Fayat Group BOMAG BW 80 AD-5 Service Manual

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Service - Manual

BW 80 AD-5/BW 90 AD-5/BW 100 ADM-5

BW 90 SC-5 / BW 100 SC-5

BW 100 ACM-5/BW 100 SCC-5

S/N 101 462 00 .... > / S/N 101 462 01 .... > / S/N 101 462 03 .... >

Tandem Vibratory Roller

Combination Roller

Catalogue number.

008 917 37

S/N 101 462 05 .... > / S/N 101 462 07 .... >

S/N 101 462 04 .... > / S/N 101 462 06 .... >

12/2013

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Summary of Contents for Fayat Group BOMAG BW 80 AD-5

Page 1 Service - Manual BW 80 AD-5/BW 90 AD-5/BW 100 ADM-5 BW 90 SC-5 / BW 100 SC-5 BW 100 ACM-5/BW 100 SCC-5 S/N 101 462 00 ..> / S/N 101 462 01 ..> / S/N 101 462 03 ..> S/N 101 462 05 ..
Page 2 Find manuals at https://best-manuals.com...
Page 3 Table of Contents General 1.1 Introduction 1.2 Safety regulations 1.3 General repair instructions 1.4 Tightening torques The series 5 2.1 The series 5 Technical data 3.1 Technical data Maintenance 4.1 General notes on maintenance 4.2 Fuels and lubricants 4.3 Table of fuels and lubricants 4.4 Running-in instructions 4.5 Maintenance table Overall view of machine...
Page 4 Table of Contents 7.6 Changing the coolant 7.7 Check radiator hoses and hose clamps 7.8 Cleaning radiator and hydraulic oil cooler 7.9 Checking, tensioning, replacing the V-belt 7.10 Checking, cleaning the air filter, replacing if necessary 7.11 Check the air intake lines 7.12 Checking, cleaning the water separator 7.13 Change the fuel filter 7.14 Checking fuel lines and clamps...
Page 5 Table of Contents Flushing and bleeding 11.1 Special tools for flushing 11.2 Flushing - general 11.3 Flushing schematic for travel system, AD/SC-machine 11.4 Travel system, flushing AD/SC-machine 11.5 Flushing schematic for travel system, AC-machine 11.6 Travel system, flushing AC-machine 11.7 Bleeding the travel circuit Drum 12.1 Repair overview for drums 12.2 Removing and installing the AD-drum...
Page 6 Table of Contents BOMAG 008 917 37 Find manuals at https://best-manuals.com...
Page 7 1 General 008 917 37 BOMAG Find manuals at https://best-manuals.com...
Page 8 Introduction 1.1 Introduction This manual addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and effi- cient repair and maintenance work. This manual describes the disassembly, dismantling, assembly, installation and repair of components and assemblies.
Page 9 Safety regulations Important notes Block the articulated joint with the articulation lock. Safety regulations Use protective clothes like hard hat, safety boots These safety regulations must be read and ap- and gloves. plied by every person involved in the repair /main- tenance of this machine.
Page 10 Safety regulations Start the extraction fan before starting work and Operation of high-voltage systems guide with the progressing work as required. Always isolate the burner when laying it down (re- Note move possible electrode residues). The rules and statutory regulations valid in the corre- Protect cables from being damaged, use cables sponding do apply in addition to the notes given here.
Page 11 Safety regulations Fire extinguishers charged with FOAM, CO Environment or POWDER must be available wherever fuel is It is strictly prohibited to drain off oil into the soil, stored, filled in, drained off, or where work on fuel the sewer system or into natural waters. Old oil systems is performed.
Page 12 Safety regulations Engine The installation and use of non-genuine spare parts or non-genuine accessories may therefore have an adverse effect on the specific characteristics of the Danger machine and thereby impair the active and/or pas- Do not work on the fuel system while the engine is sive driving safety.
Page 13 General repair instructions General Electrics General repair instructions Before removing or disassembling parts, assem- General blies, components or hoses mark these parts for Due to the fast technical development electric and easier assembly. electronic vehicle systems become more intelligent Before assembling and installing parts, assemblies and more comprehensive day by day, and can hardly or components oil or grease all movable parts or be dispensed with in hydraulic and mechanical vehicle...
Page 14 General repair instructions Battery Plug-in connectors on control units are only dust and water tight if the mating connector is plugged Rules for the handling of batteries on! Control units must be protected against spray water, until the mating connector is finally plugged When removing a battery always disconnect the mi- nus pole before the plus pole.
