Bomag BW 80 AD-2 Operating Instructions, Maintenance Instructions
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Bomag BW 80 AD-2 Operating Instructions, Maintenance Instructions

Tandem vibratory/combination roller, side free tandem roller
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Operating instructions
Maintenance instructions
BW 80 AD-2 / BW 80 ADH-2
BW 90 AD-2 / BW 100 ADM-2
BW 90 AC-2 / BW 80 ADS
Tandem vibratory/combination roller
Side-free tandem roller
Catalogue number
008 104 31
S/N 101 460 42 0101 S/N 101 460 62 0101
S/N 101 460 52 0101 S/N 101 460 72 0101
S/N 101 460 73 0101
07/2003

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Summary of Contents for Bomag BW 80 AD-2

  • Page 1 Operating instructions Maintenance instructions BW 80 AD-2 / BW 80 ADH-2 BW 90 AD-2 / BW 100 ADM-2 BW 90 AC-2 / BW 80 ADS S/N 101 460 42 0101 S/N 101 460 62 0101 S/N 101 460 52 0101 S/N 101 460 72 0101...
  • Page 3 Please observe strictly the safety regulations. The vast experience of BOMAG as well as modern production and testing methods such Please observe also the guidelines of the civil en- as lifetime tests of all important components gineering liability association "safety regulations...
  • Page 4 Fill in the above listed data when receiving the ma- chine. Upon receipt of the machine our organization will instruct you about correct operation and mainte- nance. Please observe strictly all safety regulations and notes on potential dangers! Fig. 2 Fig. 3 BOMAG BW 80 AD-2 Fam.

