Fayat Group BOMAG BW 191/206 AD-5 Service Manual
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Fayat Group BOMAG BW 191/206 AD-5 Service Manual

Tandem vibratory roller
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Service Manual
BW 191/206 AD-5 / BW 191/206 ADO-5
S/N 101 921 20 1001> / S/N 101 921 21 1001> / S/N 101 921 33 1001> / S/N 101 921 34 1001>
Tandem vibratory roller
008 401 00 EN
© 02/2018

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Summary of Contents for Fayat Group BOMAG BW 191/206 AD-5

  • Page 1 Service Manual BW 191/206 AD-5 / BW 191/206 ADO-5 S/N 101 921 20 1001> / S/N 101 921 21 1001> / S/N 101 921 33 1001> / S/N 101 921 34 1001> Tandem vibratory roller 008 401 00 EN © 02/2018...
  • 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.................... 25 1.2.6 Start-up procedure........................
  • Page 4 Table of contents 3.6 Terms and basis of calculation....................100 Overview of machine........................101 4.1 Electric systems........................105 4.2 Diesel engine..........................107 4.3 Hydraulic system........................110 4.3.1 Pump overview......................... 111 4.4 Water spraying system......................114 4.4.1 Tandem rollers.......................... 114 4.4.2 Pump overview......................... 114 4.5 Air conditioning.........................
  • Page 5 Table of contents 5.25 Deutsch plug, series DT and DTM..................210 5.26 Inspection and maintenance work..................214 5.26.1 Maintenance Table......................... 214 5.26.2 Every 500 operating hours..................... 214 5.26.3 As required..........................215 Diesel engine............................. 217 6.1 Overview of diesel engine......................218 6.2 Lubrication oil circuit TCD 4.1 / 6.1..................
  • Page 6 Table of contents 7.6 Vibration circuit......................... 343 7.7 Steering and crabwalk......................352 7.8 Steering and crabwalk using slidable swivel seat..............357 7.9 Edge cutter..........................362 7.10 Chip spreader.......................... 364 7.11 Tests and adjustments......................368 7.11.1 Pump overview........................368 7.11.2 Activate service mode......................370 7.11.3 Driving against the closed brake....................
  • Page 7 Table of contents 9.4 Compressor oil / refrigeration oil.................... 448 9.5 Working principle of the air conditioning system..............451 9.6 Monitoring devices........................452 9.7 Description of components...................... 453 9.8 Compressor..........................459 9.9 Emptying in case of repair....................... 461 9.10 Drying and evacuation......................462 9.11 Filling instructions........................
  • Page 8 Table of contents Troubleshooting..........................595 13.1 Preliminary remarks........................ 596 13.2 Emergency procedures......................597 13.2.1 Actuating the emergency stop switch..................597 13.2.2 Disconnecting the battery....................... 597 13.2.3 Towing the machine....................... 597 13.3 Troubleshooting, electrical systems..................601 13.3.1 Preliminary remarks....................... 601 13.3.2 Starting the engine with jump leads..................604 13.3.3 Checking the main battery shutoff..................
  • Page 9 Table of contents A.2 Hydraulic diagram 921 130 76..............882 A.3 Circuit diagram 366................... 884 BW 191/206 AD-5 / BW 191/206 ADO-5 Find manuals at https://best-manuals.com...
  • Page 10 Table of contents BW 191/206 AD-5 / BW 191/206 ADO-5 Find manuals at https://best-manuals.com...

  • Page 11: General

    General General BW 191/206 AD-5 / BW 191/206 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 AdBlue ® /DEF CAUTION! Health hazard caused by ammonia vapours! – Wear your personal protective equipment (pro- tective gloves, protective clothing). – Do not inhale ammonia vapours. –...
  • Page 22 General – Concerning your safety 1.2.4.5 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 1.2.4.6 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 General – Concerning your safety 1.2.4.7 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: Loading / Transporting The Machine

    General – Concerning your safety Safety regulations and environmental protection regulations when handling lubrication 1.2.4.8 grease CAUTION! Health hazard caused by contact with lubrica- tion grease! – Wear your personal protective equipment (pro- tective gloves, safety goggles, protective clothing). – Avoid contact.

  • Page 26: Start-Up Procedure

    General – Concerning your safety Secure the machine on the transport vehicle against rolling, slip- ping and turning over. Loads must only be attached and hoisted by an expert / qualified person. Use only lifting and lashing tackle with sufficient load bearing capacity for the weight to be loaded.

