Fayat Group BOMAG BW 226 DH-4i BVC User manual

BW 226 DH-4i BVC
Single drum roller
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 585 01 1001> / S/N 101 585 44 1001>
© 08/2015008 076 41

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Table of contents
1Introduction........................................................................................................................................... 7
1.1 Foreword........................................................................................................................................ 8
1.2 Machine type plate and engine type plate................................................................................ 10
2 Technical data..................................................................................................................................... 11
2.1 Noise and vibration data............................................................................................................ 14
2.1.1 Noise data.................................................................................................................................. 14
2.1.2 Vibration data............................................................................................................................. 14
3 Safety regulations............................................................................................................................... 15
3.1 Information and safety stickers/decals on the machine......................................................... 27
4 Display and control elements............................................................................................................ 29
4.1 General notes.............................................................................................................................. 31
4.2 Description of indicators and control elements....................................................................... 32
4.2.1 Monitor for reversing camera..................................................................................................... 45
4.3 Display and control elements Variocontrol.............................................................................. 46
4.4 Description of indicating and control elements Variocontrol................................................. 47
4.5 Line graph Automatic (EVIB)....................................................................................................... 51
4.6 Description of line diagram Automatic (EVIB)........................................................................... 52
4.7 Line graph Manual (EVIB)............................................................................................................. 54
4.8 Description of line diagram Manual (EVIB)................................................................................. 55
4.9 Bar diagram (EVIB)....................................................................................................................... 57
5 Operation............................................................................................................................................. 59
5.1 General......................................................................................................................................... 60
5.2 Tests before taking into operation ........................................................................................... 61
5.3 Adjusting the driver’s seat......................................................................................................... 62
5.4 Electronic immobilizerOptional equipment ........................................................................................ 64
5.5 Starting the engine...................................................................................................................... 65
5.6 Driving the machine ................................................................................................................... 67
5.7 Stopping the machine, operating the parking brake............................................................... 70
5.8 Using the machine for rock crushing........................................................................................ 71
5.9 Shutting down the engine.......................................................................................................... 72
5.10 DPF-regeneration...................................................................................................................... 74
5.11 Switching the vibration on and off.......................................................................................... 76
5.12 What to do in events of emergency......................................................................................... 79
5.13 Operating the heating/air conditioning systemOptional equipment .............................................. 80
5.14 Operating the hood................................................................................................................... 82
5.15 LC-Display - changing display fields...................................................................................... 83
5.16 LC-Display - changing settings............................................................................................... 86
5.17 BVC/BTM05 settings before start-up ...................................................................................... 91
5.18 Variocontrol, selecting the operating mode........................................................................... 95
5.19 Measuring pass with Variocontrol........................................................................................... 99
5.20 Finishing compaction of a track............................................................................................ 103
5.21 Printing measuring data after completing compaction....................................................... 104
5.22 Teaching distance pulses...................................................................................................... 105
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5.23 Amplitude limitation (BVC only)............................................................................................ 108
5.24 Changing the paper roll in the measuring value printeronly BTM prof .................................... 111
5.25 Changing the printer ribbon in the measuring value printeronly BTM prof ............................. 112
5.26 Towing in case of an engine failure...................................................................................... 113
5.27 Loading/transport................................................................................................................... 115
6 Maintenance...................................................................................................................................... 119
6.1 General notes on maintenance................................................................................................ 120
6.2 Fuels and lubricants................................................................................................................. 122
6.2.1 Engine oil................................................................................................................................. 122
6.2.2 Fuel.......................................................................................................................................... 123
6.2.3 Coolant..................................................................................................................................... 124
6.2.4 Hydraulic oil.............................................................................................................................. 127
6.2.5 Gear oil..................................................................................................................................... 127
6.2.6 Exciter system.......................................................................................................................... 128
6.3 Table of fuels and lubricants................................................................................................... 129
6.4 Running-in instructions............................................................................................................ 131
6.4.1 General.................................................................................................................................... 131
6.4.2 After 250 operating hours......................................................................................................... 131
6.4.3 After 500 operating hours......................................................................................................... 131
6.4.4 After 1000 operating hours....................................................................................................... 131
6.5 Maintenance table..................................................................................................................... 133
6.6 Every 10 operating hours......................................................................................................... 135
6.6.1 Check the engine oil level........................................................................................................ 135
6.6.2 Checking the fuel level............................................................................................................. 135
6.6.3 Check the coolant level............................................................................................................ 137
6.6.4 Check the hydraulic oil level .................................................................................................... 137
