Bomag BW 100 ADM-2 Operating Instructions, Maintenance Instructions Download Page 58

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Maintenance

BOMAG

BW 80 AD-2 Fam.

5.3

Table of fuels and lubri-
cants

Assembly

Fuel or lubricant

Quantity approx.

Summer

Winter

Attention

Observe the level marks

Engine

Engine oil API: CD/SE or CD/SF SHPD CCMC-D4-

D5-PD1

3,9 l
up to max. dipstick mark

SAE 10W/40 (-20 °C to +30 °C)

SAE 15W/40

(-10°C to + 40°C)

SAE 30

SAE 10W

(+5 °C to +30 °C)

(-5 °C to -30 °C)

SAE 40

SAE 20W/20

(+25°C to +40°C)

(+10°C to -10°C)

Fuel

Diesel

Winter diesel fuel (down
to -12 °C)

23 litres

Cooling system

Coolant

Water + anti-freeze

1,9 l

Hydraulic system

Hydraulic oil (ISO), HV32, kinem. viscosity

32 mm

/s at 40 °C

up to middle of dipstick
approx. 9 litres (tank ca-
pacity)

or biodegradable hydraulic oil,

ester based

Sprinkler system

Water

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

Summary of Contents for BW 100 ADM-2

Page 1: ...e number 008 104 31 07 2003 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 S N 101 460 73 0101 Tand...

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Page 3: ...This manual was written for operators and mainte nance personnel on construction sites Make sure that these instructions are always close at hand e g in the tool compartment of the ma chine or in the...

Page 4: ...e type Fig 3 Engine No Fig 3 i Note 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 Pl...

Page 5: ...47 4 12 Switching the tire sprinkler system in or off 47 4 13 Stopping the engine machine 48 4 14 Adjusting the operator s seat 49 4 15 Towing 50 4 16 Loading and transport 51 Maintenance 53 5 1 Gene...

Page 6: ...nging the main fuel filter 77 5 25 Draining the fuel tank sludge 77 5 26 Checking the condition of the battery 78 5 27 Checking adjusting the valve clearance 80 5 28 Changing the hydraulic oil 82 5 29...

Page 7: ...BOMAG 7 BW 80 AD 2 Fam 1 Technical Data...

Page 8: ...W 100 ADM 2 1282 1056 458 580 1482 2300 250 1862 28 12 1000 BW 80 AD 2 BW 80 ADH 2 BW 90 AD 2 BW 100ADM 2 Weights Basic weight kg 1335 1485 1385 1435 Operating weight CECE kg 1470 1620 1520 1570 Mean...

Page 9: ...rake hydrostatic Parking brake hydrost mechanical Steering Type of steering Oscill articul Steering operation hydrostatic Steering oscillation angle Degree 31 6 Vibration system Vibrating drum front r...

Page 10: ...82 956 458 580 1562 2380 250 1870 28 12 900 BW 90 AC 2 Weights Basic weight kg 1530 Operating weight CECE kg 1670 Mean axle load CECE drum kg 701 Mean axle load CECE wheels kg 969 Mean static linear l...

Page 11: ...rostatic Driven axles front rear Brakes Service brake hydrostatic Parking brake hydrost mechanical Steering Type of steering Oscill articul Steering operation hydrostatic Steering oscillation angle De...

Page 12: ...13 900 BW 80 ADS Weights Basic weight kg 1467 Operating weight CECE kg 1564 Mean static linear load kg cm 10 2 Dimensions Working width mm 800 Outer track radius mm 2870 Length with ROPS mm 1870 Trav...

Page 13: ...c Parking brake hydrost mechanical Steering Type of steering Oscill articul Steering operation hydrostatic Steering oscillation angle Degree 31 6 Vibration system Vibrating drum front Drive system hyd...

Page 14: ...90 AD 2 LpA 83 8 dB A BW 100 ADM 2 LpA 82 3 dB A The nose emission value for the machine according to the noise emission regulation 2000 14 EG is guaranteed sound capacity level of the machine BW 80 A...

Page 15: ...BOMAG 15 BW 80 AD 2 Fam 2 Safety regulations...

Page 16: ...l You should only operate the unit with fully functional safety equipment l Have the machine inspected by an expert once every year Unintended use However dangers may arise from this machine if it is...

Page 17: ...ti disc brake secure the machine against unintended rolling Checking the roll over protection structure ROPS The frame of the machine must not be warped bent or cracked in the area of the ROPS fasteni...

Page 18: ...emergency stop switch immediately Do not use the emergen cy stop switch as a service brake Restart the machine only after the danger that has caused the actuation of the emergency stop has been elimin...

