Working on wheels and tires Explosion-like bursting of tires or parts of tires and rims can cause most severe or even deadly injuries. BOMAG BW 80 AD-5 Fam.
  • Page 49 Information and safety stickers/decals on the machine Keep stickers/decals in good and legible condition (see spare parts catalogue) and comply with their meaning. BW 80 AD-5 Fam. BOMAG...
  • Page 50 Safety regulations Replace damaged and illegible stickers/decals. BOMAG BW 80 AD-5 Fam.
  • Page 51 ULTRA LOW SULFUR FUEL ONLY HYDRAULIK 462161 Fig. 12 Decals and stickers BW 80 AD-5 / BW 90 AD-5 / BW 100 ADM-5 1 Information sticker - Engine oil Warning sticker - Danger of tip- drain ping over Information sticker - Guaranteed...
  • Page 52 Safety regulations crushing sulphur fuel 10 Information sticker - Ultra-low 11 Information sticker - Hydraulic oil BOMAG BW 80 AD-5 Fam.
  • Page 53 Information sticker - Guaranteed Prohibition sticker - High pres- sound capacity level sure cleaner Information sticker - Lifting point Warning sticker - Danger of crushing Information sticker - Battery Information sticker - Ultra-low Operation sticker - Throttle lever BW 80 AD-5 Fam. BOMAG...
  • Page 54 Safety regulations sulphur fuel 11 Information sticker - Lashing point 10 Information sticker - Hydraulic oil BOMAG BW 80 AD-5 Fam.
  • Page 55 Warning sticker - Danger of tip- Information sticker - Guaranteed ping over sound capacity level Information sticker - Emulsion Information sticker - Lifting point Prohibition sticker - High pres- Information sticker - Foot switch sure cleaner BW 80 AD-5 Fam. BOMAG...
  • Page 56 Safety regulations 10 Information sticker - Lashing 12 Information sticker - Ultra-low point sulphur fuel 11 Warning sticker - Danger of 13 Information sticker - Hydraulic oil crushing BOMAG BW 80 AD-5 Fam.
  • Page 57 Warning sticker - Danger of tip- Information sticker - Guaranteed ping over sound capacity level Information sticker - Emulsion Information sticker - Lifting point Prohibition sticker - High pres- Information sticker - Foot switch sure cleaner BW 80 AD-5 Fam. BOMAG...
  • Page 58 Safety regulations 10 Information sticker - Lashing 12 Information sticker - Ultra-low point sulphur fuel 11 Warning sticker - Danger of 13 Information sticker - Hydraulic oil crushing BOMAG BW 80 AD-5 Fam.
  • Page 59 Information sticker - Foldable ROPS seat belt - Operation S_0019 008 320 00 462136 Fig. 19 Fig. 17 Information sticker - Main battery Warning sticker - Foldable ROPS switch Optional equipment Optional equipment Optional equipment BW 80 AD-5 Fam. BOMAG...
  • Page 60 1 2 3 4 5 6 # START S_0029 Fig. 20 Fig. 22 Information sticker - Biodegradable Information sticker - Electronic im- hydraulic oil mobilizer Fig. 21 Information sticker - Panolin 46 Optional equipment Optional equipment Optional equipment BOMAG BW 80 AD-5 Fam.

  • Page 61: Display And Control Elements

    4 Display and control elements BW 80 AD-5 Fam. BOMAG...
  • Page 62 Display and control elements Fig. 23 BOMAG BW 80 AD-5 Fam.
  • Page 63 Rotary switch for hazard light bration, warning horn and edge system cutter Rotary switch for vibration pre- 16 Double travel lever with buttons selection for vibration and warning horn Optional equipment 17 Throttle lever not on ACM/SCC-machines BW 80 AD-5 Fam. BOMAG...