  • Page 5: Table Of Contents

    5.12 Checking the emulsion level (BW 90 AC-2) 5.13 Cleaning the scrapers 5.14 Greasing the articulated joint 5.15 Checking the tire pressure 5.16 Checking, cleaning, changing the dry air filter cartridge 5.17 Changing the engine oil 5.18 Change the engine oil filter BW 80 AD-2 Fam. BOMAG...
  • Page 6 5.32 Replacing the dry air filter cartridge 5.33 Water sprinkler system, maintenance in the event of frost 5.34 Tightening torques for screws with metric unified thread 5.35 Engine conservation Trouble shooting 6.1 General notes 6.2 Engine BOMAG BW 80 AD-2 Fam.
  • Page 7 1 Technical Data BW 80 AD-2 Fam. BOMAG...
  • Page 8 1282 1482 2300 1862 BW 90 AD-2 BW 100 ADM-2 1282 1056 1482 2300 1862 1000 BW 80 AD-2 BW 80 ADH-2 BW 90 AD-2 BW 100ADM- Weights Basic weight 1335 1485 1385 1435 Operating weight (CECE) 1470 1620 1520...
  • Page 9 Technical Data BW 80 AD-2 BW 80 ADH-2 BW 90 AD-2 BW 100ADM- Travel characteristics Travel speed (1) km/h 0 to 4,5 0 to 4,5 0 to 4,5 0 to 4,5 Travel speed (2) km/h 0 to 8 0 to 8...
  • Page 10 Weights Basic weight 1530 Operating weight (CECE) 1670 Mean axle load (CECE), drum Mean axle load (CECE), wheels Mean static linear load kg/cm Dimensions Working width 900/860 Outer track radius 2870 Length with ROPS 1985 BOMAG BW 80 AD-2 Fam.
  • Page 11 Vibrating drum front Drive system hydrostatic Frequency 60/40 Amplitude Centrifugal force Water sprinkler system Type of sprinkling Pressure sprinkling with interval Filling capacities Fuel (diesel) Water Emulsion Hydraulic oil The right for technical modifications remains reserved BW 80 AD-2 Fam. BOMAG...
  • Page 12 Working width Outer track radius 2870 Length with ROPS 1870 Travel characteristics Travel speed (1) km/h 0 to 4,5 Travel speed (2) km/h 0 to 8 Max. gradability without/ 40/30 with vibration (soil de- pendent) BOMAG BW 80 AD-2 Fam.
  • Page 13 Drive system hydrostatic Frequency 60/40 Amplitude 0,52 Centrifugal force 15,7 Water sprinkler system Type of sprinkling Pressure sprinkling with interval Filling capacities Fuel (diesel) Water Hydraulic oil The right for technical modifications remains reserved BW 80 AD-2 Fam. BOMAG...
  • Page 14 Vibration of the entire boy (driver’s seat) The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec Hand-arm vibration values The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec BOMAG BW 80 AD-2 Fam.
  • Page 15 2 Safety regulations BW 80 AD-2 Fam. BOMAG...
  • Page 16 General Notes Unintended use However, dangers may arise from this machine if This BOMAG machine has been built in ac- it is operated by untrained personnel or if it is sub- cordance with the latest technical standard ject of unintended use.
  • Page 17 Max. towing speed 1 km/h, max. towing distance steering, brakes, control elements, light sys- 500 m. tem and warning horn work correctly Before releasing the multi-disc brake secure the machine against unintended rolling. BW 80 AD-2 Fam. BOMAG...
  • Page 18 In events of an emergency operate the emergency Switch the lights on when the visibility is poor. stop switch immediately. Do not use the emergen- Keep clear of edges and embankments. cy stop switch as a service brake. BOMAG BW 80 AD-2 Fam.
  • Page 19 Observe all fire alarm Hydraulic hoses must be changed immediately if: and fire fighting possibilities. the outer layer is worn down to the metal lining (e.g. chafing, cuts, cracks) BW 80 AD-2 Fam. BOMAG...
  • Page 20 Ensure good ventilation, especially when charging hose connection. the battery in a closed room. Only genuine BOMAG hydraulic hoses ensure Working on the fuel system that the correct type of hose (pressure range) is Do not inhale fuel fumes.
  • Page 21 Test The safety of compaction equipment must be checked by a specialist as required in dependence on the application and the operating conditions, however at least once every year. BW 80 AD-2 Fam. BOMAG...
  • Page 22 Safety regulations BOMAG BW 80 AD-2 Fam.
  • Page 23 3 Indicators and Controls BW 80 AD-2 Fam. BOMAG...
  • Page 24 Indicators and Controls Fig. 7 BOMAG BW 80 AD-2 Fam.
  • Page 25 Indicators and Controls Fig. 8 BW 80 AD-2 Fam. BOMAG...
  • Page 26 23 Cock valve for rear vibration shut off 11 Rotary switch for lighting acc. to StVZO* or working lights* 24 Fuel level gauge (in engine compartment) 12 Rotary switch for hazard light system* 25 Additional travel lever* Option BOMAG BW 80 AD-2 Fam.

  • Page 27: General Notes

    No. 2 = Oil pressure warning light lights up = with the ignition switch in posi- tion "I" (test) in case of insuffi- cient oil pressure the engine will be shut down immediately. goes out = after starting the engine BW 80 AD-2 Fam. BOMAG...
  • Page 28 = after starting the engine Caution If the control light lights up while the engine is running, the battery is not being charged. De- tect the cause and eliminate the fault. BOMAG BW 80 AD-2 Fam.
  • Page 29 10 minutes. Do not shut the engine down all of a sudden Fig. 16 from full speed, but let it idle for a while for No. 9 = Parking brake warning light temperature equalization. Option BW 80 AD-2 Fam. BOMAG...
  • Page 30 Design with seat contact for engine shut-down Fig. 19 No. 12 = Rotary switch for hazard light sys- lights when the machine is driv- = when the driver’s seat is unoc- Option cupied. Warning buzzer ** Option BOMAG BW 80 AD-2 Fam.
  • Page 31 = flashing beacon off (5), 15A = (F11) head lights, left* Position "right" = flashing beacon on (6), 15A = (F12) head lights, right* Fuses on terminal strip *** Option Option = (30A) potential 30 ** Option BW 80 AD-2 Fam. BOMAG...
  • Page 32 Position "0" = Service brake, the machine is tem on or off. automatically braked by the hydrostatic drive. Position direction "I" = the forward speed is adjusted according to the travel lever position. Optional equipment BOMAG BW 80 AD-2 Fam.
  • Page 33 (60 Hz). Caution Always drive and vibrate in throttle lever posi- tion I or II! Control the travel speed only with the travel le- ver! Note Pull up the locking plate to move the throttle lever. BW 80 AD-2 Fam. BOMAG...
  • Page 34 Position horizon- = Vibration of both drums Position down- ward = Vibration of front drum only Fig. 32 No. 24 = Fuel gauge shows the filling level in the fuel tank Optional equipment ** Option BOMAG BW 80 AD-2 Fam.
  • Page 35 4 Operation BW 80 AD-2 Fam. BOMAG...