6.7 Every 250 operating hours....................................................................................................... 139
6.7.1 Check the tire pressure............................................................................................................ 139
6.7.2 Clean the cooling fins on engine and hydraulic oil cooler........................................................ 139
6.7.3 Check the oil level in the drive axle.......................................................................................... 140
6.7.4 Check the oil level in the wheel hubs....................................................................................... 141
6.7.5 Check the oil level in the axle reduction gear........................................................................... 142
6.7.6 Check the oil level in the drum reduction gear......................................................................... 142
6.7.7 Check the parking brake.......................................................................................................... 142
6.7.8 Servicing the V-belt for the air-con compressorOptional equipment ................................................. 143
6.8 Every 500 operating hours....................................................................................................... 144
6.8.1 Change engine oil and oil filter cartridge.................................................................................. 144
6.8.2 Check the anti-freeze concentration and the condition of the coolant..................................... 145
6.8.3 Checking, cleaning the water separator................................................................................... 146
6.8.4 Draining the sludge from the fuel tank..................................................................................... 147
6.8.5 Battery service......................................................................................................................... 148
6.8.6 Servicing the air conditioning systemoptional equipment ................................................................. 149
6.8.7 Cleaning the circulation air filter for the heatingOptional equipment ................................................. 152
6.8.8 Changing the bypass filterOptional equipment .................................................................................. 153
6.9 Every 1000 operating hours..................................................................................................... 154
6.9.1 Checking / replacing the ribbed V-belt..................................................................................... 154
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6.9.2 Replace the fuel filter cartridge................................................................................................ 155
6.9.3 Change the fuel pre-filter cartridge........................................................................................... 156
6.9.4 Checking the crankcase ventilation valve................................................................................ 158
6.9.5 Check the engine mounts ....................................................................................................... 158
6.9.6 Checking the engine pillow blocks .......................................................................................... 158
6.9.7 Changing the oil in the drive axle............................................................................................. 158
6.9.8 Changing the oil in the wheel hubs.......................................................................................... 160
6.9.9 Changing the oil in the axle reduction gear.............................................................................. 161
6.9.10 Changing the oil in the drum reduction gear.......................................................................... 161
6.9.11 Vario exciter oil change.......................................................................................................... 162
6.9.12 Retighten the fastening of the axle on the frame................................................................... 163
6.9.13 Tighten the wheel nuts........................................................................................................... 164
6.9.14 Check the ROPS.................................................................................................................... 164
6.9.15 Check the travel control......................................................................................................... 165
6.10 Every 2000 operating hours................................................................................................... 166
6.10.1 Adjust the valve clearance..................................................................................................... 166
6.10.2 Changing hydraulic oil and breather filter .............................................................................. 167
6.10.3 Replace hydraulic oil filter...................................................................................................... 169
6.10.4 Changing the coolant............................................................................................................. 170
6.10.5 Replacing ribbed V-belt and idler pulley................................................................................. 172
6.10.6 Checking the DBF-burner ..................................................................................................... 173
6.10.7 Checking, cleaning the components of the exhaust gas aftertreatment system.................... 173
6.11 Every 4000 operating hours................................................................................................... 174
6.11.1 Servicing the DBF-burner....................................................................................................... 174
6.12 Every 6000 operating hours................................................................................................... 175
6.12.1 Replace the injection valves................................................................................................... 175
6.12.2 Replace the crank case ventilation valve .............................................................................. 175
6.13 As required.............................................................................................................................. 176
6.13.1 Air filter maintenance............................................................................................................. 176
6.13.2 Retightening the padfoot shell................................................................................................ 179
6.13.3 Adjust the scrapers................................................................................................................ 179
6.13.4 Clean the machine................................................................................................................. 180
6.13.5 Change the tires..................................................................................................................... 180
6.13.6 Change the fresh air filter in the cabin................................................................................... 181
6.13.7 Fill the provision tank for the windscreen washer systemOptional equipment ................................ 181
6.13.8 Tightening torques................................................................................................................. 181
6.13.9 Engine conservation .............................................................................................................. 182
7 Trouble shooting............................................................................................................................... 183
7.1 Preliminary remarks.................................................................................................................. 184
7.2 Starting the engine with jump leads........................................................................................ 185
7.3 Fault code display..................................................................................................................... 186
7.4 Reading out faults BVC/BTM05............................................................................................... 187
7.5 Fuse assignment....................................................................................................................... 189
7.6 Engine faults.............................................................................................................................. 192
8 Cabin assembly before initial commissioning............................................................................... 195
8.1 Preparations.............................................................................................................................. 197
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8.2 Cabin assembly......................................................................................................................... 199
8.3 Final function tests and checks............................................................................................... 206
9 Disposal............................................................................................................................................. 207
9.1 Final shut-down of machine..................................................................................................... 208
Table of contents
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1 Introduction
Introduction
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1.1 Foreword
BOMAG manufactures machines for earth, asphalt and refuse
compaction, stabilizers/recyclers as well as planers and
pavers.
