Bomag BW 80 AD-5 to BW 100 SCC-5 Tandem Vibratory Roller Service Manual 00892560

Description

• Model List:
  • BW 80 AD-5 Tandem Vibratory Roller
  • BW 90 AD-5 Tandem Vibratory Roller
  • BW 100 ADM-5 Tandem Vibratory Roller
  • BW 100 ACM-5 Tandem Vibratory Roller
  • BW 90 SC-5 Tandem Vibratory Roller
  • BW 100 SC-5 Tandem Vibratory Roller
  • BW 100 SCC-5 Tandem Vibratory Roller

• 1. Table of contents
• 2. General
• 2.1. Introduction
• 2.2. Safety regulations
• 2.3. Maintenance and repair
• 2.3.1. Notes on repair
• 2.3.1.1. General repair instructions
• 2.3.1.2. Tightening torques
• 2.3.2. General notes on maintenance
• 3. Technical data
• 3.1. BW 80 AD5
• 3.1.1. Noise and vibration data
• 3.1.1.1. Noise data
• 3.1.1.2. Vibration data
• 3.2. BW 90 AD5
• 3.2.1. Noise and vibration data
• 3.2.1.1. Noise data
• 3.2.1.2. Vibration data
• 3.3. BW 90 AC5
• 3.3.1. Noise and vibration data
• 3.3.1.1. Noise data
• 3.3.1.2. Vibration data
• 3.4. BW 100 ADM5
• 3.4.1. Noise and vibration data
• 3.4.1.1. Noise data
• 3.4.1.2. Vibration data
• 3.5. BW 90 SC5
• 3.5.1. Noise and vibration data
• 3.5.1.1. Noise data
• 3.5.1.2. Vibration data
• 3.6. BW 100 SC5
• 3.6.1. Noise and vibration data
• 3.6.1.1. Noise data
• 3.6.1.2. Vibration data
• 3.7. BW 100 ACM5
• 3.7.1. Noise and vibration data
• 3.7.1.1. Noise data
• 3.7.1.2. Vibration data
• 3.8. BW 100 SCC5
• 3.8.1. Noise and vibration data
• 3.8.1.1. Noise data
• 3.8.1.2. Vibration data
• 3.9. Additional technical data
• 3.10. Terms and basis of calculation
• 3.11. Fuels and lubricants
• 3.11.1. Engine oil
• 3.11.1.1. Oil quality
• 3.11.1.2. Oil viscosity
• 3.11.1.3. Oil change intervals
• 3.11.2. Fuel
• 3.11.2.1. Fuel quality
• 3.11.2.2. Winter fuel
• 3.11.2.3. Storage
• 3.11.3. Coolant
• 3.11.4. Hydraulic oil
• 3.11.4.1. Mineral oil based hydraulic oil
• 3.11.4.2. Biodegradable hydraulic oil
• 3.12. List of fuels and lubricants
• 4. Overview of machine
• 4.1. General information
• 4.2. Overviews
• 4.3. Electric systems
• 4.4. Hydraulic system
• 4.5. Machine assemblies
• 4.5.1. Diesel engine
• 4.5.2. Oscillating articulated joint
• 4.5.3. Drum
• 5. Electric systems
• 5.1. Basic principles
• 5.1.1. Measuring method
• 5.1.2. Understanding circuit diagrams
• 5.1.2.1. Circuit diagrams
• 5.1.2.2. Circuit symbols in EPlan
• 5.1.2.3. Identification of switch blocks
• 5.1.3. Telemecanique switch
• 5.1.4. Deutsch plug, series DT and DTM
• 5.1.5. Magnetic coil plug
• 5.2. Overview of electric system
• 5.2.1. Drivers stand, old version
• 5.2.1.1. Control elements
• 5.2.2. Drivers stand, new version
• 5.2.2.1. Control elements
• 5.2.3. Wiring
• 5.2.4. CAN BUS overview
• 5.2.5. Table of fuels and lubricants
• 5.3. Starting with jump wires
• 5.4. Central electrics
• 5.5. Fuse assignment
• 5.5.1. Central electrics
• 5.5.2. Main battery fuse
• 5.6. Description of electrical components
• 5.6.1. Angle sensor on travel lever, B39
• 5.6.2. Inductive proximity switch, B63
• 5.6.3. Switching the vibration on, old version
• 5.6.4. Switching the vibration on, new version
• 5.6.5. Switching the pressurized spraying system on, old version
• 5.6.6. Switching the pressurized spraying system on, new version
• 5.6.7. Sensor, water in fuel filter, B124
• 5.6.8. Engine oil pressure monitoring
• 5.6.9. Coolant temperature monitoring
• 5.6.10. Level sensor in diesel tank, R03
• 5.6.11. Charge control light and operating hour meter
• 5.6.12. Glow plugs, R81, R82 R83
• 5.6.13. Engine solenoid, Y13
• 5.6.14. Instrument cluster, old version
• 5.6.15. Instrument cluster, new version
• 5.6.16. Seat contact control
• 5.7. Repairs
• 5.7.1. Generator repair
• 5.7.2. Repair of starter
• 5.8. Inspection and maintenance work
• 5.8.1. Maintenance Table
• 5.8.2. Every 250 operating hours
• 5.8.2.1. Battery service
• 5.8.3. As required
• 5.8.3.1. Battery service during prolonged machine downtimes
