Fayat Group BOMAG BW 190/202 AD-5 Service Manual
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Fayat Group BOMAG BW 190/202 AD-5 Service Manual

Tandem vibratory roller
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Service Manual
BW 190/202 AD-5 / BW 190/202 ADO-5
S/N 101 921 12 1001> / S/N 101 921 42 1001> / S/N 101 921 11 1001> / S/N 101 921 41 1001> /
S/N 101 921 31 1001> / S/N 101 921 49 1001> / S/N 101 921 32 1001> / S/N 101 921 48 1001>
Tandem vibratory roller
008 925 92
© 02/2018

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Summary of Contents for Fayat Group BOMAG BW 190/202 AD-5

  • Page 1 Service Manual BW 190/202 AD-5 / BW 190/202 ADO-5 S/N 101 921 12 1001> / S/N 101 921 42 1001> / S/N 101 921 11 1001> / S/N 101 921 41 1001> / S/N 101 921 31 1001> / S/N 101 921 49 1001> / S/N 101 921 32 1001> / S/N 101 921 48 1001> Tandem vibratory roller 008 925 92 ©...
  • Page 2 Find manuals at https://best-manuals.com...

  • Page 3: Table Of Contents

    Table of contents Table of contents General..............................11 1.1 Introduction..........................12 1.2 Concerning your safety......................14 1.2.1 General prerequisites......................... 14 1.2.2 Definition of responsible persons....................16 1.2.3 Fundamentals for safe operation....................17 1.2.4 Handling fuels and lubricants..................... 19 1.2.5 Loading / transporting the machine.................... 24 1.2.6 Start-up procedure........................
  • Page 4 Table of contents 3.6 Terms and basis of calculation....................88 Overview of machine.......................... 89 4.1 Electric systems.......................... 93 4.2 Diesel engine..........................95 4.3 Hydraulic system........................97 4.3.1 Pump overview........................... 98 4.4 Water spraying system......................101 4.4.1 Tandem rollers.......................... 101 4.4.2 Pump overview......................... 101 4.5 Air conditioning.........................
  • Page 5 Table of contents 5.27 Inspection and maintenance work..................195 5.27.1 Maintenance Table......................... 195 5.27.2 Every 500 operating hours..................... 195 5.27.3 As required..........................196 Diesel engine............................. 199 6.1 Overview of diesel engine......................200 6.2 Features............................. 202 6.3 Cooling system......................... 203 6.3.1 Removing and installing the thermostat................... 204 6.4 Intake air heating........................
  • Page 6 Table of contents 7.7 Steering and crabwalk......................306 7.8 Steering and crabwalk using slidable swivel seat..............311 7.9 Edge cutter..........................316 7.10 Chip spreader.......................... 318 7.11 Tests and adjustments......................322 7.11.1 Pump overview........................322 7.11.2 Activate service mode......................324 7.11.3 Driving against the closed brake.................... 325 7.11.4 Pressure tests in the travel circuit..................
  • Page 7 Table of contents 9.5 Working principle of the air conditioning system..............403 9.6 Monitoring devices........................404 9.7 Description of components...................... 405 9.8 Compressor..........................411 9.9 Emptying in case of repair....................... 413 9.10 Drying and evacuation......................414 9.11 Filling instructions........................415 9.12 Steam table for R134a......................
  • Page 8 Table of contents 12.3 Final function tests and checks..................... 555 Troubleshooting..........................557 13.1 Preliminary remarks........................ 558 13.2 Emergency procedures......................559 13.2.1 Actuating the emergency stop switch..................559 13.2.2 Disconnecting the battery....................... 559 13.2.3 Towing the machine....................... 559 13.3 Troubleshooting, electrical systems..................564 13.3.1 Preliminary remarks.......................
  • Page 9 Table of contents A.2 Hydraulic diagram 921 125 81c..............778 A.3 Circuit diagram 366................... 780 BW 190/202 AD-5 / BW 190/202 ADO-5 Find manuals at https://best-manuals.com...
  • Page 10 Table of contents BW 190/202 AD-5 / BW 190/202 ADO-5 Find manuals at https://best-manuals.com...

