Fayat BOMAG BW 191 AD-5 AM User manual

BW 191 AD-5 AM / BW 206 AD-5 AM
Tandem vibratory roller
Service Manual
S/N 101 921 23 1001> / S/N 101 921 24 1001>
© 02/2018008 401 18 EN

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Table of contents
1 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..................................................................................................................... 25
1.2.7 Driving the machine; working operation..................................................................................... 26
1.2.8 Refuelling................................................................................................................................... 28
1.2.9 Topping up AdBlue®/DEF........................................................................................................... 29
1.2.10 Emergency procedures............................................................................................................ 29
1.2.11 Maintenance work.................................................................................................................... 30
1.2.12 Repair....................................................................................................................................... 32
1.2.13 Signage.................................................................................................................................... 32
1.3 Maintenance and repair.............................................................................................................. 40
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
2 Technical data...................................................................................................................................... 63
2.1 Technical data, BW 191 AD-5 AM.............................................................................................. 64
2.1.1 Technical data............................................................................................................................ 64
2.2 Technical data, BW 206 AD-5 AM.............................................................................................. 69
2.2.1 Technical data............................................................................................................................ 69
2.3 Additional technical data............................................................................................................ 73
2.4 Fuels and lubricants................................................................................................................... 75
2.4.1 Engine oil................................................................................................................................... 75
2.4.2 Fuel............................................................................................................................................ 76
2.4.3 AdBlue®/DEF.............................................................................................................................. 77
2.4.4 Coolant....................................................................................................................................... 80
2.4.5 Hydraulic oil................................................................................................................................ 82
2.4.6 Gear oil SAE 75W-90................................................................................................................. 83
2.4.7 Optipit lubrication grease........................................................................................................... 83
2.5 List of fuels and lubricants........................................................................................................ 84
2.6 Terms and basis of calculation.................................................................................................. 85
3 Overview of machine.......................................................................................................................... 87
3.1 General information.................................................................................................................... 88
3.2 Electric systems.......................................................................................................................... 96
3.3 Hydraulic system........................................................................................................................ 98
3.4 Machine assemblies................................................................................................................. 100
3.4.1 Diesel engine........................................................................................................................... 100
3.4.2 ASPHALT MANAGER.............................................................................................................. 102
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3.4.3 AD drum................................................................................................................................... 103
3.4.4 AM drum................................................................................................................................... 104
3.4.5 Water system........................................................................................................................... 105
3.4.6 Air conditioning......................................................................................................................... 107
4 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........................................................................................... 130
4.2 Overview of electric system..................................................................................................... 134
4.2.1 Operator’s stand...................................................................................................................... 136
4.2.2 Wiring....................................................................................................................................... 138
4.2.3 Table of fuels and lubricants..................................................................................................... 163
4.2.4 CAN BUS overview.................................................................................................................. 175
4.3 Starting the engine with jump leads........................................................................................ 177
4.4 Fuse assignment....................................................................................................................... 178
4.4.1 Notes on safety........................................................................................................................ 178
4.4.2 Central electrics....................................................................................................................... 178
4.4.3 Engine compartment................................................................................................................ 179
4.4.4 Control console cabin............................................................................................................... 181
4.5 Description of electrical components..................................................................................... 182
4.5.1 Power board............................................................................................................................. 182
4.5.2 Power board for SCR-heating.................................................................................................. 187
4.5.3 Control console cabin .............................................................................................................. 188
4.5.4 Electric steering wheel, A45..................................................................................................... 190