BOMAG’s vast experience in connection with state-of-the-art
production and testing methods, such as lifetime tests of all
important components and highest quality demands guar-
antee maximum reliability of your machine.
The machine described in this manual complies with the applicable
standards and safety regulations.
If your machine is used in traffic on public roads, it must comply
with all applicable national legal regulations. The driving permit
must be acquired from the responsible authorities.
The machine is equipped with latest technology. Now it's a matter
of handling your machine properly and keeping it in good working
order.
These instructions will provide you with all necessary information.
Read and follow these notes before starting to operate your
machine!
In case of operating errors, inadequate maintenance or the use of
unapproved fuels and lubricants all warranty claims will become
null and void.
This manual was written for operators and maintenance personnel.
Always keep this manual close at hand, e.g. in the tool compart-
ment of the machine or in a specially provided container. These
operating and maintenance instructions are part of the machine.
You should only operate the machine in compliance with these
instructions.
Strictly observe the safety regulations.
If you are not yet acquainted with the controls and indicating ele-
ments on this machine, you should thoroughly read the corre-
sponding chapter
Ä Chapter 4 ‘Display and control elements’
on page 29.
The description of the individual operating steps including the
notes on safety to be followed can be found in chapter "Operation"
Ä Chapter 5 ‘Operation’ on page 59.
Thorough maintenance of the machine guarantees far longer safe
functioning of the machine and prolongs the lifetime of important
components. The effort required for this purpose is by all means
lower than the faults that may occur in case of non-compliance.
The machine must only be serviced by qualified and authorized
personnel. A description of all necessary service work as well as
information on fuels and lubricants can be found in the chapter
"Maintenance" Ä Chapter 6 ‘Maintenance’ on page 119.
For your own personal safety you should only use original parts
from BOMAG.
For your machine we offer original parts kits to make maintenance
easier.
Introduction – Foreword
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In the course of technical development we reserve the right for
technical modifications without prior notification.
These operating and maintenance instructions are also available in
other languages.
Apart from that, you can also order the spare parts catalogue
against the serial number of your machine.
The above notes do not constitute an extension of the warranty
and liability conditions specified in the general sales and delivery
conditions of BOMAG GmbH.
We wish you successful work with your BOMAG machine.