  • Page 27: Driving The Machine, Working Operation

    General – Concerning your safety Before starting and moving the machine, make sure that there is nobody in the danger zone. To start, set all control levers to “neutral position”. Do not use any starting aids like start pilot or ether. The machine must not be operated with damaged, missing or non- functional safety installations.
  • Page 28 General – Concerning your safety Keep the cabin doors closed. Do not adjust the driver’s seat while driving. Do not climb onto or off the machine while the machine is driving. Do not use the machine to transport persons. In case of unusual noises and development of smoke perform trouble shooting to determine the cause and have the fault cor- rected.

  • Page 29: Refuelling

    General – Concerning your safety 1.2.8 Refuelling Do not inhale any fuel fumes. Refuel only with the engine shut down. Do not refuel in closed rooms. No open fire, do not smoke. Static charges may be generated in the fuel as it passes through the filling system.

  • Page 30: Maintenance Work

    General – Concerning your safety In case of frequent use the wear on the multi-discs brakes will be very high, you should therefore never use the emergency stop switch as a service brake. 1.2.10.2 Disconnecting the battery In events of emergency, e.g. in case of a cable fire, disconnect the battery from the vehicle network.
  • Page 31 General – Concerning your safety Do not step in front of or behind the machine when performing adjustment work in the hydraulic system. Do not change the setting of pressure relief valves. Drain the hydraulic oil at operating temperature – danger of scalding! Any hydraulic oil must be collected and disposed of in an environ- mentally friendly way.
  • Page 32 General – Concerning your safety 1.2.11.4 Exhaust gas aftertreatment system, regeneration at standstill During regeneration at standstill the exhaust gas reaches very high temperatures and the exhaust gas quantity increases - fire hazard! When performing regeneration at standstill park the machine out- doors at a safe distance from any combustible or explosive mate- rials.

  • Page 33: Repair

    General – Concerning your safety When cleaning with a high pressure cleaner, do not subject elec- trical parts and insulation material to the direct jet of water, or cover them beforehand. Do not guide the water jet into the exhaust pipe and into the air filter.
  • Page 34 General – Concerning your safety ULTRA LOW SULFUR FUEL ONLY DIESEL WATER · AQUA B-921-0550 Fig. 8 BW 191/206 AD-5 / BW 191/206 ADO-5...
  • Page 35 General – Concerning your safety HYDRAULIK ® AdBlue /DEF 008 331 41 STOP 3 sec 30 min 5152 5153 SERVICE 5154 5155 5156 B-921-0558 Fig. 9 Warning sticker - Danger of crushing Fig. 10 BW 191/206 AD-5 / BW 191/206 ADO-5...
  • Page 36 General – Concerning your safety Warning sticker - Follow operating instructions Fig. 11 Warning sticker - Articulation lock (optional equipment) Fig. 12 Prohibition sticker - High pressure cleaning Fig. 13 Instruction sticker - Always wear your seat belt Fig. 14 BW 191/206 AD-5 / BW 191/206 ADO-5...
  • Page 37 General – Concerning your safety Information sticker - Lashing point Fig. 15 Information sticker - Lifting point Fig. 16 Information sticker - Diesel Fig. 17 Information sticker - Ultra-low sulphur fuel Fig. 18 BW 191/206 AD-5 / BW 191/206 ADO-5...

  • Page 38: Def

    General – Concerning your safety Information sticker - Water Fig. 19 Information sticker - Hydraulic oil Fig. 20 Information sticker - AdBlue ® /DEF Fig. 21 Information sticker - Minimum topping up quantity AdBlue ® /DEF Fig. 22 BW 191/206 AD-5 / BW 191/206 ADO-5...
  • Page 39 General – Concerning your safety Information sticker - Drain fluids (hydraulic oil, engine oil, coolant) Fig. 23 Information sticker - Main battery switch plus side Fig. 24 Information sticker - Push button assignment on travel lever Fig. 25 Information sticker - Regeneration of exhaust gas aftertreatment system Fig.
  • Page 40 General – Concerning your safety Information sticker - Guaranteed sound capacity level Fig. 27 Information sticker - Low ash engine oil Fig. 28 BW 191/206 AD-5 / BW 191/206 ADO-5...

  • Page 41: Maintenance And Repair

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This manual is also suitable for:

Bomag bw 191/206 ado-5101 921 20 1001101 921 21 1001101 921 33 1001101 921 34 1001

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