  • Page 64: General Notes

    No. 1 = Rotary switch for working lights Position Left = Working lights off Position Right = Working light on (with starter switch in position "I") 462129 Fig. 25 No. 2 = Rotary switch for light- Optional equipment BOMAG BW 80 AD-5 Fam.
  • Page 65 2 seconds. radiator, if necessary repair = Warning light for seat con- engine. tact switch with machine at f green = Indicator control light rest BW 80 AD-5 Fam. BOMAG...
  • Page 66 Maintenance work is to be Position Right = Vibration of rear carried out in accordance drum with the indicated operat- ing hours. Optional equipment Optional equipment not on ACM/SCC-machines BOMAG BW 80 AD-5 Fam.
  • Page 67 With interval sprinkling the machine needs to drive forward or backward. With the travel lever in neutral posi- tion sprinkling will continue for anoth- er 15 seconds. Optional equipment BW 80 AD-5 Fam. BOMAG...
  • Page 68 "1" to position "2". instrument clus- The vibration ter start flashing. push button in the travel lever is not active. 650091 Fig. 31 No. 8 = Rotary switch for vibra- tion pre-selection Optional equipment BOMAG BW 80 AD-5 Fam.
  • Page 69 Position Left = Seat heating off Always keep the travel lever in Position Right = Seat heating on parking brake position. Position Left = Hydraulic breaker Optional equipment Optional equipment Optional equipment BW 80 AD-5 Fam. BOMAG...
  • Page 70 The emergency stop switch is auto- tures below +10 matically actuated when the dash- °C (+50 °F) hold board protection is closed. the ignition key in position "II" for up actuate = Press the button to 10 seconds, completely down, BOMAG BW 80 AD-5 Fam.
  • Page 71 Do not shut down the engine all of Position "2" = Forward/reverse a sudden from full load speed, but travel up to ap- let it idle for about 2 minutes. prox. 10 km/h (6.2 mph) BW 80 AD-5 Fam. BOMAG...
  • Page 72 Position brake closed. "MAX II" = Full load position Position "1" = Forward/reverse operating posi- travel up to ap- tion for driving prox. 5 km/h (3.1 and vibration mph) Optional equipment Optional equipment BOMAG BW 80 AD-5 Fam.
  • Page 73 F153 (10A) = Potential 15 against the end stop. F241 (15A) = Optional head- lights F68 (10A) = Potential 30 F23 (10A) = Warning horn F30 (10A) = Potential 15 only on ACM/SCC-machines BW 80 AD-5 Fam. BOMAG...
  • Page 74 The main battery switch is located in- side the battery compartment. Position horizontal= Disconnects the batteries from the vehicle electrics in case of burning cables and fire in the engine com- partment, protec- Optional equipment BOMAG BW 80 AD-5 Fam.
  • Page 75 Position 90° up = Operating posi- tion, engine can be started. Fig. 49 No. 24 = Hydraulicm oil level gauge Fig. 47 No. 22 = Fuel level gauge Fig. 48 No. 23 = Water level gauge BW 80 AD-5 Fam. BOMAG...
  • Page 76 Display and control elements BOMAG BW 80 AD-5 Fam.

  • Page 77: Operation

    5 Operation BW 80 AD-5 Fam. BOMAG...

  • Page 78: General

    Air pressure in rubber tires (only ACM/SCC-machines) BOMAG BW 80 AD-5 Fam.

  • Page 79: Electronic Immobilizer

    When entering the code, the light emitting diode (6) lights up with every digit. Press the diamond button. The electronic immobilizer is now disarmed and the engine can be started within the next 15 minutes. Optional equipment BW 80 AD-5 Fam. BOMAG...

  • Page 80: Adjusting The Driver's Seat

    Then adjust to the weight of the operator by sliding the lever down. Pull up lever (b) and adjust the seat in longitudinal direction by sliding it forward or back. BOMAG BW 80 AD-5 Fam.