Page 19: ...ce Observe the maintenance tasks described in the operating and maintenance instructions including the exchange of parts Maintenance work must only be carried out by qualified and authorized personnel...

Page 20: ...isconnect the battery before starting to weld on the machine Working on the battery When working on the battery do not smoke no open flames Do not let your hands or clothes come in contact with acid I...

Page 21: ...k Reinstall all protective devices after completing the maintenance work Repair Mark a defective machine by attaching a warning tag to the steering wheel Repair work must only be performed by qualifie...

Page 22: ...Safety regulations BOMAG 22 BW 80 AD 2 Fam...

Page 23: ...BOMAG 23 BW 80 AD 2 Fam 3 Indicators and Controls...

Page 24: ...Indicators and Controls BOMAG 24 BW 80 AD 2 Fam Fig 7...

Page 25: ...Indicators and Controls BOMAG 25 BW 80 AD 2 Fam Fig 8...

Page 26: ...itch 11 Rotary switch for lighting acc to StVZO or working lights 12 Rotary switch for hazard light system 13 Rotary switch for direction indicators 14 Rotary switch for flashing beacon 15 Push button...

Page 27: ...he individual operating steps 3 2 Description of indicators and control elements Fig 9 No 1 Preheating control light lights up for approx 6 seconds with the ignition switch 6 in position II goes out a...

Page 28: ...e fault Fig 13 No 5 Emergency stop switch The engine will be shut down and the brake will close Danger Danger of accident Operate only in emergency situations during operation do not use as a service...

Page 29: ...sure start the engine turn the ignition key back to posi tion I once the engine has started Caution Run the engine warm for a short while before starting to work Do not let the engine run at idling sp...

Page 30: ...ed when actu ating the travel lever while the driver s seat is not occupied i Note Standard design lights when the machine is driv ing when the driver s seat is unoc cupied i Note Design with seat con...

Page 31: ...light up the control light in the switch flashes Fig 21 No 14 Rotary switch for flashing beacon Position left flashing beacon off Position right flashing beacon on Fig 22 No 15 Push button for warning...

Page 32: ...ystem only AC depress to switch the tire sprinkler sys tem on or off Fig 26 No 19 Push button for vibration depress to switch the vibration on or off Fig 27 No 20 Travel lever i Note Double travel lev...

Page 33: ...ever out of neutral Fig 28 No 21 Throttle lever Position 0 Idle speed position engine start Position I Full load position 2000 rpm operating position for driving and vibration 40 Hz Position II Full l...

Page 34: ...n up ward Vibration of rear drum only Position horizon tal 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 Fig...

Page 35: ...BOMAG 35 BW 80 AD 2 Fam 4 Operation...

Page 36: ...si ble Check l fuel tank and fuel lines for leaks l screw joints for tight fit l function of steering l machine for cleanliness damage l presence of the appropriate operating and maintenance instructi...

Page 37: ...res Fig 34 l Check whether the fuiel shut off lever Fig 34 is pointing vertically down 4 3 Starting the engine Caution In this chapter it is assumed that the operator is fully acquainted with the func...

Page 38: ...ht The parking closes automatically in 0 position and is released when shifting the travel lever out of neutral Fig 38 l Set the throttle lever Fig 38 to 0 position Fig 39 l Check whether the emergenc...

Page 39: ...l As soon as the engine ignites return the igni tion key to position I Caution Run the engine warm for a short while but do not run with idle speed for more than 10 min utes 4 4 Starting at low temper...

Page 40: ...nce the engine ignites turn the ignition switch back to position I l Once the engine runs properly reduce the en gine speed l If required the ignition key may be held in po sition II longer than 6 sec...

Page 41: ...ce the ground adhesion of the machine on inclina tions and slopes Soil conditions and weather influences impair the gradability of the machine Do not drive up and down inclinations exceed ing the maxi...

Page 42: ...eed only with the travel lever Fig 51 Fig 51 Caution When changing the travel direction hold the travel lever for a moment in 0 position until the machine has stopped before actuating to the new trave...

Page 43: ...tic drive automatically brakes the machine Fig 53 l Check whether the travel lever Fig 53 is locked to the right in braking position i Note The travel lever returns automatically to parking brake posi...

Page 44: ...he travel lever to the desired travel direction l Switch the vibration off before stopping the machine Pre selecting vibration only AD Fig 55 Caution Destruction of hydraulic components Switch over on...

Page 45: ...k it Fig 58 l Shift the travel lever Fig 58 slowly to the de sired travel direction max to position III Fig 59 l Actuate the vibration push button Fig 59 i Note When actuating the travel lever Fig 58...