  • Page 11: General

    General General BW 190/202 AD-5 / BW 190/202 ADO-5...

  • Page 12: Introduction

    General – Introduction 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. This manual described the deinstallation, dismantling , assembly, installation as well as the repair of components and assembly groups as far as this makes sense with respect to tools and spare parts supply.
  • Page 13 General – Introduction Updating service This manual is not subject of an updating service. For this reason we would like to draw your attention to the additionally published service informations. In case of a new release all necessary changes will be included. In the course of technical development we reserve the right for technical modifications without prior notification.

  • Page 14: Concerning Your Safety

    General – Concerning your safety 1.2 Concerning your safety 1.2.1 General prerequisites 1.2.1.1 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,...
  • Page 15 General – Concerning your safety CAUTION! Danger of injury if failing to comply! Sections marked accordingly indicate a dangerous situation that could lead to fatal or severe injuries, if this warning is disregarded. NOTICE! Danger of material damage if failing to comply! Sections marked accordingly indicate possible dangers for machines or components.

  • Page 16: Definition Of Responsible Persons

    General – Concerning your safety Safety goggles To protect the eyes against airborne particles and squirting fluids. Face protection To protect the face against airborne particles and squirting fluids. Hard hat To protect the head against falling parts and to protect against injuries.

  • Page 17: Fundamentals For Safe Operation

    General – Concerning your safety The operating company must make sure that all users read and understand the information concerning safety. The operating company is responsible for the planning and profes- sional execution of regular safety inspections. 1.2.2.2 Expert / qualified person An expert / qualified person is a person who, based on his/her pro- fessional education and experience, has profound knowledge in the field of construction equipment and the machine in question in...
  • Page 18 General – Concerning your safety Both the machine as well as all other system components comply with the currently valid safety regulations. Nevertheless, remaining risks cannot be ruled out completely, even when using the machine for the purpose it is intended for and following all information given in the operating instructions.

  • Page 19: Handling Fuels And Lubricants

    General – Concerning your safety The ROPS must not show any rust, damage, hairline cracks or open fractures. The real machine weight must never exceed the testing weight for the ROPS. No accessories may be welded or bolted on and no additional holes must be drilled without the consent of the manufacturer, since this will impair the strength of the unit.
  • Page 20 General – Concerning your safety 1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuel WARNING! Danger of burning by ignited diesel fuel! – Do not allow diesel fuel to come into contact with hot components. – Smoking and open fire is prohibited! –...
  • Page 21 General – Concerning your safety 1.2.4.3 Safety regulations and environmental protection regulations for handling oil WARNING! Danger of burning by ignited oil! – Do not allow oil to come into contact with hot components. – Smoking and open fire is prohibited! –...
  • Page 22 General – Concerning your safety 1.2.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil WARNING! Danger of injury caused by escaping pressure fluid! – Always depressurize the hydraulic system before starting work in the hydraulic system. – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles).
  • Page 23 General – Concerning your safety 1.2.4.5 Safety regulations and environmental protection regulations for handling coolants WARNING! Danger of scalding by hot fluid! – Open the compensation tank only when the engine is cold. – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles).

  • Page 24: Loading / Transporting The Machine

    General – Concerning your safety 1.2.4.6 Safety regulations and environmental protection regulations for handling battery acid WARNING! Danger of cauterization with acid! – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles). – Do not allow clothes, skin or eyes to come into contact with acid.

  • Page 25: Start-Up Procedure

    General – Concerning your safety Make sure that persons are not endangered by the machine tipping or sliding off. The instructing person must stand within the view of the operator, but outside the danger area. Do not drive onto the transport vehicle with crabwalk. Secure the machine with the articulation lock after driving it onto the transport vehicle or before loading it with a crane.