  • Page 81: Starting The Engine

    Caution In this chapter it is assumed that the operator is fully acquainted with the function of the different control elements on the machine. Fig. 52 Fasten your seat belt (Fig. 52). BW 80 AD-5 Fam. BOMAG...
  • Page 82 (Fig. 55) is unlocked. parking brake position. MAX I MAX II 462132 Fig. 56 Fig. 54 Turn the ignition key (Fig. 56) to Set the throttle lever (Fig. 54) to position "I". position "MIN". BOMAG BW 80 AD-5 Fam.
  • Page 83 Do not re-start lock. The ignition key must rev up a cold engine to high idle first be turned back to position "0" be- speed/full load speed. fore a new starting attempt can be made. BW 80 AD-5 Fam. BOMAG...

  • Page 84: Starting With Jump Wires

    (ground cable) first and the positive poles after. Switch off the consumer. Fig. 60 Caution A wrong connection will cause se- vere damage in the electric sys- tem. Bridge the machine only with a 12 Volt battery. BOMAG BW 80 AD-5 Fam.

  • Page 85: Driving The Machine

    (3.3 ft) or less there is a consid- erable risk of tipping over near Fig. 61 edges (e.g. curbstones, embank- Turn the rotary switch for hydraulic breaker (Fig. 61) anti-clockwise to position "0". Optional equipment BW 80 AD-5 Fam. BOMAG...
  • Page 86 Do not operate jerkily! Control the travel speed with the travel lever. When driving up and down incli- nations move the travel lever slowly back towards neutral to brake the machine. 462096 Fig. 63 Caution Do not operate jerkily! BOMAG BW 80 AD-5 Fam.
  • Page 87 2 seconds and the parking brake will close. To continue driving occupy the seat and put on the seat belt within 2 seconds. The warning lights go out and the warning buzzer stops to sound. BW 80 AD-5 Fam. BOMAG...

  • Page 88: Stopping The Machine, Operating The Parking Brake

    Fig. 68 The parking brake warning light (g) Fig. 66 (Fig. 68) in the instrument cluster The parking brake warning light (g) in lights up. the instrument cluster (Fig. 66) lights BOMAG BW 80 AD-5 Fam.
  • Page 89 Do not shut down the engine all of a sudden from full load speed, but let it idle for about 2 minutes. Fig. 70 Turn the ignition key (Fig. 70) to position "0" and pull it out. BW 80 AD-5 Fam. BOMAG...

  • Page 90: Switching The Vibration On And Off

    Danger Risk of damage! When compacting with vibration you must check the effect of near- by buildings and underground supply lines (gas, water, sewage, electric power), if necessary stop compaction with vibration. not on ACM/SCC-machines BOMAG BW 80 AD-5 Fam.
  • Page 91 Switch on vibration only with the to position "0" (Fig. 75). throttle lever in position "MAX I" or "MAX II". Set the throttle lever (Fig. 73) to position "Max I" or "MAX II". Optional equipment BW 80 AD-5 Fam. BOMAG...
  • Page 92 (0.6 mph). When shifting the travel lever through position "1" to position "2", the vibration will be automatically switched off. Fig. 76 Turn the rotary vibration pre-se- lection switch (Fig. 76) clockwise to position "IVC". BOMAG BW 80 AD-5 Fam.
  • Page 93 The vibration switches off automati- cally when falling short of a travel speed of approx. 1 km/h (0.6 mph). If the vibration is to be switched on with the travel lever in position "2", a BW 80 AD-5 Fam. BOMAG...

  • Page 94: Switching The Pressure Sprinkling System On And Off

    Position "5" = Permanent sprin- tion sprinkling will continue for anoth- kling er 15 seconds. To switch off the pressure sprin- kling system switch the interval switch for pressure sprinkling (Fig. 80) to position "0". BOMAG BW 80 AD-5 Fam.
  • Page 95 462112 discharged. Fig. 84 Set the interval switch for pressure sprinkling (Fig. 84) to position "5" (permanent sprinkling). The pressure sprinkler system is switched on. Check water output and spray pat- tern on all nozzles. BW 80 AD-5 Fam. BOMAG...

  • Page 96: Switching The Tire Sprinkling System On And Off

    462111 Fig. 85 Actuate the foot switch (Fig. 85). The tire sprinkling system is switched Release the foot switch. The tire sprinkling system is switched off. only on ACM/SCC-machines BOMAG BW 80 AD-5 Fam.