Introduction – Foreword
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1.2 Machine type plate and engine type plate
Please enter here:
Machine type (1):
Serial number (2):
Please enter here:
Engine type (1):
Engine number (2):
Fig. 1: Machine type plate (example)
Fig. 2: Engine type plate (example)
Introduction – Machine type plate and engine type plate
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2 Technical data
Technical data
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Fig. 3
BW 226 DH-4i BVC A B D H H2K L O1/2 S W
Dimensions in mm 3355 2440 1700 2300 3072 430 6582 155 40 2130
Dimensions in inch 132 96 67 91 121 16.9 259 6.1 1.6 84
Weights
Max. operating weight 27700 kg 61068 lbs
Operating weight (CECE) with ROPS-cabin 25760 kg 56791 lbs
Axle load, drum (CECE) 17590 kg 38779 lbs
Axle load, wheels (CECE) 8170 kg 18012 lbs
Static linear load 82.6 kg/cm 462.5 pli
Travel characteristics
Travel speed 0 – 10 km/h 0 – 6.2 (machine type dependent)
Max. gradability without/with vibration (soil
dependent)
48% / 45% 48% / 45%
Drive
Engine manufacturer Deutz Deutz
Type TCD 6.1 L6 TCD 6.1 L6
Cooling Water Water
Number of cylinders 6 6
Technical data
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Rated power ISO 3046 150 kW 150 kW
Rated power SAE J 1995 201 hp 201 hp
Rated speed 2200 min-1 2200 rpm
Electrical equipment 12 V 12 V
Drive system hydrostatic hydrostatic
Driven axles 2 2
Permissible ambient temperatures -20 ... +50 °C -4 ... +122 °F
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrostatic hydrostatic
Steering angle ± 35 ° ± 35 °
Oscillation angle ± 12 ° ± 12 °
Inner track radius 3950 mm 155.5 in
Vibration
Variocontrol Standard Standard
Frequency 26 Hz 1560 vpm
Amplitude 0 – 2.7mm 0 – 0.106 in
Centrifugal force 530 119149 lbf
Tires
Tire size 23,5-25 16PR 23,5-25 16PR
Air pressure, nominal value 2 bar 29 psi
Air pressure, span 1 – 2 bar 14.5 – 29 psi
Filling capacities
Fuel (diesel) 340 l 90 gal us
Technical data
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2.1 Noise and vibration data
The following noise and vibration data were determined in accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
nEC Machine Directive edition 2006/42/EC
nNoise Emission Directive 2000/14/EC, Noise Protection Direc-
tive 2003/10/EC
nVibration Protection Directive 2002/44/EC
During operation these values may vary because of the prevailing
operating conditions.
2.1.1 Noise data
LpA = 82 dB(A), determined acc. to ISO 11204 and EN 500
WARNING!
Loss of hearing caused by too high noise burdens!
– Wear your personal protective outfit (ear
defenders).
LWA = 110 dB(A), determined acc. to ISO 3744 and EN 500
2.1.2 Vibration data
The weighted effective acceleration value determined according to
ISO 7096 is ≤ 0.5 m/s2.
The weighted effective acceleration value determined according to
EN 500/ISO 5349 is ≤ 2.5 m/s2.
Sound pressure level on the opera-
tor's stand
Guaranteed sound power level
Vibration of the entire body
(driver’s seat)
Hand-arm vibration
Technical data – Noise and vibration data
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3 Safety regulations
Safety regulations
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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 regulations. If necessary, this must be confirmed
by obtaining the signature of the customer.
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 these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.
This machine must only be used for:
nmedium to heavy compaction work in earth construction (road
sub-bases)
nprobably compaction of bituminous material, e.g. road surface
layers.
Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by intended use is the sole responsibility of the
customer or driver/operator, the manufacturer cannot be made
liable.
Examples for unintended use are:
nwork with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
ndriving on unstable subbases or too small contact area (danger
of tipping over)
nusing the machine for towing
nuse to pull down walls or demolish buildings
Transporting persons, except the machine driver, is prohibited.
Starting and operation of the machine in explosive environments
and in underground mining is prohibited.
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.
General
Intended use
Unintended use
Remaining dangers, remaining
risks
Safety regulations
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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 ion the area of the machine must be
informed about the dangers that arise from the operation of the
machine.
Have the machine inspected by an expert (capable person) as
required for the conditiosn the machine is working under, but at
least once every year.
Only trained, instructed and authorized persons of at least 18 years
of age are permitted to drive and operate this machine. For opera-
tion of the machine the responsibilities must be clearly specified
and complied with.
Persons under the influence of alcohol, medicine 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.
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.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.
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.
Regular safety inspections
Who is allowed to operate the
machine?
Changes and conversions to the
machine
Damage, deficiencies, misuse of
safety installations
Safety regulations
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WARNING!
Paragraphs marked like this highlight possible dangers
for persons.