4.5.5 Hydraulic cylinder with distance measuring system................................................................. 191
4.5.6 Asphalt temperature sensor, B106........................................................................................... 192
4.5.7 Acceleration transducer, B84 & B85........................................................................................ 193
4.5.8 Switching on the pressurized spraying system........................................................................ 194
4.5.9 Data collector, A80................................................................................................................... 195
4.5.10 Differential pressure switch for hydraulic oil filter, B21........................................................... 200
4.5.11 Air filter vacuum switch, B03.................................................................................................. 200
4.5.12 Sensor, water in fuel, B124.................................................................................................... 201
4.5.13 Float switch coolant tank, B55............................................................................................... 201
4.5.14 Charge control light................................................................................................................ 201
4.5.15 Electric module, A108............................................................................................................ 203
4.6 Training of electric system....................................................................................................... 204
4.6.1 Electrics training machine control............................................................................................ 204
4.6.2 Elektrotraining Messsteuerung................................................................................................. 311
4.7 Inspection and maintenance work.......................................................................................... 340
4.7.1 Maintenance Table................................................................................................................... 340
4.7.2 Every 500 operating hours....................................................................................................... 340
4.7.3 As required............................................................................................................................... 341
5 Hydraulic system.............................................................................................................................. 343
5.1 Basic principles......................................................................................................................... 345
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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..................................................................................... 358
5.3.1 Travel pump, A4VG71 EP........................................................................................................ 358
5.3.2 Vibration pump, A10VG28 / 45 EP........................................................................................... 365
5.3.3 Drum drive motor..................................................................................................................... 370
5.3.4 Travel motor A2FM32.............................................................................................................. 374
5.3.5 Vibration motor, A10FE 14....................................................................................................... 376
5.3.6 Hydraulic cylinder with distance measuring system................................................................. 378
5.4 Description of hydraulic circuits............................................................................................. 380
5.4.1 Charge circuit and fan circuit.................................................................................................... 380
5.4.2 Travel circuit............................................................................................................................. 382
5.4.3 Vibration circuit......................................................................................................................... 387
5.4.4 Steering and crabwalk.............................................................................................................. 398
5.4.5 Edge cutter............................................................................................................................... 403
5.4.6 Chip spreader........................................................................................................................... 405
5.5 Tests and adjustments............................................................................................................. 409
5.5.1 Pump overview......................................................................................................................... 410
5.5.2 Activate service mode.............................................................................................................. 412
5.5.3 Driving against the closed brake.............................................................................................. 414
5.5.4 Pressure tests in the travel circuit............................................................................................ 416
5.5.5 Checking / adjusting the neutral positions of the travel pump.................................................. 418
5.5.6 Checking the setting of the high pressure limiting valves in the travel system........................ 420
5.5.7 Pressure tests in the front vibration circuit............................................................................... 422
5.5.8 Pressure tests in the rear vibration circuit................................................................................ 424
5.5.9 Checking the high pressure relief valves in the front vibration circuit...................................... 426
5.5.10 Checking the high pressure relief valves in the rear vibration circuit..................................... 428
5.6 Flushing and bleeding.............................................................................................................. 431
5.6.1 Flushing - general.................................................................................................................... 431
5.6.2 Flushing diagram for front drum drive...................................................................................... 434
5.6.3 Flushing the front drum drive................................................................................................... 435
5.6.4 Flushing diagram for rear drum drive....................................................................................... 439
5.6.5 Flushing the rear drum drive.................................................................................................... 440
5.6.6 Flushing diagram for front vibration drive................................................................................. 445
5.6.7 Flushing the front vibration circuit ........................................................................................... 446
5.6.8 Flushing diagram for rear vibration circuit................................................................................ 451
5.6.9 Flushing the rear vibration circuit ............................................................................................ 452
5.6.10 Bleeding................................................................................................................................. 456
5.7 Inspection and maintenance work.......................................................................................... 461
5.7.1 Maintenance Table................................................................................................................... 461