  • Page 97: Setting The Crabwalk

    The machine must not swing Displace the front frame. about when being lifted. Lower the machine to the ground. Do not step or stand under sus- Tighten the screws, tightening pended loads. torque. 300 Nm (221 ft.lbs). BW 80 AD-5 Fam. BOMAG...

  • Page 98: What To Do In Events Of Emergency

    Danger In order to be able to disconnect the battery quickly in case of dan- ger (e.g. cable fire or electrical malfunction) the minus terminal has been designed as a quick re- lease pole clamp. BOMAG BW 80 AD-5 Fam.

  • Page 99: Connecting/Disconnecting The Hydraulic Breaker

    Pull up the cap from the minus pole (Fig. 90). The pole clamp on the minus pole thereby becomes loose. Disconnect the pole clamp from the minus pole of the battery and lay it to the side. Optional equipment BW 80 AD-5 Fam. BOMAG...
  • Page 100 Before connecting hydraulic lines 462151 to the couplings make sure that Fig. 94 the rotary switch for the hydraulic breaker (Fig. 92) is in position "0". Turn the rotary switch for hydraulic breaker (Fig. 94) clockwise. BOMAG BW 80 AD-5 Fam.
  • Page 101 The hydraulic breaker can now be used. Disconnect the hydraulic breaker from the couplings . Connecting the hydraulic breakedr MAX I MAX II 462132 Fig. 96 Set the throttle lever (Fig. 96) to position "MIN". BW 80 AD-5 Fam. BOMAG...

  • Page 102: Towing

    Release the brakes in both drums. Caution 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). Fig. 99 Remove two plugs (Fig. 99). BOMAG BW 80 AD-5 Fam.
  • Page 103 20 Nm rolling away before disconnecting (14.8 ft.lbs). the tow bar. The machine must only be started without the mechanical brake re- leasing device being activated. Apply the brakes in both drums. BW 80 AD-5 Fam. BOMAG...
  • Page 104 "0", turn the lock- valve to position "I". ing screw (1) back in and counter Turn the steering wheel slowly ap- it with the hexagon nut. prox. two turns in clockwise direc- tion. Optional equipment BOMAG BW 80 AD-5 Fam.

  • Page 105: Loading/Transport

    Fold down the foldable ROPS Drive the machine carefully on the transport. Loosen the eye bolts transport vehicle. (Fig. 107) and adjust the clamping plates vertically. Fold the foldable ROPS back. Optional equipment BW 80 AD-5 Fam. BOMAG...
  • Page 106 The machine must not swing and turning over. about when being lifted. Always apply the articulation lock Do not step or stand under sus- for transportation. pended loads. Fold down the foldable ROPS Engage the articulation lock. Optional equipment BOMAG BW 80 AD-5 Fam.
  • Page 107 To fold up the foldable ROPS align torque. the clamping plates on both sides After transport release the articu- vertically (Fig. 111). lation lock again and store it in the receptacle. Optional equipment BW 80 AD-5 Fam. BOMAG...
  • Page 108 Fig. 112 Fold up the foldable ROPS (Fig. 112). Turn the clamping plates to hori- zontal position and tighten the eye bolts with a tightening torque of 50 – 80 Nm (37 – 60 ft.lbf). BOMAG BW 80 AD-5 Fam.

  • Page 109: Maintenance

    6 Maintenance BW 80 AD-5 Fam. BOMAG...

  • Page 110: General Notes On Maintenance

    The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel. Keep fuel free of contaminants and water, since this will damage the injec- tion elements of the engine. BOMAG BW 80 AD-5 Fam.
  • Page 111 If your engine has to work permanently in "thin air" (at higher altitudes) and un- der full load, you should consult the customer service of BOMAG or the cus- tomer service of the engine manufacturer.
  • Page 112 Do not store drums with hydraulic oil outdoors, or at least under a cover. Water can be drawn in through the bunghole when the weather changes. We recommend to use the BOMAG filling and filtering unit with fine filter to fill the system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system.