Page 46: ...ling ON l Set the interval switch 7 to the desired flow interval Position A Permanent sprinkling Position B to F Interruption intervals of sprin kling of 4 8 16 24 and 32 sec onds always switched on f...

Page 47: ...g brake the water sprinkling system is automat ically switched off checking of sprinkling sys tem is not possible l Shift the travel lever to the left through brake position 0 and hold it in position...

Page 48: ...ke position i Note The travel lever returns automatically to parking brake position when releasing it in 0 position The pressure sprinkler system is automatically switched off Fig 66 i Note The parkin...

Page 49: ...ould be in the way with appropriate measures 4 14 Adjusting the operator s seat Danger Danger of accident Do not adjust the seat while driving Fig 69 l To adjust the seat in longitudinal direction pus...

Page 50: ...Switch the ball valve over Position I Brake released Position II Brake applied l Turn the steering wheel anti clockwise until the brake is released Towing the machine Fig 71 Caution Generally use the...

Page 51: ...t or lash down the machine Always check the fastening of the central lift ing hook before attempting to lift the machine Fig 73 l After driving the machine on the transport ve hicle swing the articula...

Page 52: ...Operation BOMAG 52 BW 80 AD 2 Fam Loading weight see technical data After the transport Fig 76 l After the transport release the articulation lock and fix it in its receptacle Fig 76...

Page 53: ...BOMAG 53 BW 80 AD 2 Fam 5 Maintenance...

Page 54: ...he sludge on the bottom of the drum l Do not draw off fuel from near the bottom of the fuel drum l Fuel left in the fuel drum is not suitable for the engine and should only be used for cleaning purpos...

Page 55: ...d starting it is import to chose the viscosity SAE class of the engine oil according to the ambient temperature Fig 77 Lubrication oil with a too high viscosity index caus es starting difficulties The...

Page 56: ...75 BS 2869 A1 and A2 ASTM D 975 78 1 D and 2 D Winter fuel For winter operation use only winter diesel fuel to avoid clogging because of paraffin separation At very low temperatures disturbing paraffi...

Page 57: ...en 6 5 and 8 5 As a protection against frost corrosion and boiling point anti freeze agents must be used under any climatic conditions The proportion of cooling system protection agent must be between...

Page 58: ...C 10 C to 10 C Fuel Diesel Winter diesel fuel down to 12 C 23 litres Cooling system Coolant Water anti freeze 1 9 l Hydraulic system Hydraulic oil ISO HV32 kinem viscosity 32 mm2 s at 40 C up to midd...

Page 59: ...engine for leaks l Tighten the fastening screws on air filter ex haust manifold and other attachments Caution Retighten the cylinder head fastening screws to the engine Maintenance after 200 operating...

Page 60: ...Every 50 operating hours 5 14 Grease the articulated joint High pressure grease 5 15 Check the tire pressure AC machines 5 16 Check clean dry air filter replace if necessary Every 250 operating hours...

Page 61: ...lter cartridge at least 1 x per year 5 33 Water sprinkler system maintenance in case of frost 5 34 Tightening torques for screws with metric unified thread 5 35 Engine conservation When using diesel f...

Page 62: ...g capaci ties l Check the oil level again after a running time of approx 1 minute with the engine shut down 5 7 Checking the fuel level Danger Fire hazard Do not inhale any fuel fumes When working on...

Page 63: ...nspection of the oil level the hy draulic oil level is found to have dropped check all lines hoses and components for leaks In hydraulic systems filled with Panolin HLP Synth 32 always use the same oi...

Page 64: ...os es and engine for leaks l 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 5 11 Checking the water level...

Page 65: ...emulsion must be in accordance with the instructions of the manufac turer Fig 84 l Check the emulsion level in the emulsion tank at the back of the machine top up if necessary Fig 84 5 13 Cleaning the...

Page 66: ...i cate with approx 5 strokes from the grease gun For quality of oil refer to the section about fu els lubricants and filling capacities 5 15 Checking the tire pressure i Note AC machines only Fig 87 l...

Page 67: ...does not make sense Use a new filter cartridge Incorrectly handled filter elements may be inef fective because of faults e g cracks and cause engine damage Always replace the filter cartridge if it is...

Page 68: ...gasoline or any hot fluids to clean the filter cartridge Fig 91 l Use a torch to examine the dry air filter Fig 91 from inside for any holes cracks grooves and damage l Replace a damaged dry air filte...

Page 69: ...ts Drain the engine oil only when the engine is warm Danger Danger of scalding When draining hot oil Environment Catch running out oil and dispose of environ mentally Fig 93 l Remove the lid from the...

Page 70: ...ewing the engine oil filter Environment Environmental hazard Catch running out oil and dispose of environ mentally together with the engine oil filter car tridge Fig 97 l Unscrew the filter cartridge...