• 6. Hydraulic system
• 6.1. Basic principles
• 6.1.1. Open and closed hydraulic circuit
• 6.1.2. Swash plate principle, pump
• 6.1.3. External gear pumps
• 6.1.4. Reversible external gear motor
• 6.2. Overview of hydraulics
• 6.2.1. Pump overview
• 6.3. Description of hydraulic components
• 6.3.1. Travel pump, A10VG18 HW
• 6.3.1.1. Variable displacement pumps, A10VG18 HW A10VG28 HW
• 6.3.2. Drum drive motor MK 04
• 6.3.2.1. Radial piston motor
• 6.3.3. Wheel drive motor, MS/MSE
• 6.3.3.1. Radial piston motor with multidisc brake
• 6.3.4. Steering valve
• 6.4. Description of hydraulic circuits
• 6.4.1. Travel circuit
• 6.4.2. Vibration circuit
• 6.4.3. Steering circuit
• 6.4.4. Edge cutter
• 6.4.5. Hydraulic cutting tool
• 6.5. Tests and adjustments
• 6.5.1. Pump overview
• 6.5.2. Checking the rotation speeds
• 6.5.3. Pressure tests in the travel circuit
• 6.5.4. Checking / adjusting the neutral positions of the travel pump
• 6.5.5. Pressure test in the vibration circuit
• 6.5.6. Checking the leakage rate of the vibration motor
• 6.6. Flushing and bleeding
• 6.6.1. Flushing general
• 6.6.2. Flushing schematic for travel system, AD/SCmachine
• 6.6.3. Travel system, flushing AD/SCmachine
• 6.6.4. Flushing schematic for travel system, ACmachine
• 6.6.5. Travel system, flushing ACmachine
• 6.6.6. Bleeding the travel circuit
• 6.7. Inspection and maintenance work
• 6.7.1. Maintenance Table
• 6.7.2. Checks prior to start up
• 6.7.2.1. Checking the hydraulic oil level
• 6.7.2.2. Checking the hydraulic oil filter element
• 6.7.3. Every 500 operating hours
• 6.7.3.1. Checking the hydraulic lines
• 6.7.4. Every 2000 operating hours
• 6.7.4.1. Changing hydraulic oil and breather filter
• 6.7.4.2. Replacing the hydraulic oil filter
• 7. Machine assemblies
• 7.1. Diesel engine
• 7.1.1. Overview of diesel engine
• 7.1.2. Kubota diesel engine
• 7.1.3. Check the injection valves
• 7.1.4. Checking the fuel injection pump
• 7.1.5. Inspection and maintenance work
• 7.1.5.1. Maintenance Table
• 7.1.5.2. Checks prior to start up
• 7.1.5.3. Every 50 operating hours
• 7.1.5.4. Every 250 operating hours
• 7.1.5.5. Every 500 operating hours
• 7.1.5.6. Every 1000 operating hours
• 7.1.5.7. Every 2000 operating hours
• 7.1.5.8. Every 3000 operating hours
• 7.1.5.9. As required
• 7.2. Oscillating articulated joint
• 7.2.1. Overview oscillating articulated joint
• 7.2.2. Removing and installing the oscillating articulated joint
• 7.2.3. Repairing the oscillating articulated joint
• 7.3. Drum
• 7.3.1. Overview drum
• 7.3.2. Removing and installing the ADdrum
• 7.3.3. Dismantling the ADdrum
• 7.3.4. Assembling the ADdrum
• 8. Troubleshooting
• 8.1. Preliminary remarks
• 8.2. Emergency procedures
• 8.2.1. Actuating the emergency stop switch
• 8.2.2. Disconnecting the battery
• 8.2.3. Towing the machine
• 8.3. Towing tandem vibratory roller
• 8.4. Towing combination roller
• 8.5. Troubleshooting, electrical systems
• 8.5.1. Preliminary remarks
• 8.5.2. Starting with jump wires
• 8.5.3. Fuse assignment
• 8.5.3.1. Central electrics
• 8.5.3.2. Main battery fuse
• 8.5.4. Trouble shooting Starter
• 8.5.5. Fault detection via instrument cluster, A15
• 8.5.6. Trouble shooting ECONOMIZER
• 8.5.7. The machine does not drive
• 8.5.8. Seat contact control
• 8.5.9. Check the parking brake
• 8.6. Trouble shooting, hydraulics
• 8.6.1. Insufficient hydraulic power
• 8.6.2. Troubleshooting axial piston pumps
• 8.6.3. The machine does not drive
• 8.6.4. Insufficient travel power
• 8.6.5. Check the parking brake
• 8.7. Trouble shooting, diesel engine
• 8.7.1. Engine problems
• 9. Special tools
• 9.1. Special tools, hydraulic system
• 9.1.1. Special tools, tests and adjustments
• 9.1.2. Special tools for flushing
• 9.2. Special tools, electrics
• 10. Index
• 11. Appendix
• 11.1. A Circuit diagrams
• 11.1.1. Circuit diagram 368
• 11.1.2. Hydraulic diagram 289