  • Page 113: Fuels And Lubricants

    (SAE-class) . Optimal operating conditions can be achieved by using the following oil viscos- ity chart as a reference. American Petroleum Institute BW 80 AD-5 Fam. BOMAG...
  • Page 114 1500 m (4921 ft) and more. Diesel fuel specifications: With respect to the percentage (ppm) of sulphur the fuel used in the engine must comply with all relevant exhaust emission regu- lations in the are of use of the engine. BOMAG BW 80 AD-5 Fam.
  • Page 115 At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel. Coolant Always use a mixture of anti-freeze agent and clean, dehardened water with a mixing ratio of 1:1. United States Environmental Protection Agency BW 80 AD-5 Fam. BOMAG...
  • Page 116 HVLP according to DIN 51524, part 3, or hydraulic oils type HV according to ISO 6743/3. The viscosity index (VI) should be at least 150 (observe information of manufacturer). BOMAG BW 80 AD-5 Fam.
  • Page 117 Caution Check the filter more frequently after this change. Perform regular oil analyses for content of water and mineral oil. Replace the hydraulic oil filter element every 500 operating hours. BW 80 AD-5 Fam. BOMAG...

  • Page 118: Table Of Fuels And Lubricants

    CI-4 (1.0 gal us) SAE 10W-40 (-20 °C to +40 °C) (-4 °F to +104 °F) (BOMAG 009 920 06; 20 l) SAE 10W-30 (-15 °C to +30 °C) (+5 °F to +86 °F) SAE 15W-40 (-15 °C to 40 °C) (+5 °F to +104 °F)
  • Page 119 Summer Winter Attention! Observe the level marks Hydraulic system Hydraulic oil (ISO), HLP 46 approx. 14 l (BOMAG 009 930 09; 20 l) (3.7 gal us) ester based biodegradable hydraulic oil Sprinkler system Water Anti-freeze mixture approx. 100 l water (26.4 gal us)
  • Page 120 Maintenance BOMAG BW 80 AD-5 Fam.

  • Page 121: Running-In Instructions

    Maintenance after 50 operating hours Change engine oil and filter Check the engine for leaks Retighten the fastening screws on air filter, exhaust and other attachments. Check screw connections on the machine, retighten as necessary. BW 80 AD-5 Fam. BOMAG...

  • Page 122: Maintenance Table

    6.12 Check the emulsion level only on ACM/SCC-ma- chines Every 50 operating hours 6.13 Check, clean the air filter, replace if necessary min. 1 x year 6.14 Check fuel lines and clamps 6.15 Check, clean the water separator BOMAG BW 80 AD-5 Fam.
  • Page 123 6.25 Check the anti-freeze concentration and the condition of the coolant Running-in instructions: oil change after 50 operating hours, then every 250 operating hours When using fuels with a sulphur content higher than 0.5% the oil change intervals must be halved. BW 80 AD-5 Fam. BOMAG...
  • Page 124 6.31 Change the coolant at least every 2 years 6.32 Change the fuel lines at least every 2 years 6.33 Check the injection nozzles only by authorized service personnel Also after repairs in the hydraulic system. BOMAG BW 80 AD-5 Fam.
  • Page 125 As required 6.35 Check the tire pressure only on ACM/SCC-ma- chines 6.36 Water sprinkler system, maintenance in the event of frost 6.37 Tightening torques 6.38 Measures to be applied for longer periods of rest BW 80 AD-5 Fam. BOMAG...
  • Page 126 Maintenance BOMAG BW 80 AD-5 Fam.

  • Page 127: Every 10 Operating Hours

    Pull the dipstick back out. The oil level must always be between the "MIN"- and "MAX"-marks. If the oil level is too low top up oil immediately. BW 80 AD-5 Fam. BOMAG...

  • Page 128: Check The Fuel Level

    Clean the area around the filler Danger opening. Health hazard! Open the cover (Fig. 115). Do not inhale any fuel fumes. Top up with fuel (diesel or winter diesel). Screw the cover back on again. BOMAG BW 80 AD-5 Fam.