5.7.2 Checks prior to start up............................................................................................................ 461
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5.7.3 Every 500 operating hours....................................................................................................... 462
5.7.4 Every 1000 operating hours..................................................................................................... 462
5.7.5 Every 2000 operating hours..................................................................................................... 464
6 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.................................................................................................... 478
6.1.4 Common Rail System (CRS)................................................................................................... 479
6.1.5 Wastegate charge pressure controller..................................................................................... 486
6.1.6 Exhaust gas recirculation......................................................................................................... 488
6.1.7 EAT – Exhaust Aftertreatment System..................................................................................... 489
6.1.8 Engine electrics........................................................................................................................ 504
6.1.9 Inspection and maintenance work............................................................................................ 522
6.2 ASPHALT MANAGER................................................................................................................ 555
6.2.1 Controlled compaction............................................................................................................. 555
6.2.2 Description of function.............................................................................................................. 557
6.2.3 Automatic measuring and controlling....................................................................................... 559
6.2.4 Description of components....................................................................................................... 560
6.2.5 Hydraulic circuit........................................................................................................................ 568
6.2.6 Inspection and maintenance work............................................................................................ 569
6.3 Drum........................................................................................................................................... 573
6.3.1 Overview, AD drum.................................................................................................................. 573
6.3.2 Overview, AM drum.................................................................................................................. 574
6.3.3 Repair....................................................................................................................................... 575
6.3.4 Inspection and maintenance work............................................................................................ 582
6.4 Water system............................................................................................................................. 590
6.4.1 Overview of water spraying system......................................................................................... 590
6.4.2 Inspection and maintenance work............................................................................................ 593
6.5 Air conditioning......................................................................................................................... 600
6.5.1 Overview of air conditioning system......................................................................................... 601
6.5.2 Physical principles.................................................................................................................... 603
6.5.3 Refrigerant R134a.................................................................................................................... 605
6.5.4 Compressor oil / refrigeration oil.............................................................................................. 607
6.5.5 Working principle of the air conditioning system...................................................................... 609
6.5.6 Monitoring devices................................................................................................................... 610
6.5.7 Description of components....................................................................................................... 611
6.5.8 Compressor.............................................................................................................................. 617
6.5.9 Emptying in case of repair........................................................................................................ 618
6.5.10 Drying and evacuation........................................................................................................... 619
6.5.11 Filling instructions................................................................................................................... 620
6.5.12 Steam table for R134a........................................................................................................... 623
6.5.13 Inspection and maintenance work.......................................................................................... 627
6.6 Chip spreader............................................................................................................................ 633
6.6.1 Mounting / removing the precision spreader............................................................................ 633
6.6.2 Inspection and maintenance work............................................................................................ 638
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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
7 Troubleshooting................................................................................................................................ 659
7.1 Preliminary remarks.................................................................................................................. 660
7.2 Emergency procedures............................................................................................................ 661
7.2.1 Actuating the emergency stop switch....................................................................................... 661
7.2.2 Disconnecting the battery......................................................................................................... 661
7.2.3 Towing the machine................................................................................................................. 661
7.3 Troubleshooting, electrical systems....................................................................................... 666
7.3.1 Preliminary remarks................................................................................................................. 666
7.3.2 Starting the engine with jump leads......................................................................................... 669
7.3.3 Servicing the battery, checking the main battery switch........................................................... 671
7.3.4 Fuse assignment...................................................................................................................... 672
7.3.5 ESX, checking the electric power supply................................................................................. 676
7.3.6 Diagnostics concept................................................................................................................. 683
7.4 Trouble shooting, hydraulics................................................................................................... 686