  • Page 36: General Notes

    Check the hydraulic oil level, top up if neces- sary. Hydraulic oil filter contamination indicator Check the coolant level, top up if necessary. Danger Fire hazard! Do not refuel in closed rooms. Check the fuel level, top up if necessary. BOMAG BW 80 AD-2 Fam.

  • Page 37: Starting The Engine

    Always start the engine from the driver’s seat is pointing vertically down. with seat contact switch (Fig. 35). Danger Danger of accident! Always wear your seat belt. Fig. 36 Fasten your seat belt (Fig. 36). BW 80 AD-2 Fam. BOMAG...
  • Page 38 Turn the ignition key (Fig. 40) to position "I". Fig. 38 Set the throttle lever (Fig. 38) to "0"-position. Fig. 41 Oil pressure warning light 2 (Fig. 41), charge con- gtrol light (4) and parking brake warning light (9) light up. Optional equipment BOMAG BW 80 AD-2 Fam.

  • Page 39: Starting At Low Temperatures

    Run the engine warm for a short while, but do not run with idle speed for more than 10 min- utes. Fig. 44 Turn the ignition key (Fig. 44) through position "I" to position "II" and hold it for approx. 6 sec- onds. BW 80 AD-2 Fam. BOMAG...
  • Page 40 "I". Once the engine runs properly, reduce the en- gine speed. If required, the ignition key may be held in po- sition "II" longer than 6 seconds. The preheat- ing time will be extended accordingly. BOMAG BW 80 AD-2 Fam.

  • Page 41: Starting With Jump Leads

    = when the driver’s seat is occu- pied. lights up when the machine is at rest = when the driver’s seat is unoc- cupied. Drive operation is not possible. (The brake is closed). BW 80 AD-2 Fam. BOMAG...
  • Page 42 "I" or "II" . When shifting the travel lever through position "III" Control the travel speed only with the travel lever to position "I" or "II", the vibration will be automati- (Fig. 51). cally switched off. Optional equipment BOMAG BW 80 AD-2 Fam.

  • Page 43: Operating The Parking Brake, Stopping The Machine

    Check, whether the travel lever (Fig. 53) is locked to the right in braking position. Note The travel lever returns automatically to parking brake position when releasing it in "0"-position. The pressure sprinkler system is automatically switched off. BW 80 AD-2 Fam. BOMAG...

  • Page 44: Switching The Vibration On And Off

    (Fig. 56). Position up- ward = Vibration of rear drum only Position horizon- = Vibration of both drums Position down- ward = Vibration of front drum only Fig. 55 Caution Destruction of hydraulic components! Optional equipment BOMAG BW 80 AD-2 Fam.
  • Page 45 (40 Hz) or "II" (60 Hz) and lock it. Fig. 58 Shift the travel lever (Fig. 58) slowly to the de- sired travel direction, max. to position "III". Fig. 59 Actuate the vibration push button (Fig. 59). BW 80 AD-2 Fam. BOMAG...

  • Page 46: Switching The Gravity Sprinkler System On Or Off

    This ensures that the machine will not use any wa- ter when not in operation In order to test the function of the sprinkling sys- tem with the machine stopped shift the travel lever sideways out of braking position. Optional equipment BOMAG BW 80 AD-2 Fam.

  • Page 47: Checking The Sprinkling System With The Machine Stopped

    = to switch on or off. tem is not possible. Shift the travel lever to the left through brake position "0" and hold it in position, check whether sprinkling system switches on. BW 80 AD-2 Fam. BOMAG...

  • Page 48: Stopping The Engine/Machine

    Note The travel lever returns automatically to parking brake position when releasing it in "0"-position. The pressure sprinkler system is automatically switched off. BOMAG BW 80 AD-2 Fam.