  • Page 26: Driving The Machine, Working Operation

    General – Concerning your safety Before start up, carry out all required visual inspections and func- tion tests. If the following tests reveal damages or other faults, the machine must not be operated, until these deficiencies have been corrected. Do not operate the machine with defective indicators and control elements.
  • Page 27 General – Concerning your safety 1.2.7.2 Driving the machine Always wear the seat belt when driving. Do not drive on bases with insufficient load bearing capacity. Do not drive on ice and snow. If the machine has touched high-voltage power lines: do not leave the driver’s stand, warn others from coming close to or touching the machine, if possible, drive the machine out of the danger zone,...

  • Page 28: Refuelling

    General – Concerning your safety Before leaving the machine: shift all control levers to “Neutral position”, “Off” or “0”, apply the parking brake, shut down the engine, pull off the ignition key, pull off the main battery switch, secure the machine against unauthorized use. Do not jump off the machine, but use hand grips and access steps.

  • Page 29: Emergency Procedures

    General – Concerning your safety When performing regeneration at standstill, park the machine out- doors at a safe distance from any combustible or explosive mate- rials. 1.2.10 Emergency procedures 1.2.10.1 Actuating the emergency stop switch In events of emergency and in case of danger actuate the emer- gency stop switch immediately.
  • Page 30 General – Concerning your safety Keep unauthorized persons away from the machine. Perform maintenance work only with the engine shut down. Make sure that the engine cannot be accidentally started during maintenance work. 1.2.11.2 Work on hydraulic lines Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury.
  • Page 31 General – Concerning your safety Engine and exhaust system work at high temperatures. Keep com- bustible materials away and do not touch any hot surfaces. Check and change coolant only when the engine is cold. Collect coolant and dispose of it in an environmentally friendly way. 1.2.11.4 Maintenance work on electric components and battery Before starting to work on electric parts of the machine disconnect...

  • Page 32: Repair

    General – Concerning your safety 1.2.11.7 After maintenance work Reassemble all guards and protective devices. Close all maintenance flaps and maintenance doors again. 1.2.12 Repair Identify a defective machine with a warning sign. Only operate the machine after it has been repaired. Repairs must only be performed by an expert/qualified person.
  • Page 33 General – Concerning your safety Warning sticker - Articulation lock (optional equipment) Fig. 8 Prohibition sticker - High pressure cleaning Fig. 9 Instruction sticker - Always wear your seat belt Fig. 10 Information sticker - Lashing point Fig. 11 BW 190/202 AD-5 / BW 190/202 ADO-5...
  • Page 34 General – Concerning your safety Information sticker - Lifting point Fig. 12 Information sticker - Diesel Fig. 13 Information sticker - Ultra-low sulphur fuel Fig. 14 Information sticker - Water Fig. 15 BW 190/202 AD-5 / BW 190/202 ADO-5...
  • Page 35 General – Concerning your safety Information sticker - Hydraulic oil Fig. 16 Information sticker - Drain fluids (hydraulic oil, engine oil, coolant) Fig. 17 Information sticker - Main battery switch plus side Fig. 18 Information sticker - Push button assignment on travel lever Fig.
  • Page 36 General – Concerning your safety Information sticker - Regeneration of exhaust gas aftertreatment system Fig. 20 Information sticker - Guaranteed sound capacity level Fig. 21 Information sticker - Low ash engine oil Fig. 22 BW 190/202 AD-5 / BW 190/202 ADO-5...

  • Page 37: Maintenance And Repair

    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 38 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 39: Hydraulic Oil

    General – Maintenance and repair 1.3.1.1.2 Repair notes for hydraulics Please note Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system. Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal. Before loosening hoses, pipe lines etc.
  • Page 40 General – Maintenance and repair Taking into operation Bleed the hydraulic circuits. Start up the hydraulic system without load. Check the hydraulic oil level in the tank, if necessary top up with hydraulic oil as specified in the operating and maintenance instructions or drain oil off into a suitable container.
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Bomag bw 190/202 ado-5101 921 12 1001101 921 42 1001101 921 11 1001101 921 41 1001101 921 31 1001 ... Show all

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