  • Page 129: Checking The Hydraulic Oil Level

    For quality of oil refer to the "table of fuels and lubricants". Fig. 116 Check the oil level in the oil level inspection glass (Fig. 116). Note At a room temperature of approx. 20 °C (68 °F) the oil level should reach BW 80 AD-5 Fam. BOMAG...

  • Page 130: Checking The Hydraulic Oil Filter Element

    Check the coolant level in the element o.k. compensation tank (Fig. 118). Pin pops out = Replacing the hy- To top up unscrew the filler cap draulic oil filter el- and fill in coolant up to the MAX- ement mark. BOMAG BW 80 AD-5 Fam.

  • Page 131: Checking The Water Level

    If necessary fill in water through the filler screen and close the cap again. Fig. 119 Check the water tank filling level on the water level gauge (Fig. 119). BW 80 AD-5 Fam. BOMAG...

  • Page 132: Check The Emulsion Level

    Make sure that the ventilation bore in the filler cap is free. Fig. 121 Open the lid (Fig. 121) on the tank, fill up with emulsion as necessary and close the lid again. only on ACM/SCC-machines BOMAG BW 80 AD-5 Fam.

  • Page 133: Every 50 Operating Hours

    Incorrectly handled air filter car- tridges may become ineffective Unclip the clamps on the housing because of damage (e.g. cracks) cover (3) and take off the cover . and cause damage to the engine. Open the engine hood. BW 80 AD-5 Fam. BOMAG...
  • Page 134 Fig. 125 Check the air filter cartridge (Fig. 125) from inside with a torch for holes, cracks, flutes or other dam- age. Always replace damaged filter cartridges. Fig. 124 Danger Eye injury! Wear safety goggles. BOMAG BW 80 AD-5 Fam.

  • Page 135: Check Fuel Lines And Clamps

    If the clamps are not fastened cor- rectly dirt and dust may be drawn in. This can damage the engine. Fig. 128 Check the condition and tight fit of all fuel lines (1) (Fig. 128) and hose clamps (2). BW 80 AD-5 Fam. BOMAG...

  • Page 136: Checking, Cleaning The Water Separator

    After taking the engine into operation you should therefore check the water separator every day for signs of water. Environment Any fuel must be caught and dis- posed of in an environmentally friendly manner. BOMAG BW 80 AD-5 Fam.

  • Page 137: Every 250 Operating Hours

    Unscrew the drain plug (Fig. 131) cants". and catch running out oil. Turn the oil drain plug back in with Environment a new seal ring. Catch running out oil and dispose of environmentally together with the oil filter cartridge. BW 80 AD-5 Fam. BOMAG...
  • Page 138 Slightly oil the rubber seal on the (MAX). new filter cartridge (Fig. 133). Turn the new filter cartridge on by hand, until the seal contacts. Tighten the filter element for an- other half turn. BOMAG BW 80 AD-5 Fam.

  • Page 139: Checking, Tensioning, Replacing The V-Belt

    (0.28 – 0.35 inch) between the V- belt pulleys, retighten if neces- sary. Tightening the V-belt Slightly slacken the fastening screws (2) . Press the generator in direction outward using a lever, until the correct V-belt tension is reached. BW 80 AD-5 Fam. BOMAG...

  • Page 140: Checking The Air Intake Lines

    For this all air intake lines and hose reason you should always seal clamps. any oil or fuel leaks in the vicinity of the cooling fan or the radiator and clean the cooling surfaces af- ter. BOMAG BW 80 AD-5 Fam.
  • Page 141 Fig. 138 Blow the hydraulic oil cooler (Fig. 138) out with compressed air. Cleaning with cold cleans- ing agent Caution Protect electrical equipment such as generator, regulator and starter against the direct water jet. BW 80 AD-5 Fam. BOMAG...