  • Page 49: Adjusting The Operator's Seat

    In its setting the lever (3) is locked in upwards di- rection. This lock can be released by pressing the lever down against the end stop. Then adjust the operator's weight by sliding the lever downwards. BW 80 AD-2 Fam. BOMAG...

  • Page 50: Towing

    (Fig. 72). the brake is released. After towing Danger Switch the ball valve (Fig. 70) back to position "II", turn the locking screw back in and counter it with the hexagon nut. Optional equipment BOMAG BW 80 AD-2 Fam.

  • Page 51: Loading And Transport

    1 (Fig. 73) out To lift the machine attach the lifting gear to the of its receptacle to the front. Insert the pin (2) central lifting device (Fig. 75). and secure it with the cotter pin (3). BW 80 AD-2 Fam. BOMAG...
  • Page 52 Operation Loading weight: see technical data. After the transport Fig. 76 After the transport release the articulation lock and fix it in its receptacle (Fig. 76). BOMAG BW 80 AD-2 Fam.
  • Page 53 5 Maintenance BW 80 AD-2 Fam. BOMAG...

  • Page 54: General Notes On Maintenance

    Always use the filling and filtering unit Notes on the fuel system (BOMAG part-no. 007 610 01) to fill the hy- The lifetime of the diesel engine is decisively de- draulic system. This unit is fitted with a fine fil- pending on the cleanliness of the fuel.

  • Page 55: Fuels And Lubricants

    The longest permissible time a lubrication oil should remain in an engine is 1 year. If the follow- ing oil change intervals are not reached over a pe- riod of 1 year, the oil change should be performed BW 80 AD-2 Fam. BOMAG...
  • Page 56 3 and fuel tank is never run dry, as otherwise filter and in- 12 °dGH. The water should not contain more than jection lines need to be bled. BOMAG BW 80 AD-2 Fam.
  • Page 57 The proportion of cooling system protection agent must be between min. 35% and max. 45% to the water. Caution Do not mix different coolants and additives of any other kind. BW 80 AD-2 Fam. BOMAG...

  • Page 58: Table Of Fuels And Lubricants

    Anti-freeze mixture as required Water 100 litres Sprinkling of tires Emulsion 10 litres Oscillating articulated joint High pressure grease (lithium saponified) as required **Mix water and anti-freeze agent by following the instructions of the manufacturer BOMAG BW 80 AD-2 Fam.

  • Page 59: Running-In Instructions

    After the running-in period it is quite sufficient to check the oil level once every day. Check and retighten the screws on the ma- chine. Watch out for leaks. BW 80 AD-2 Fam. BOMAG...

  • Page 60: Maintenance Chart

    Clean the sprinkler system Every 500 operating hours 5.24 Changing the main fuel filter 5.25 Fuel tank, draining the sludge off 5.26 Service the battery Every 1000 operating hours 5.27 Check and adjust the valve clearance BOMAG BW 80 AD-2 Fam.
  • Page 61 When using diesel fuel with a sulphur content of more than 0,5 % by weight the engine oil change intervals must be halved. This applies also when using engine oil of API-class CC/SE or CC/SF. Example: Fuel 1 % sulphur and lubrication oil CD/SE. ** Also in case of repairs in the hydraulic system. BW 80 AD-2 Fam. BOMAG...

  • Page 62: Checking The Engine Oil Level

    Clean the area around the filler opening. Unscrew the filler cap. If necessary top up fuel (diesel or winter die- sel). For quality of fuel refer to the table of fuels and lubricants. BOMAG BW 80 AD-2 Fam.

  • Page 63: Check The Hydraulic Oil Level

    In hydraulic systems filled with Panolin HLP Synth. 32 always use the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer. BW 80 AD-2 Fam. BOMAG...

  • Page 64: Checking The Coolant Level

    Make sure that the bores in the lid are free. To top up unscrew the filler cap and fill in cool- ant up to the MAX-mark. For quality of coolant refer to the chapter 5.2, fuels and lubricants. BOMAG BW 80 AD-2 Fam.

