Fayat BOMAG BW 191 AD-5 AM Service Manual
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Fayat BOMAG BW 191 AD-5 AM Service Manual

Tandem vibratory roller
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Service Manual
BW 191 AD-5 AM / BW 206 AD-5 AM
S/N 101 921 23 1001> / S/N 101 921 24 1001>
Tandem vibratory roller
008 401 18 EN
© 02/2018

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Summary of Contents for Fayat BOMAG BW 191 AD-5 AM

  • Page 1 Service Manual BW 191 AD-5 AM / BW 206 AD-5 AM S/N 101 921 23 1001> / S/N 101 921 24 1001> Tandem vibratory roller 008 401 18 EN © 02/2018...
  • Page 2 Find manuals at https://best-manuals.com...

  • Page 3: Table Of Contents

    Table of contents Table of contents General..............................9 1.1 Introduction..........................10 1.2 Concerning your safety......................12 1.2.1 Basic prerequisites........................12 1.2.2 Definition of responsible persons....................15 1.2.3 Fundamentals for safe operation....................16 1.2.4 Handling fuels and lubricants..................... 18 1.2.5 Loading / transporting the machine.................... 24 1.2.6 Start-up procedure........................
  • Page 4 Table of contents 3.4.3 AD drum........................... 103 3.4.4 AM drum........................... 104 3.4.5 Water system........................... 105 3.4.6 Air conditioning......................... 107 Electric systems..........................109 4.1 Basic principles......................... 111 4.1.1 Measuring method........................111 4.1.2 Understanding electric circuit diagrams................... 115 4.1.3 Telemecanique switch......................128 4.1.4 Deutsch plug, series DT and DTM...................
  • Page 5 Table of contents 5.1.1 Open and closed hydraulic circuit.................... 345 5.1.2 Swash plate principle, pump....................347 5.1.3 Swash plate principle, motor....................348 5.1.4 External gear pumps........................ 349 5.1.5 Outer gear motors non-reversible.................... 352 5.2 Overview of hydraulics......................353 5.2.1 Pump overview......................... 355 5.3 Description of hydraulic components..................
  • Page 6 Table of contents 5.7.3 Every 500 operating hours....................... 462 5.7.4 Every 1000 operating hours..................... 462 5.7.5 Every 2000 operating hours..................... 464 Machine assemblies......................... 467 6.1 Diesel engine..........................469 6.1.1 Overview of diesel engine......................469 6.1.2 Lubrication oil circuit TCD 4.1 / 6.1..................476 6.1.3 Coolant circuit TCD 4.1 / 6.1....................
  • Page 7 Table of contents 6.7 Edge cutter..........................641 6.7.1 Changing the pressure roller....................641 6.7.2 Operating the edge cutter......................642 6.8 Cabin assembly......................... 643 6.8.1 Safety............................643 6.8.2 Preparations..........................644 6.8.3 Cabin assembly........................645 6.8.4 Programming the cabin electrics....................655 6.8.5 Final function tests and checks....................656 Troubleshooting..........................
  • Page 8 Table of contents A Circuit diagrams.................... 815 A.1 Circuit diagram 485................... 815 A.2 Hydraulic diagram 921 130 77..............909 A.3 Water spraying diagram 921 133 28............911 BW 191 AD-5 AM / BW 206 AD-5 AM Find manuals at https://best-manuals.com...

  • Page 9: General

    General General BW 191 AD-5 AM / BW 206 AD-5 AM Find manuals at https://best-manuals.com...

  • Page 10: Introduction

    General – Introduction 1.1 Introduction............... 10 1.2 Concerning your safety..........12 1.2.1 Basic prerequisites..........12 1.2.2 Definition of responsible persons......15 1.2.3 Fundamentals for safe operation......16 1.2.4 Handling fuels and lubricants........18 1.2.5 Loading / transporting the machine......24 1.2.6 Start-up procedure...........
  • Page 11 General – Introduction Documentation For the BOMAG machines described in this manual the following documentation is additionally available: Operating and maintenance instructions Spare parts catalogue Service information (if necessary) Maintenance/parts service Specialist teams are available for you in Germany, Europe and overseas.

  • Page 12: Concerning Your Safety

    General – Concerning your safety 1.2 Concerning your safety 1.2.1 Basic 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 13 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 14 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 15: Definition Of Responsible Persons

    General – Concerning your safety Examples for improper use are: work with vibration on hard concrete, cured bitumen layers or extremely frozen ground cleaning the drums while driving or changing nozzles during travel driving on subsoils with too low load bearing capacity driving on slippery subsoils (e.g.