  • Page 142: Battery Service

    Each battery plates) are not covered under war- suffers under self-discharge, which ranty! may, in not checked occasionally, even cause damage to the battery as a result of exhaustive discharge. BOMAG BW 80 AD-5 Fam.

  • Page 143: Checking Radiator Hoses And Hose Clamps

    (Vaseline). Fig. 141 Retighten the pole clamps. Check the condition and tight fit of all radiator hoses and hose Check the fastening of the battery. clamps (Fig. 141). BW 80 AD-5 Fam. BOMAG...

  • Page 144: Check The Scrapers, Adjust If Necessary

    Adjust the scrapers with the 462118 screws to a uniform distance of Fig. 142 approx. 2 mm (0.08 in) from the Check the scrapers (Fig. 142), ad- rubber tires. just if necessary only on ACM/SCC-machines BOMAG BW 80 AD-5 Fam.

  • Page 145: Every 500 Operating Hours

    Catch running out fuel, do not let it seep into the ground. Note When performing this work the fuel tank shall only hold max. 5 l (1.3 gal us) of fuel, pump off if necessary. BW 80 AD-5 Fam. BOMAG...

  • Page 146: Change The Fuel Filter

    Catch running out fuel, do not let it Fasten the hose clamps. seep into the ground. Change the fuel filter car- Dispose of the used fuel filter en- tridge vironmentally. Fig. 146 Slacken and unscrew the fuel filter cartridge (Fig. 146). BOMAG BW 80 AD-5 Fam.

  • Page 147: Check The Anti-Freeze Concentration And The Condition Of The Coolant

    "Fuels and Lubricants - Coolant". If the coolant is contaminated by corrosion residues or other sus- pended matter, flush the cooling system, see section "Changing the coolant". Environment Catch coolant and dispose of en- vironmentally. BW 80 AD-5 Fam. BOMAG...
  • Page 148 Every 500 operating hours 462115 Fig. 147 Remove the cap (Fig. 147) from the coolant compensation tank and check the anti-freeze concen- tration with a conventional tester. Check the condition of the coolant. Screw the cap back on. BOMAG BW 80 AD-5 Fam.

  • Page 149: Every 1000 Operating Hours

    (0.006 in) valve by following the adjustment diagram 1"(Fig. 149), black mark. Fig. 148 Remove the valve cover (Fig. Fig. 150 148). Check the gap between rocker arm and valve with a feeler gauge (Fig. 150). BW 80 AD-5 Fam. BOMAG...

  • Page 150: Check The Engine Mounts

    Install the cylinder head cover with ness. a new gasket. Check fastening and tightness of the lubrication oil sump. Note Check condition and tight fit of en- After a short test run check the en- gine mounts. gine for leaks. BOMAG BW 80 AD-5 Fam.

  • Page 151: Check The Travel Control

    Thereby check for func- tion, light movement, clearance and damage. In case of malfunction perform trouble shooting and replace the corresponding parts. Caution Only operate the machine after the travel control has been repaired. BW 80 AD-5 Fam. BOMAG...
  • Page 152 Every 1000 operating hours BOMAG BW 80 AD-5 Fam.

  • Page 153: Every 2000 Operating Hours

    When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details. Environment Catch running out oil and dispose of environmentally. BW 80 AD-5 Fam. BOMAG...
  • Page 154 Reconnect the leak oil hose tight- 462155 Fig. 155 Machines with lateral overhang: Disconnect bthe leak oil hose from the front right hand vibration motor BOMAG BW 80 AD-5 Fam.
  • Page 155 This ensures finest filtration filler cap. of the hydraulic oil, prolongs the life- time of the hydraulic oil filter and pro- tects the hydraulic system. BW 80 AD-5 Fam. BOMAG...

  • Page 156: Change The Hydraulic Oil Filter

    (1) and (2). Do not clean or reuse the filter el- ement. Apart from the normal oil change intervals, the filter element must also be changed after major re- pairs in the hydraulic system. BOMAG BW 80 AD-5 Fam.

