Fayat Group Bomag MPH 122-2 Installation and operation manual

Operating instructions
Maintenance instructions
Original operating instructions
Catalogue No.
008 061 61 05/2011
MPH 122-2
S/N 101 590 06 .... S/N 101 590 07 ....
Soil Stabilizer
Asphalt Recycler

Foreword
BOMAG 3MPH 122-2
F oreword
These BOMAG machines are products from
the wide range of BOMAG machines for earth
work, asphalt and refuse compaction as well
as stabilizers/recyclers.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your ma-
chine.
This manual comprises:
lSafety regulations
lOperating instructions
lMaintenance instructions
lTrouble shooting
Using these instructions will
lhelp you to become familiar with the machine.
lavoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
lenhance the reliability of the machine on con-
struction sites,
lprolong the lifetime of the machine,
lreduce repair costs and downtimes.
BOMAG will not assume liability for the function of
the machine
lif it is handled in a way not complying with the
usual modes of use,
lif it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-
age resulting from
loperating errors,
linsufficient maintenance and
lwrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and mainte-
nance instructions are part of the machine.
You should only operate the machine after you
have been instructed and in compliance with these
instructions.
Strictly observe the safety regulations.
Please observe the applicable accident prevention
instructions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Furthermore, the spare parts catalogue is availa-
ble from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines.
The above notes do not constitute an extension of
the warranty and liability conditions specified in the
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG

Foreword
BOMAG4MPH 122-2
Please fill in
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Machine type (Fig. 1)
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Serial-number (Fig. 1 and 2)
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Motor type (Fig. 3)
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Motor number (Fig. 3)
i
Note
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 1
Fig. 2
Fig. 3

Table of Contents
BOMAG 5MPH 122-2
Technical Data 9
Safety regulations 13
Indicators and Controls 25
3.1 General notes 29
3.2 Description of indicators and control elements 29
Operation 49
4.1 General 50
4.2 Tests before taking into operation 50
4.3 Starting the engine 51
4.4 Starting with jump wires 53
4.5 Driving the machine to work 54
4.6 Operating the service brake 57
4.7 Operating the parking brake 57
4.8 Actuating the emergency stop switch 58
4.9 Emergency exit 58
4.10 Shutting down engine and machine 59
4.11 Parking on a slope 61
4.12 Preparing for work 62
4.13 Work operation, setting the cutting depth 65
4.14 Adjusting the tailgate 68
4.15 Steering the rear axle 69
4.16 Adjusting the oscillation angle of the rotor (cross-slope) 69
4.17 Mixing water connection, preparing for operation 70
4.18 Water dosing system nozzle change 72
4.19 Taking the attachment plates into service 73
4.20 Finishing work 74
4.21 Raising/lowering the cabin 75
4.22 Towing 77
4.23 Transport 79
4.24 Final shut-down of machine 81
Operation of binder dosing system 83
5.1 Inspection before starting the binder dosing system 84
5.2 Preparing for work 84
5.3 Starting work with emulsion 87
5.4 Starting work with foam bitumen 89
5.5 Changing the bitumen tank 91
5.6 Finishing work 92
5.7 Blowing out bitumen system and spray bar 93
5.8 Flushing the binder pump 94
Maintenance 95
6.1 General notes on maintenance 96

Table of Contents
BOMAG6MPH 122-2
6.2 Fuels and lubricants 97
6.3 Table of fuels and lubricants 102
6.4 Running-in instructions 104
6.5 Maintenance table 105
6.6 Checking the engine oil level 111
6.7 Checking the fuel level 111
6.8 Checking the hydraulic oil level 112
6.9 Check the coolant level 113
6.10 Checking the condition of the cutters 114
6.11 Check the tire pressure 116
6.12 Visual inspection for leakages and damage, clean the machine 117
6.13 Clean the lateral hood boxes 118
6.14 Cleaning the dirt scrapers on the hydraulic cylinders for the rotor hood 118
6.15 Cleaning the intercooler 119
6.16 Checking the reaction water level 120
6.17 Checking the oil level for the reaction water pump 120
6.18 Checking the oil level in compressor and service unit 121
6.19 Checking the thermal oil level 121
6.20 Checking the contamination of the hydraulic oil filters 122
6.21 Checking the binder pump for leaks 122
6.22 Checking the spraying sections for leaks 123
6.23 Lubricating the machine 125
6.24 Cleaning front radiator (water/hydraulics) 127
6.25 Checking, cleaning the additional fuel filter water separator 129
6.26 Service the air conditioning 131
6.27 Checking the oil level in the front right/left hand travel gear 134
6.28 Checking the oil level in the rear axle reduction gear 134
6.29 Clean the breather valve for the reduction gear on the rear axle 135
6.30 Check the oil level in the rear axle 135
6.31 Cleaning the rear axle ventilation valve 136
6.32 Check the oil level in the rear planetary gear 136
6.33 Changing engine oil and oil filter cartridge 137
6.34 Check, clean the water separator 138
6.35 Servicing the generator V-belt 139
6.36 Servicing the air conditioning compressor V-belt 140
6.37 Battery service, checking the main battery switch 141
6.38 Checking the engine mounts 143
6.39 Draining the fuel tank sludge 144
6.40 Oil change in rotor gearbox, check rotor water level 144
6.41 Check, adjust the valve clearance 151
6.42 Changing the fuel filter 152
6.43 Replacing the fuel pre-filter cartridge, bleed the fuel system 153