  • Page 65: Cleaning The Scrapers

    Fold the scrapers up and clean them (Fig. 85). This is of particular importance before com- pacting asphalt surfaces. Fig. 84 Check the emulsion level in the emulsion tank at the back of the machine, top up if necessary (Fig. 84). BW 80 AD-2 Fam. BOMAG...

  • Page 66: Greasing The Articulated Joint

    (Fig. 87). For quality of oil refer to the section about fu- els, lubricants and filling capacities. Note Ensure even pressure in all tires. Specified value 2 ... 2,5 bar (29 ... 36 psi) BOMAG BW 80 AD-2 Fam.

  • Page 67: Checking, Cleaning, Changing The Dry Air Filter Cartridge

    Unscrew the wing screw and take the air filter cartridge (Fig. 88) out of the air filter housing. Caution Do not hold the pressure air nozzle closer than 3 cm to the filter. Always blow along the inner folds. BW 80 AD-2 Fam. BOMAG...
  • Page 68 Replace a damaged dry air filter immediately. Fig. 92 Before inserting the cartridge check the seal- ing faces on the dry air filter. Insert the dry air filter and fasten it with the wing screw. BOMAG BW 80 AD-2 Fam.

  • Page 69: Changing The Engine Oil

    For quality and quantity of oil refer to the sec- tion about fuels, lubricants and filling capaci- ties. Fig. 93 Screw the lid back on the oil filler neck. Remove the lid from the oil filler opening (Fig. 93). BW 80 AD-2 Fam. BOMAG...

  • Page 70: Change The Engine Oil Filter

    Apply some clean oil to the rubber seal on the new filter cartridge. Screw the new filter cartridge on and tighten it hand tight. After a short test run examine the engine for leaks and check the oil level, if necessary top up oil. BOMAG BW 80 AD-2 Fam.

  • Page 71: Checking The Condition, Tension Of The V-Belt, Changing The V-Belt

    7 to 9 mm between the V-belt pulleys, if necessary reten- sion. Fig. 100 Slacken the fastening screws 1 and 2 (Fig. 100). Push the generator completely towards the engine.. Take the old V-belt off. BW 80 AD-2 Fam. BOMAG...

  • Page 72: Checking The Condition And Tension Of The Toothed Belt For The Pump Drive

    Have the toothed belt replaced if starting cracks are found. Use the belt tension tester (BOMAG P/N 079 947 10) to check whether the toothed belt can be depressed 6 to 8 mm between the BOMAG BW 80 AD-2 Fam.

  • Page 73: Changing The Fuel Precleaner, Bleeding The Fuel System

    Fuel may drip onto the hot exhaust. In the following cases the fuel system needs to be bled: after changing the fuel filter, after run- ning the fuel tank dry, after a long resting peri- od of the machine. BW 80 AD-2 Fam. BOMAG...

  • Page 74: Cleaning The Cooling Fins On Radiator And Hydraulic Oil Cooler

    Retighten the bleeding screw. Fig. 106 Remove the blower grid. Note Start to blow out from the air discharge side. Blow the radiator (Fig. 106) out with com- pressed air from the air discharge side. BOMAG BW 80 AD-2 Fam.
  • Page 75 Run the engine warm for a short time to avoid corrosion. Reassemble the blower grid. Fig. 108 Blow the hydraulic oil cooler (Fig. 108) out from the air discharge side first. BW 80 AD-2 Fam. BOMAG...

  • Page 76: Cleaning The Water Sprinkler System

    Screw the water filter back in, tighten the spig- Reinsert the emulsion filter. ot nut and close the flap. Turn the fitting back on. Fig. 111 Pull the caps 3 (Fig. 111) off both sprinkler tubes. BOMAG BW 80 AD-2 Fam.

  • Page 77: Changing The Main Fuel Filter

    Screw the filter bowl back on and bleed the back on with a new seal ring. fuel system, refer to the section "changing the fuel precleaner". Check the fuel lines for wear and damage, re- place if necessary. BW 80 AD-2 Fam. BOMAG...

  • Page 78: Checking The Condition Of The Battery

    Tighten the terminal clamps. Colour indication on hydrometer. Check the fastening of the battery. Indication green, battery ready. Non-maintenance free batteries: Indication dark green, charge battery. Clean battery and battery compartment. Indication yellow, replace battery. BOMAG BW 80 AD-2 Fam.
  • Page 79 Every 500 operating hours BW 80 AD-2 Fam. BOMAG...

