Fayat Group BOMAG BW 202 AD-50 Service Manual
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Fayat Group BOMAG BW 202 AD-50 Service Manual

Tandem vibratory roller
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Service Manual
BW 202 AD-50 / BW 206 AD-50 /
BW 202 ADO-50
S/N 101 921 19 1001> / S/N 101 921 28 1001> / S/N 101 921 38 1001>
Tandem vibratory roller
008 400 30 EN
© 02/2018

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Summary of Contents for Fayat Group BOMAG BW 202 AD-50

  • Page 1 Service Manual BW 202 AD-50 / BW 206 AD-50 / BW 202 ADO-50 S/N 101 921 19 1001> / S/N 101 921 28 1001> / S/N 101 921 38 1001> Tandem vibratory roller 008 400 30 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 General 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.................... 23 1.2.6 Start-up procedure........................
  • Page 4 Table of contents Overview of machine.......................... 93 4.1 Electric systems.......................... 97 4.2 Diesel engine..........................99 4.3 Hydraulic system........................101 4.3.1 Pump overview......................... 102 4.4 Water spraying system......................105 4.4.1 Tandem rollers.......................... 105 4.4.2 Pump overview......................... 105 4.5 Air conditioning......................... 108 4.6 Drum............................
  • Page 5 Table of contents 5.30.1 CAN bus overview........................197 5.30.2 Level sensor in diesel tank, R03.................... 198 5.30.3 Immersion pipe sensor in water tank, R14................199 5.30.4 Float switch in water tank, B33....................200 5.30.5 Float switch for coolant compensation tank, B55..............200 5.31 Inspection and maintenance work..................
  • Page 6 Table of contents 7.3.7 Outer gear motors non-reversible.................... 293 7.3.8 Steering valve.......................... 294 7.4 Charge circuit and fan circuit....................296 7.5 Travel circuit..........................299 7.6 Vibration circuit......................... 305 7.7 Steering and crabwalk......................315 7.8 Edge cutter..........................320 7.9 Tests and adjustments......................322 7.9.1 Pump overview.........................
  • Page 7 Table of contents 9.2 Physical principles........................398 9.3 Refrigerant R134a........................401 9.4 Compressor oil / refrigeration oil.................... 404 9.5 Working principle of the air conditioning system..............407 9.6 Monitoring devices........................408 9.7 Description of components...................... 409 9.8 Compressor..........................415 9.9 Emptying in case of repair....................... 417 9.10 Drying and evacuation......................
  • Page 8 Table of contents 12.2.3 Towing the machine....................... 553 12.3 Troubleshooting, electrical systems..................556 12.3.1 Preliminary remarks....................... 556 12.3.2 Starting the engine with jump leads..................559 12.3.3 Checking the main battery shutoff..................560 12.3.4 Fuse assignment........................560 12.3.5 Understanding electric circuit diagrams................. 564 12.3.6 Measuring method.........................

  • Page 9: General

    General General BW 202 AD-50 / BW 206 AD-50 / BW 202 ADO-50 Find manuals at https://best-manuals.com...

  • Page 10: 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 11 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 12: 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 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 Transporting persons, except the machine driver, is prohibited. Starting and operating the machine in explosive environments and in underground mining is prohibited. 1.2.1.6 Improper use Dangers may arise from the machine when it is used for purposes other than the one it is intended for.

  • Page 16: Fundamentals For Safe Operation

    General – Concerning your safety 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 particular.
  • Page 17 General – Concerning your safety All persons remaining in the area of the machine must be informed about the dangers that arise from the operation of the machine. 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.

  • Page 18: Handling Fuels And Lubricants

    General – Concerning your safety A defect ROPS must generally be replaced with an original spare part in close coordination with the manufacturer. 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.
  • 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 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 21 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 22 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 23: 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 24: Start-Up Procedure

    General – Concerning your safety The ramp inclination must be less than the gradeability of the machine. 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.

  • Page 25: Driving The Machine, Working Operation

    General – Concerning your safety Use only the intended access steps and grips to mount the machine. 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.
  • Page 26 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 27 General – Concerning your safety 1.2.7.4 Cross slope The tipping angle was measured statically on level, hard ground with the machine stopped and without steering. The max. permissible inclination of the machine may be limited by the max. permissible slanted position of the engine. The specified angle must not be exceeded.

  • Page 28: Refuelling

    General – Concerning your safety 1.2.7.8 Working with the precision spreader Pay attention to the maximum filling capacity, as otherwise the per- missible total weight may be exceeded. Do not step between precision spreader and machine while the engine is running. Always empty the precision spreader before mounting or removing Loads must only be attached and hoisted by an expert / qualified person.

  • Page 29: Emergency Procedures

    General – Concerning your safety 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. The discharge of these charges in the presence of combustible vapours can cause fire or an explosion.

  • Page 30: Maintenance Work

    General – Concerning your safety If no tow bar is used, towing is only permitted uphill. Before starting towing operations make sure that the fastening means are able to withstand the load and are fastened at the points provided for this purpose. Before removing the towing facility apply appropriate measures to secure the machine against unintended rolling.
  • Page 31 General – Concerning your safety 1.2.10.3 Working on the engine Do not work on the fuel system while the engine is running - danger to life due to high pressures! Wait until the engine has stopped, then wait approx. another 15 minutes.

  • Page 32: Repair

    General – Concerning your safety 1.2.10.6 Working on wheels and tyres Explosion-like bursting of tyres or parts of tyres and rims can cause most severe or even fatal injuries. Do not drive with damaged wheels or tyres. Install the tyres only if you are sufficiently experienced and with the right tools at hand.

  • Page 33: Signage

    General – Concerning your safety 1.2.12 Signage Keep stickers and signage in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or signage immediately. BW 202 AD-50 / BW 206 AD-50 / BW 202 ADO-50...
  • Page 34 General – Concerning your safety Fig. 8 BW 202 AD-50 / BW 206 AD-50 / BW 202 ADO-50...
  • Page 35 General – Concerning your safety Fig. 9 BW 202 AD-50 / BW 206 AD-50 / BW 202 ADO-50...
  • Page 36 General – Concerning your safety Fig. 10 BW 202 AD-50 / BW 206 AD-50 / BW 202 ADO-50...
  • Page 37 General – Concerning your safety Fig. 11 Warning sticker - Danger of crushing Fig. 12 BW 202 AD-50 / BW 206 AD-50 / BW 202 ADO-50...
  • Page 38 General – Concerning your safety Warning sticker - Follow operating instructions Fig. 13 Warning sticker - Articulation lock (optional equipment) Fig. 14 Prohibition sticker - High pressure cleaning Fig. 15 Instruction sticker - Always wear your seat belt Fig. 16 BW 202 AD-50 / BW 206 AD-50 / BW 202 ADO-50...
  • Page 39 General – Concerning your safety Information sticker - Lashing point Fig. 17 Information sticker - Lifting point Fig. 18 Information sticker - Diesel Fig. 19 Information sticker - Water Fig. 20 BW 202 AD-50 / BW 206 AD-50 / BW 202 ADO-50...
  • Page 40 General – Concerning your safety Information sticker - Emulsion Fig. 21 Information sticker - Hydraulic oil Fig. 22 Information sticker - Drain fluids (hydraulic oil, engine oil, coolant) Fig. 23 Information sticker - Main battery switch plus side Fig. 24 BW 202 AD-50 / BW 206 AD-50 / BW 202 ADO-50...

  • Page 41: Maintenance And Repair

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This manual is also suitable for:

Bomag bw 206 ad-50Bomag bw 202 ado-50101 921 19 1001101 921 28 1001101 921 38 1001

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