Page 15 General repair instructions Generator Starter motor Before removing the generator you must disconnect So-called jump starting (using an additional external the ground cable from the minus pole of the battery battery) without the battery connected is dangerous. while the ignition is switched off. Do not disconnect When disconnecting the cables from the poles high in- the generator while the engine is running, because ductivities (arcs, voltage peaks) may occur and de-...
Page 16 General repair instructions Hydraulic system Perform measurements at operating temperature of the hydraulic oil (approx. 40 ¯C). After changing a component perform a high and Caution charge pressure test, if necessary check the speed Repair work on hydraulic elements shall only per- of the exciter shaft.
Page 17 General repair instructions Fuel hoses Gaskets and mating surfaces Leaking sealing faces can mostly be traced back to in- correct assembly of seals and gaskets. Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, cor- rosion or other damage.
Page 18 General repair instructions Feather keys and keyways able, you should use a plastic tube or adhesive tape to prevent the sealing lip from being damaged. Lubricate the outer rim (arrow 3 (Fig. 2)) of the seal Caution and press it flat on the housing seat. Feather keys may only be reused if they are free of damage.
Page 19 General repair instructions Ball and roller bearings Check shaft and bearing housing for discolouration or other signs of movement between ball or roller bearing and seats. Caution Make sure that shaft and housing are free of burrs Ball and roller bearings may only be reused if they before assembling the ball or roller bearing.
Page 20 General repair instructions Screws and nuts Strength classes, metric screws The strength classes (from 3.6 to 12.9) are specified Tightening torque for all strength classes from a nominal diameter of 5mm. The corresponding identification can be found where allowed for by the shape of the screw. Caution Tighten nuts or screws with the tightening tor- ques specified in the following tables of tighten-...
Page 21 General repair instructions Strength classes of metric nuts Identification in clock system Nuts are differentiated by three load groups. Each load group has a special designation system for the strength class assigned, so that the load group can be clearly identified. Nuts for screw joints with full load capability (4, 5, 6, 8, 10, 12) Fig.
Page 22 General repair instructions Identification of UNF-threads Cotter pins Fig. 11 In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly. Cotter pins must be assembled as shown in the illus- tration, unless specified differently. Fig.
Page 23 Tightening torques The values specified in the table apply for screws: Tightening torques black oiled with surface protection A4C with surface protection DACROMET Note DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC- ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.
Page 24 Tightening torques Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste) Tightening torques Nm Screw dimension 10.9 12.9 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 1036 1184 1520 M27 X 2 1263 1536 1136...
Page 25 Tightening torques The values specified in the table apply for screws: black oiled with surface protection A4C with surface protection DACROMET Note The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks, as the metric ISO-thread, whereas Withworth has a flank of only 55°.
Page 26 Tightening torques Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American Unified Fine Thread Tightening torques Nm Screw dimension 10.9 12.9 1“ - 12 1300 1600 1 1/8“ - 12 1350 1900 2300 1 1/4“ - 12 1900 2700 3200...
Page 27 2 The series 5 008 917 37 BOMAG...
Page 28 The series 5 The success story continues: the series 5 The series 5 Proven technology linked with a moden concept. In the future building contractors or rental companies can choose from 3 drum widths (800/900/1,000 mm) and 6 different models; the tandem rollers BW 80 AD-5, BW 90 AD-5 and BW 100 ADM-5, the side free tandem rollers BW 90 SC-5 and BW 100 SC-5 as well as the combina- tion roller BW 100 ACM-5.
Page 29 The series 5 Service and maintenance friendly – here the evidence Generally no grease nipples Lifetime lubricated exciter system and long service intervals, e.g. changing the engine oil after 250 h and the hydraulic oil after 2,000 h. Well accessible: all service and maintenance points on the engine Safety without compromise Standard with the CE-compliant rollers: Audible backup alarm, EMERGENCY STOP and seat contact switch- Reliable parking and service brakes;...
Page 30 The series 5 BOMAG 008 917 37...
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