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Fayat Group BOMAG BW 80/90 AD-5 Service Manual
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Fayat Group BOMAG BW 80/90 AD-5 Service Manual

Tandem vibratory roller, combination roller
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Service Manual
BW 80/90 AD-5 / BW 100 ADM/ACM-5 /
BW 90/100 SC-5 / BW 100 SCC-5
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>
Tandem vibratory roller
Combination roller
008 925 60
© 05/2018

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Summary of Contents for Fayat Group BOMAG BW 80/90 AD-5

  • Page 1 Service Manual BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5 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> Tandem vibratory roller Combination roller 008 925 60...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 Table of contents Table of contents 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 Technical data............................45 2.1 BW 80 AD-5..........................47 2.1.1 Noise and vibration data......................49 2.2 BW 90 AD-5..........................
  • Page 4 Table of contents 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........................
  • Page 5 Table of contents 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.........................
  • Page 6 Table of contents 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..................
  • Page 7 General General BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5 Find manuals at https://best-manuals.com...
  • Page 8 General – Introduction 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 General This manual: addresses the BOMAG Customer Service and professionally trained personnel. provides support for repair work or maintenance procedures on the machine.
  • Page 9 General – Introduction Maintenance/parts service Specialist teams are available for you in Germany, Europe and overseas. This tight network ensures close customer contact all over the world. Parts for maintenance, service and repair are available from our branch offices and dealers at very short notice. BOMAG guarantees long-term availability of all common parts.
  • Page 10 General – Safety regulations 1.2 Safety regulations General 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: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel, it is changed or converted in an unprofessional way,...
  • Page 11 General – Safety regulations starting and operation of the machine in explosive environments and in underground mining is prohibited. Remaining dangers, remaining Despite careful work and compliance with standards and regula- risks tions it cannot be ruled out that further dangers may arise when working with and handling the machine.
  • Page 12 General – Safety regulations Safety installations and switches must neither be removed nor must they be made ineffective. Notes on safety in the operating and maintenance instructions WARNING! Paragraphs marked like this highlight possible dan- gers for persons. NOTICE! Paragraphs marked like this highlight possible dan- gers for machines or parts of the machine.
  • Page 13 General – Safety regulations Check all lifting points and fastening elements for damage before lifting the machine. Do not use damaged or in any other way impaired lifting points. Lift the machine only with suitable lifting gear. Use only safe lifting gear of sufficient load bearing capacity Minimum lifting capacity of lifting gear: see operating weight in chapter "Technical Data".
  • Page 14 General – Safety regulations The ROPS must not rattle about when driving. This indicates that it is not properly fastened. All bolted connections must comply with the specifications and should be absolutely tight (observe the tight- ening torques). Screw and nuts must not be damaged, bent or deformed.
  • Page 15 General – Safety regulations Connect plus to plus and minus to minus (ground cable) – always connect the ground strap last and disconnect it first! A wrong con- nection will cause severe damage in the electric system. Do not start the engine by shorting the electric terminals on the starter motor, because the machine may start to drive immediately.
  • Page 16 General – Safety regulations In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected. Always keep a sufficient distance to excavation walls and embank- ments and do not use working methods that could impair the sta- bility of the machine.
  • Page 17 General – Safety regulations For rollers with a drum width of 1 m (3.3 ft) or less there is a con- siderable risk of tipping over near edges (e.g. curbstones, embank- ments, trenches, potholes) when driving over these edges. Behaviour in traffic Match the speed to the working conditions.
  • Page 18 General – Safety regulations Do not spill any fuel. Catch running out fuel, do not let it seep into the ground. Wipe off spilled fuel. Keep dirt and water away from the fuel. A leaking fuel tank can cause an explosion. Ensure tight fit of the fuel tank cover, if necessary replace immediately.
  • Page 19 General – Safety regulations the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks). the outer layer is brittle (formation of cracks in the hose mate- rial). the hose shows deformations in pressurized and depressurized condition, which do not comply with the genuine shape of the hydraulic hose.
  • Page 20 General – Safety regulations Ensure sufficient ventilation, especially if the battery is to be charged in a closed room. Dispose of old batteries according to regulations. Working on the fuel system Do not inhale any fuel fumes. Avoid open fire, do not smoke, do not spill any fuel. Catch running out fuel, do not let it seep into the ground and dis- pose off environmentally.
  • Page 21 General – Safety regulations Information and safety stickers/ Keep stickers/decals in good and legible condition (see spare parts decals on the machine catalogue) and comply with their meaning. Replace damaged and illegible stickers/decals. LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY Hydraulic Oil B-462-0007...
  • Page 22 General – Safety regulations LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY Hydraulic Oil B-462-0008 Fig. 3: Signage BW 90 SC-5 / BW 100 SC-5 BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5...
  • Page 23 General – Safety regulations LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY Hydraulic Oil B-462-0009 Fig. 4: Signage BW 90 AC-5 / BW 100 ACM-5 BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5...
  • Page 24 General – Safety regulations LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY Hydraulic Oil B-462-0010 Fig. 5: Signage BW 100 SCC-5 Warning sticker - Danger of tipping over B-DEC-0206 Fig. 6 BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5...
  • Page 25 General – Safety regulations Warning sticker - Follow operating instructions Fig. 7 Warning sticker - Danger of crushing Fig. 8 Prohibition sticker - High pressure cleaning Fig. 9 Instruction sticker - Always wear your seat belt Fig. 10 BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5...
  • Page 26 General – Safety regulations Information sticker - Lifting point Fig. 11 Information sticker - Lashing point Fig. 12 Information sticker - Filler opening for hydraulic oil Hydraulic Oil B-DEC-0214 Fig. 13 Information sticker - Engine oil drain B-DEC-0211 Fig. 14 BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5...
  • Page 27 General – Safety regulations Information sticker - Disconnecting the battery B-DEC-0219 Fig. 15 Information sticker - Emulsion Fig. 16 Information sticker - Foot switch for emulsion spraying system B-DEC-0235 Fig. 17 Operation sticker - Throttle lever B-DEC-0236 Fig. 18 BW 80/90 AD-5 / BW 100 ADM/ACM-5 / BW 90/100 SC-5 / BW 100 SCC-5...
  • Page 28 General – Safety regulations Information sticker - Foldable ROPS operation Nm 50-80 ft.lb. 37-60 8 kg ~ 80 Nm 17 kg ~ 50 Nm B-DEC-0007 Fig. 19 Warning sticker - Foldable ROPS B-DEC-0207 Fig. 20 Information sticker - Low sulphur fuel Fig.
  • Page 29 General – Maintenance and repair 1.3 Maintenance and repair 1.3.1 Notes on repair 1.3.1.1 General repair instructions NOTICE! Ensure strict cleanliness when performing repair work! – No foreign objects should enter into open sys- tems. – Thoroughly clean the area around the affected components.
  • Page 30 General – Maintenance and repair Always keep battery poles and terminal clams clean to avoid high transition resistances when starting and the related devel- opment of heat. Make sure the battery is properly fastened in the vehicle. Generator Before removing the generator you must disconnect the ground cable from the minus pole of the battery while the ignition is switched off.
  • Page 31 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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