NOTICE!
Paragraphs marked like this highlight possible dangers
for machines or parts of the machine.
Paragraphs marked like this contain technical informa-
tion for the optimal economical use of the machine.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubricants
as well as replacement parts.
Observe the regulations for the protection of the envi-
ronment.
Use only strong and stable loading ramps. The ramp inclination
must be lower than the gradability of the machine.
Secure the machine against turning over or slipping off.
Secure the machine on the transport vehicle against rolling off,
slipping and turning over.
Persons are highly endangered if
nthey step or stand under loads being lifted
nthey remain in the drive range of the machine during a demon-
stration or during loading.
The machine must not swing about when lifted off the ground.
Use only safe lifting gear of sufficient load bearing capacity.
Attach the lifting gear only to the specified lifting points.
You should generally use a tow bar.
Max. towing speed 1 km/h (1.6 mph), max. towing distance 500 m
(1640 ft.).
Before releasing the multi-disc brakes secure the machine properly
against unintended rolling.
Notes on safety in the operating
and maintenance instructions:
Loading the machine
Towing the machine
Safety regulations
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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 actual weight of the machine must not exceed the testing
weight of the ROPS.
The ROPS must not rattle about when driving. This indicates that it
is not properly fastened. All bolted connections must comply with
the specifications and should be absolutely tight (observe the tight-
ening torques). Screw and nuts must not be damaged, bent or
deformed.
With the cab assembled check also the state of the cabin mounts
(rubber elements and screws).
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.
Before starting
Operation of the machine is only permitted when sitting in the oper-
ator's seat.
Use only machines which have been properly serviced at regular
intervals.
Become acquainted with the equipment, the control elements, the
working mode of the machine and the area you will be working in.
Use your personal protective outfit (hard hat, safety boots etc.).
Check before mounting the machine if:
nthere are persons or obstructions beside or under the machine
nthe machine is free of any oily and combustible material
nall handrails, steps and platforms are free of grease, oils, fuels,
dirt, snow and ice
nthe engine compartment hood is closed and locked
To climb onto the machine use steps and handrails.
Check before starting, whether:
nthe machine shows any obvious defects
nall protective devices are properly secured in their place
nsteering, brakes, control elements, lighting and warning horn
are in order
nthe seat is correctly adjusted
nthe mirrors (if available) are clean and correctly adjusted.
Checking the Roll Over Protective
Structure (ROPS)
Starting the machine
Safety regulations
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Do not start the machine if any gauges, control lights or controls
are defective.
Do not take any loose objects with you or fasten them to the
machine.
On machines with ROPS you should always wear your seat belt!
Starting
Start and operate the machine only from the operator's seat
For starting set all control levers to "neutral position".
Do not use any starting aids such as Start Pilot or ether.
After starting check all gauges.
Starting with jump leads
Connect plus with plus and minus with minus (ground cable) -
always connect the ground cable last and disconnect it first! Wrong
connections may cause severe damage in the electric system.
Never start the engine by bridging the electrical connections on the
starter, because the machine would probably start to move imme-
diately.
Starting in closed rooms
Exhaust gases are toxic! Always ensure an adequate supply of
fresh air when starting in closed rooms!
Persons in the danger area
If a machine has turned over and the cabin door is jammed, the
right hand cabin window can be used as an escape door.
Before taking up work, also after breaks, you should always con-
vince yourself that the danger zone is free of persons or obstruc-
tions, especially when driving in reverse.
Give warning signals, if necessary. Stop work immediately if per-
sons remain in the danger zone, despite the warning.
Do not step or stand in the articulation area of the machine when
the engine is running. Danger of squashing!
Driving
Always wear the seat belt when driving.
Do not drive on bases with insufficient load bearing capacity.
Do not drive on ice and snow.
In events of emergency and in case of danger actuate the emer-
gency stop switch immediately. Do not use the emergency stop
switch as service brake.
Restart the machine only after the danger that caused the actua-
tion of the emergency stop switch has been eliminated.
If the machine has contacted high-voltage power lines:
ndo not leave the operator’s stand,
nwarn others from coming close to or touching the machine,
Driving the machine
Safety regulations
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