7.4.1 Insufficient hydraulic power...................................................................................................... 686
7.4.2 Trouble shooting axial piston pumps........................................................................................ 689
7.4.3 Trouble shooting axial piston motors....................................................................................... 691
7.4.4 Fault table hydraulic components............................................................................................ 693
7.5 Trouble shooting, diesel engine.............................................................................................. 701
7.5.1 Starting the engine with jump leads......................................................................................... 701
7.5.2 Engine malfunctions................................................................................................................. 702
7.5.3 SCR system warning strategy.................................................................................................. 706
7.5.4 Deutz DTC fault code list, EMR4............................................................................................. 710
7.6 Troubleshooting, air conditioning system.............................................................................. 770
7.6.1 Trouble shooting in refrigerant circuit, basic principles............................................................ 770
7.6.2 Trouble shooting procedure..................................................................................................... 776
7.6.3 Leak test................................................................................................................................... 785
7.6.4 Checking the magnetic clutch ................................................................................................. 786
8 Special tools...................................................................................................................................... 789
8.1 List of special tools................................................................................................................... 790
8.2 Special tools, electrics............................................................................................................. 791
8.3 Special tools, hydraulic system............................................................................................... 792
8.3.1 Special tools, tests and adjustments........................................................................................ 792
8.3.2 Special tools for flushing.......................................................................................................... 794
9 Index................................................................................................................................................... 795
Appendix............................................................................................................................................ 813
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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
Table of contents
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1 General
General
BW 191 AD-5 AM / BW 206 AD-5 AM
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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................................................... 25
1.2.7 Driving the machine; working operation................... 26
1.2.8 Refuelling................................................................. 28
1.2.9 Topping up AdBlue®/DEF......................................... 29
1.2.10 Emergency procedures.......................................... 29
1.2.11 Maintenance work.................................................. 30
1.2.12 Repair.................................................................... 32
1.2.13 Signage.................................................................. 32
1.3 Maintenance and repair............................................ 40
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
1.1 Introduction
This manual:
naddresses the BOMAG Customer Service and professionally
trained personnel.
nprovides 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.
The index is a reference register that will help you to find informa-
tion in this Service Manual. The index lists keywords in alphabet-
ical order. Cross references (keywords related to page numbers)
enable quick and convenient search/navigation.
Keywords concerning the following subjects are listed in the index:
nElectrical operating means
nPlug designations
nOverviews
nFault codes
nTroubleshooting
n...
General
Index
General – Introduction
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For the BOMAG machines described in this manual the following
documentation is additionally available:
nOperating and maintenance instructions
nSpare parts catalogue
nService information (if necessary)
nSpecialist teams are available for you in Germany, Europe and
overseas. This tight network ensures close customer contact
all over the world.
nParts for maintenance, service and repair are available from
our branch offices and dealers at very short notice.
nBOMAG guarantees long-term availability of all common parts.
nWell-designed catalogues provide an easy guide to finding and
ordering the required parts.
nOnly use genuine BOMAG parts. These have been specially
adapted to the corresponding machine. In this way, you will
prevent any problems arising and unnecessary downtimes of
your machine.
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.
Information and illustrations in this manual must not be reproduced
and distributed, nor must they be used for the purpose of competi-
tion without the consent of BOMAG. All rights according to the
copyright law remain expressly reserved.
Documentation
Maintenance/parts service
Updating service
Copyright
General – Introduction
BW 191 AD-5 AM / BW 206 AD-5 AM
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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:
nit is used for purposes other than the ones it is intended for,
nit is operated by untrained personnel,
nit is changed or converted in an unprofessional way,
nthe safety instructions are not observed.
Each person involved in the operation, maintenance and repair of
the machine must therefore read and comply with these safety reg-
ulations. If necessary, the operating company must obtain the rele-
vant signatures as confirmation.
Furthermore, the following obviously also applies:
napplicable accident prevention instructions,
ngenerally accepted safety and road traffic regulations,
ncountry specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations and regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
1.2.1.2 Explanation of signal words used:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or
severe injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
General – Concerning your safety
BW 191 AD-5 AM / BW 206 AD-5 AM
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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.
Sections marked accordingly indicate technical
information or notes on using the machine or its
components.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices
for safe and environment-friendly disposal of fuels
and lubricants as well as replacement parts.
1.2.1.3 Personal protective equipment
Depending on the work to be carried out, personal protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protect against
being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on
slippery ground.
Protective gloves To protect the hands against excoriation, punctures or
deep injuries, against irritating and caustic substances
as well as against burns.
General – Concerning your safety
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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.