  • Page 80: Checking, Adjusting The Valve Clearance

    = both valves are moving and cannot be checked or adjust- Fig. 118 Compression po- Remove the protection hood (Fig. 118). sition = none of the valves moves and can be checked or adjusted. Note = Inlet valve BOMAG BW 80 AD-2 Fam.
  • Page 81 Note Mark checked and adjusted valves with chalk. Fig. 122 Turn the flywheel for another 360° and align the "1TC"-mark with the mark on the mark on the housing. BW 80 AD-2 Fam. BOMAG...

  • Page 82: Changing The Hydraulic Oil

    Fill in new hydraulic oil (Fig. 124). Do not remove the strainer filter when filling. Put the filler cap back on. Check the hydraulic oil level on the oil dipstick. Perform a test run and check the system for leaks. BOMAG BW 80 AD-2 Fam.

  • Page 83: Changing The Hydraulic Oil Filter Element

    Fig. 125 Unscrew the filter bowl (Fig. 125) from the filter housing. Take the old filter element out and dispose of environmentally. BW 80 AD-2 Fam. BOMAG...

  • Page 84: Changing The Coolant

    Fig. 126 Remove the radiator cap (Fig. 126). Fig. 127 Unscrew the drain cock (Fig. 127). Drain the coolant completely off and collect it. Screw the drain cock back in. Empty the coolant compensation tank. BOMAG BW 80 AD-2 Fam.

  • Page 85: Replacing The Pump Drive Toothed Belt

    Let the engine cool down and check the cool- Fig. 131 ant level again, top up if necessary. Pull out the cotter pin and unscrew the castle nut (Fig. 131) from the toothed belt pulley on the hydraulic pump. BW 80 AD-2 Fam. BOMAG...
  • Page 86 50Nm Lock the castle nut with the cotter pin. Note If the bore is not in line with the recess in the castle nut, turn the castle nut further, do not turn back. BOMAG BW 80 AD-2 Fam.

  • Page 87: Replacing The Dry Air Filter Cartridge

    Fig. 134 Unscrew the wing screw and pull the air filter cartridge (Fig. 134) out of the air filter housing. Fig. 135 Clean out the air filter housing with a cloth (Fig. 135). BW 80 AD-2 Fam. BOMAG...

  • Page 88: Water Sprinkler System, Maintenance In The Event Of Frost

    The compliance with the specified tightening tor- ques is checked with torque wrenches. The specified tightening torques do not apply when using a MoS lubricant. Note Self locking nuts must always be replaced after they have been unscrewed. BOMAG BW 80 AD-2 Fam.

  • Page 89: Engine Conservation

    After this run remove the cylinder head cover and spray the rocker chamber with a mixture of diesel fuel and 10% anti-corrosion oil. Reas- semble the hood. Now crank the engine several times (throttle lever in stop-position) to spray the combustion chamber. BW 80 AD-2 Fam. BOMAG...
  • Page 90 As required BOMAG BW 80 AD-2 Fam.

  • Page 91: Trouble Shooting

    6 Trouble shooting BW 80 AD-2 Fam. BOMAG...

  • Page 92: General Notes

    On the following pages you will find a selection of fault remedies. It goes without saying that not all possible reasons for faults could be listed. Danger Danger of injury! Do not touch rotating parts of the engine. BOMAG BW 80 AD-2 Fam.

  • Page 93: Engine

    Poor compression due to burned or bro- Have compression rings and pistons ex- ken compression rings or incorrect valve amined by a specialist, adjust the valve clearance clearance Injection valve defective Have examined by a specialist BW 80 AD-2 Fam. BOMAG...
  • Page 94 Engine oil of wrong SAE-class Change the engine oil. The charge con- The generator does not charge the bat- Have examined by a specialist trol light lights tery, because generator or regulator is de- during operation fective BOMAG BW 80 AD-2 Fam.

This manual is also suitable for:

Bw 80 adh-2Bw 100 adm-2Bw 90 ac-2Bw 80 adsBw 90 ad-2

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