  • Page 16: Fundamentals For Safe Operation

    General – Concerning your safety This person is acquainted with the applicable governmental indus- trial safety regulations, accident prevention instructions, guidelines and generally acknowledged technical rules and regulations (standards, directives, technical rules of other member states of the European Union or other contractual states concerning the agreement about the European Economic Area) in as far as is nec- essary to be able to judge the safe condition of this machine.
  • Page 17 General – Concerning your safety 1.2.3.2 Regular safety inspections Have the machine inspected by an expert / qualified person as required for the conditions the machine is working under, but at least once every year. 1.2.3.3 Modifications and alterations to the machine Unauthorized changes to the machine are prohibited for safety rea- sons.

  • Page 18: Handling Fuels And Lubricants

    General – Concerning your safety 1.2.4 Handling fuels and lubricants 1.2.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the individual fuels and lubricants. Safety data sheets provide valuable information about the following characteristics: name of substance possible dangers...
  • Page 19 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 20 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 21 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 22 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 23 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 24: 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 25: 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 26: 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 27 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 28: Refuelling

    General – Concerning your safety 1.2.7.5 Working with vibration When compacting with vibration you must always check the effect of the vibration on nearby buildings and underground supply lines (gas, water, sewage, electric power). If necessary stop compacting with vibration. Do not activate the vibration on hard (frozen, concrete) ground.

  • Page 29: Topping Up Adblue ® /Def

    General – Concerning your safety 1.2.9 Topping up AdBlue ® /DEF If AdBlue ® /DEF heats up to a temperature in excess of 50 °C (122 °F) over a longer period of time, e.g. caused by direct insola- tion, AdBlue ®...

  • Page 30: Maintenance Work

    General – Concerning your safety 1.2.11 Maintenance work 1.2.11.1 Preliminary remarks Adhere to the specified operating, maintenance and repair meas- ures. The machine must only be serviced by qualified personnel author- ised by the operating company. Keep unauthorised persons away from the machine. Perform maintenance work only with the engine shut down.
  • Page 31 General – Concerning your safety Store used filters and other oil contaminated materials in a sepa- rate, specially marked container and dispose of them in an environ- mentally friendly way. The settings for idle speed and highest speed must not be changed, since this would affect the exhaust gas values and cause damage to engine and power train.

  • Page 32: Repair

    General – Concerning your safety Do not release refrigerant into the atmosphere, but dispose of it in line with environmental regulations. 1.2.11.7 Cleaning work Do not perform cleaning work while the motor is running. Allow the engine to cool down before starting cleaning work on engine and exhaust system.
  • Page 33 General – Concerning your safety ULTRA LOW SULFUR FUEL ONLY Diesel Water B-921-0575 Fig. 9 BW 191 AD-5 AM / BW 206 AD-5 AM...
  • Page 34 General – Concerning your safety Hydraulic Oil ® AdBlue /DEF 008 331 41 STOP 3 sec 30 min 5152 5153 SERVICE 5154 5155 5156 B-921-0576 Fig. 10 Warning sticker - Danger of crushing Fig. 11 BW 191 AD-5 AM / BW 206 AD-5 AM...
  • Page 35 General – Concerning your safety Warning sticker - Follow operating instructions Fig. 12 Warning sticker - Articulation lock (optional equipment) Fig. 13 Prohibition sticker - High pressure cleaning Fig. 14 Instruction sticker - Always wear your seat belt Fig. 15 BW 191 AD-5 AM / BW 206 AD-5 AM...
  • Page 36 General – Concerning your safety Information sticker - Lashing point Fig. 16 Information sticker - Lifting point Fig. 17 Information sticker - Filler opening for diesel Diesel B-DEC-0215 Fig. 18 Information sticker - Ultra-low sulphur fuel Fig. 19 BW 191 AD-5 AM / BW 206 AD-5 AM...
  • Page 37 General – Concerning your safety Information sticker - Filler opening for water Water B-DEC-0218 Fig. 20 Information sticker - Filler opening for hydraulic oil Hydraulic Oil B-DEC-0214 Fig. 21 Information sticker - AdBlue /DEF ® Fig. 22 Information sticker - Hydraulic oil drain B-DEC-0210 Fig.
  • Page 38 General – Concerning your safety Information sticker - Coolant drain B-DEC-0212 Fig. 24 Information sticker - Engine oil drain B-DEC-0211 Fig. 25 Information sticker - Push button assignment on travel lever Fig. 26 Information sticker - Regeneration of exhaust gas aftertreatment system Fig.
  • Page 39 General – Concerning your safety Information sticker - Guaranteed sound capacity level Fig. 28 Information sticker - Low ash engine oil Fig. 29 BW 191 AD-5 AM / BW 206 AD-5 AM...

  • Page 40: Maintenance And Repair

    General – Maintenance and repair 1.3 Maintenance and repair 1.3.1 Notes on repair............40 1.3.2 Preliminary remarks and safety notes..... 56 1.3.3 Preparations / concluding work........ 57 1.3.4 Parking the machine in secured condition....62 1.3.1 Notes on repair 1.3.1.1 General repair instructions NOTICE! Ensure strict cleanliness when performing...
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Bomag bw 206 ad-5 am101 921 23 1001101 921 24 1001

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