Hearing protection To protect hearing against excessive noise.
Respiratory protection To protect respiratory tracts against substances or parti-
cles.
1.2.1.4 Intended use
This machine must only be used for:
nCompaction of bituminous material, e.g. road surface layers,
nCompaction work in earth construction and road bases.
Intended use also includes compliance with the specified oper-
ating, maintenance and repair measures.
1.2.1.5 Improper use
Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
General – Concerning your safety
BW 191 AD-5 AM / BW 206 AD-5 AM
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Examples for improper use are:
nwork with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
ncleaning the drums while driving or changing nozzles during
travel
ndriving on subsoils with too low load bearing capacity
ndriving on slippery subsoils (e.g. ice and snow)
ndriving on surfaces of insufficient size (danger of turning over)
nunauthorized use of public roads
nusing the machine for towing
Transporting persons, except the machine driver, is prohibited.
Starting and operating the machine in explosive environments and
in underground mining is prohibited.
1.2.2 Definition of responsible persons
1.2.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
its company. It must then take appropriate action to ensure health
and safety at work for its employees and point out any remaining
dangers.
The operating company must determine whether there are special
operational hazards such as a toxic atmosphere or limiting soil
conditions. Such conditions require special, additional measures to
remove or reduce the hazard.
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
particular.
General – Concerning your safety
BW 191 AD-5 AM / BW 206 AD-5 AM
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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.
1.2.2.3 Driver / operator
This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:
The driver or operator must:
nbe instructed about his rights and obligations,
nwear protective equipment as appropriate for the application,
nhave read and understood the operating instructions,
nhave made himself familiar with the operation of the machine,
nbe physically and psychologically able to drive and operate the
machine.
Persons under the influence of alcohol, medication or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
1.2.3 Fundamentals for safe operation
1.2.3.1 Remaining dangers, remaining risks
Despite careful work and compliance with standards and regula-
tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
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.
A remaining risk can also not be excluded beyond the actual
danger zone of the machine. Persons remaining in this area must
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
All persons remaining in the area of the machine must be informed
about the dangers that arise from the operation of the machine.
General – Concerning your safety
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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.
Original parts and accessories have been specially designed for
this machine.
We wish to make explicitly clear that we have not tested or
approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse
effect on the active and/or passive safety.
1.2.3.4 Damage, defects, misuse of safety devices
Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.
1.2.3.5 Roll Over Protective Structure (ROPS)
On machines with cab the ROPS is an integral part
of the cab.
The frame of the machine must not be warped, bent or cracked in
the area of the ROPS fastening.
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.
The ROPS must therefore also not be straightened or repaired if it
is damaged.
A defect ROPS must generally be replaced with an original spare
part in close coordination with the manufacturer.
General – Concerning your safety
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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:
nname of substance
npossible dangers
ncomposition / information on constituents
nfirst-aid measures
nfire fighting measures
nmeasures in case of accidental release
nhandling and storage
nlimitation and monitoring of exposure / personal protective
equipment
nphysical and chemical properties
nstability and reactivity
ntoxicological data
nenvironmental data
nnotes on waste disposal
ninformation on transport
nlegislation
nother data
General – Concerning your safety
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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!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with diesel
fuel!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any fuel fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous
substance!
– Always keep diesel fuel in proper containers.
– Immediately bind spilled diesel fuel with an oil-
binding agent and dispose of properly.
– Dispose of diesel fuel and fuel filters according
to regulations.
Fig. 1
General – Concerning your safety
BW 191 AD-5 AM / BW 206 AD-5 AM
19

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.
– Avoid contact and consumption.
AdBlue®/DEF has not been classified as environ-
mentally harmful.
1.2.4.4 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!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with oil!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
– Immediately bind spilled oil with an oil-binding
agent.
– Dispose of oil and oil filter according to regula-
tions.
Fig. 2
Fig. 3
General – Concerning your safety
BW 191 AD-5 AM / BW 206 AD-5 AM
20