Page 71: ...mb pressure to check whether the V belt can be depressed for more than 7 to 9 mm between the V belt pulleys if necessary reten sion Tensioning the V belt Fig 99 l Slacken the fastening screws 1 and 2...

Page 72: ...ion of the toothed belt for the pump drive Danger Danger of accident This work must only be performed with the en gine shut down Fig 101 l Remove the protection hood Fig 101 Fig 102 l Check the entire...

Page 73: ...aution Environmental hazard Catch running out fuel do not let it seep into the ground Fig 103 l Loosen the hose clamp Fig 103 l Pull the fuel filter out of the bottom and the top hoses l Install a new...

Page 74: ...k should only be carried out with the engine stopped and cooled down Caution Take care to avoid deformation of the radiator cooling fins i Note Dirt on blower wings and oil cooler reduces the cooling...

Page 75: ...ow the hydraulic oil cooler Fig 109 out from the air intake side Cleaning with cold cleansing agent Caution Protect electrical equipment such as genera tor regulator and starter against the direct wa...

Page 76: ...ly l Screw the water filter back in tighten the spig ot nut and close the flap Fig 111 l Pull the caps 3 Fig 111 off both sprinkler tubes l Loosen the hose clamps 2 and pull the hoses of the sprinkler...

Page 77: ...l Insert the new filter element l Screw the filter bowl back on and bleed the fuel system refer to the section changing the fuel precleaner l Check the fuel lines for wear and damage re place if nece...

Page 78: ...n maintenance free batteries l Clean battery and battery compartment Caution Top up missing fluid with distilled water l Unscrew the plugs and check the acid level if necessary top up with distilled w...

Page 79: ...Every 500 operating hours BOMAG 79 BW 80 AD 2 Fam...

Page 80: ...e protection hood Fig 118 Fig 119 l Align the mark 1TC 2 Fig 119 on the fly wheel to the mark 1 on the housing i Note the piston of cylinder 1 is in top dead center The 1TC mark is only valid for cyli...

Page 81: ...valve 0 145 0 185 mm l If the gap is too narrow or too wide for the feel er gauge the valve clearance must be adjust ed i Note Mark checked and adjusted valves with chalk Fig 122 l Turn the flywheel...

Page 82: ...e the hydraulic oil filter with every hydraulic oil change see next chapter See also section 5 1 Notes on the Hydraulic Sys tem l Drive the machine until the hydraulic oil has reached operating temper...

Page 83: ...ontamination indicator on the filter shows red while the engine is running and the machine has operating temperature change the filter element When the oil filter element is clean the hydraulic oil fi...

Page 84: ...f the seal ring 5 30 Changing the coolant Danger Danger of scalding Change the coolant only when the engine is cold Environment Catch running out coolant and dispose of envi ronmentally Fig 126 l Remo...

Page 85: ...iator cap and cap of the compen sation tank l Start the diesel engine and run it warm to op erating temperature l Let the engine cool down and check the cool ant level again top up if necessary 5 31 R...

Page 86: ...the woodruff key i Note When reassembling hold the new toothed belt and the toothed belt pulley always as close as possible to the pump carrier Fig 133 l Insert the woodruff key into the groove Fig 1...

Page 87: ...e latest after 1 year Fig 134 l Unscrew the wing screw and pull the air filter cartridge Fig 134 out of the air filter housing Fig 135 l Clean out the air filter housing with a cloth Fig 135 Caution D...

Page 88: ...til the anti freeze mixture starts to run out from the sprinkler tubes 5 34 Tightening torques for screws with metric unified thread Fig 137 Strength classes for screws with untreated non lubricated s...

Page 89: ...team cleaning equip ment l Run the engine warm and shut it down l Drain the still warm engine oil and fill in anti corrosion engine oil l Drain the fuel from the fuel tank mix it well with 10 anti cor...

Page 90: ...As required BOMAG 90 BW 80 AD 2 Fam...

Page 91: ...BOMAG 91 BW 80 AD 2 Fam 6 Trouble shooting...

Page 92: ...hine or insufficient mainte nance Whenever a fault occurs you should there fore thoroughly read these instruction on correct operation and maintenance If you cannot locate the cause of a fault or rect...

Page 93: ...hten them and cover them with acid free grease Especially during winter the use of too viscous engine oil Use engine oil suitable for the ambient temperature Insufficient fuel supply clogging of the f...

Page 94: ...air blow er Clean the cooling air duct V belt loose or broken Tension or replace the V belt Air filter cartridge dirty Clean change if necessary Engine oil pres sure too low shut down im mediately Le...

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