  • Page 157: Changing The Coolant

    2- filter leaks. 3 times with clear water. For quality and quantity of coolant refer to the "table of fuels and lu- bricants". Environment Catch running out coolant and dispose of environmentally. BW 80 AD-5 Fam. BOMAG...
  • Page 158 Let the engine cool down and tighten the clamp. check the coolant level again, if Check the condition of radiator necessary top up in the compen- hoses, if necessary replace all ra- sation tank. diator hoses. BOMAG BW 80 AD-5 Fam.

  • Page 159: Changing The Fuel Lines

    Hoses consist of rubber or plastic material and age over the course of time. Environment Catch running out fuel, do not let it seep into the ground. Replace all fuel hoses, including their hose clips. BW 80 AD-5 Fam. BOMAG...
  • Page 160 Every 2000 operating hours BOMAG BW 80 AD-5 Fam.

  • Page 161: Every 3000 Operating Hours

    Every 3000 operating hours Every 3000 operating hours 6.34 Check the fuel in- jection pump Caution This work must only be performed by authorized service personnel. BW 80 AD-5 Fam. BOMAG...
  • Page 162 Every 3000 operating hours BOMAG BW 80 AD-5 Fam.

  • Page 163: As Required

    Nominal value 2 – 2.5 bar (29 – 36 psi) Open the rear flap, unscrew the screw plug for water provision (Fig. 166) and let all water run out (only AC machines). Close the screw plug again. only on ACM/SCC-machines BW 80 AD-5 Fam. BOMAG...
  • Page 164 Close the drain tap again. 462 121 Fig. 170 Unscrew the water sprinkling noz- zles (Fig. 170) at front and rear and let all water run out. Screw the nozzles back in before using the machine the next time. BOMAG BW 80 AD-5 Fam.

  • Page 165: Tightening Torques For Screws With Metric Unified Thread

    Þm total = 0.14. = 0.14. Compliance with the tightening tor- ques is checked with torque wrench- When using MOS lubricants the specified tightening torques do not apply. BW 80 AD-5 Fam. BOMAG...

  • Page 166: Measures To Be Applied For Longer Periods Of Rest

    If you have forgotten to run the en- gine over a period of more than 5 to 6 months apply a sufficient amount of engine oil to the valve guidance and the valve stem seal and make sure that the valves BOMAG BW 80 AD-5 Fam.

  • Page 167: Trouble Shooting

    7 Trouble shooting BW 80 AD-5 Fam. BOMAG...

  • Page 168: General Notes

    If you cannot locate the cause of a fault or rectify it yourself by following the trouble shooting chart, you should contact our customer service department. BOMAG BW 80 AD-5 Fam.

  • Page 169: Engine Problems

    Emergency stop push but- Unlock the emergency ton is locked stop switch Especially in winter: use of Use the correct engine oil too viscous engine oil for the ambient tempera- tures BW 80 AD-5 Fam. BOMAG...
  • Page 170 Drain the oil down to the power and top dipstick mark speed, exces- Poor quality fuel Use specified fuel sive exhaust smoke Air filter dirty Clean the filter, replace if necessary. Injection nozzle defective Have examined by a spe- cialist BOMAG BW 80 AD-5 Fam.
  • Page 171 Fill up oil down to the top dipstick mark V-belt loose or broken Tension or replace the V- belt Radiator internally corrod- Replace the radiator, flush the cooling system Thermostat defective Check the thermostat, re- place if necessary. BW 80 AD-5 Fam. BOMAG...
  • Page 172 Trouble shooting BOMAG BW 80 AD-5 Fam.

  • Page 173: Disposal

    8 Disposal BW 80 AD-5 Fam. BOMAG...

  • Page 174: Final Shut-Down Of Machine

    Empty the fuel tank. Drain the hydraulic oil tank. Drain coolant from engine and cooling system. Drain the lubrication oil from the engine. BOMAG BW 80 AD-5 Fam.

This manual is also suitable for:

Bw 90 sc-5Bw 100 sc-5Bw 90 ad-5Bw 100 adm-5Bw 100 acm-5Bw 100 scc-5

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