Table of Contents
BOMAG 7MPH 122-2
6.44 Check the anti-freeze concentration and the condition of the coolant 155
6.45 Intercooler, draining off oil/condensation water 156
6.46 Check the fastening of engine / turbocharger / combustion air hoses 156
6.47 Checking the crankcase pressure 157
6.48 Oil change in front travel gear 158
6.49 Oil change in rear planetary gear 159
6.50 Change the oil in the rear axle reduction gear 160
6.51 Oil change in rear axle 161
6.52 Oil change in attachment plate exciter housing 162
6.53 Change the additional fuel filter 163
6.54 Changing the thermal oil 163
6.55 Compressor oil change 164
6.56 Changing hydraulic oil and breather filter 165
6.57 Change the hydraulic oil fine filter 167
6.58 Changing the coolant 168
6.59 Tightening the screws on the articulated joint 169
6.60 Checking the fire extinguisher . 170
6.61 Changing the injection valve 171
6.62 Replacing the crankcase ventilation valve 173
6.63 Changing the coolant pump 173
6.64 Changing the pressure retaining valve on te injection pump 174
6.65 Cleaning, changing the dry air filter cartridge 175
6.66 Replacing the cutting teeth/cutting tooth holders 177
6.67 Grease the bearings of the lift cylinder for the cabin 181
6.68 Water sprinkler system, maintenance in the event of frost 182
6.69 Change the fresh air filter in the cabin 183
6.70 Fill the provision tank for the windscreen washer system 183
6.71 Change the tires 184
6.72 Lubricate the attachment plate adjustment spindles 185
6.73 Cleaning the bitumen filter 186
6.74 Reaction water tank, maintenance in the event of frost 187
6.75 Tightening torques for screws with metric unified thread 187
6.76 Conservation 188
Trouble shooting 189
7.1 General notes 190
7.2 Engine problems 191
7.3 General notes on diagnostic push button and control light 194
7.4 Air conditioning system faulty 195
7.5 Faults in binder dosing system 196

Table of Contents
BOMAG8MPH 122-2

BOMAG 9MPH 122-2
1 Technical Data

Technical Data
BOMAG10 MPH 122-2
Fig. 4
Dimensions in mm A B B1 H1 KL
MPH 122-2 5815 2810 2790 3420 510 9050
*MPH 122-2
Weights
Operating weight (CECE) kg 20950
Front axle load (CECE) kg 14164
Rear axle load (CECE) kg 6786
Max. operating weight kg 28000
Dimensions
Track radius, inner/outer mm 3500/6300
Travel characteristics
Travel speed (1) km/h 0 – 2.7
Travel speed (2) km/h 0 – 12
Max. gradability (depending on soil) % 40
Drive
Engine manufacturer Deutz
Type TCD 2015 V06
Cooling Water
Number of cylinders 6
Rated power ISO 9249 kW 360
Rated power SAE J 1995 hp 482
Rated speed rpm 2100
Electrical equipment V 24
Drive system hydrostatic
Wheels driven All wheel drive

Technical Data
BOMAG 11MPH 122-2
Tires
Tire size, front 28 LR 26
Tire size, rear 620/75R26
Brakes
Service brake hydrostatic
Parking brake Spring accumulator
Steering
Type of steering Articulated + rear
Steering operation hydraulic
Rotor
Rotor width mm 2330
Outer rotor diameter mm 1225
Rotor speed rpm 110 – 160
Rotor oscillation angle ± ° 5
Max. working depth mm 500
Number of teeth 208
Height of teeth 200
Filling capacities
Engine oil l approx. 38
Coolant l approx. 50
Fuel l approx. 750
Hydraulic oil l approx. 280
* The right for technical modifications remains reserved
*MPH 122-2

Technical Data
BOMAG12 MPH 122-2
The following noise and vibration data acc. to
- EC Machine Regulation edition 2006/42/EC
- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC
- Vibration Protection Regulation 2002/44/EC
were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.
During operation these values may vary because of the existing operating conditions.
Noise value
Sound pressure level on the place of the operator:
LpA = 84 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:
LWA = 114 dB(A), determined acc. to ISO 3744 and EN 500
!Danger
Wear your personal noise protection means (ear defenders) before starting operation.
Vibration value
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is ≤0.5 m/s2.
Hand-arm vibration values
The weighted effective acceleration value determined according to ISO 5349 is ≤2.5 m/s2.

BOMAG 13MPH 122-2
2 Safety regulations

Safety regulations
BOMAG14 MPH 122-2
General
This BOMAG machine has been built in com-
pliance 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:
lit is used for purposes other than the ones it is
intended for,
lit is operated by untrained personnel,
lit is changed or converted in an unprofessional
way,
lthe safety instructions are not observed.
Each person involved in the operation, mainte-
nance and repair of the machine must there-
fore read and comply with these safety
regulations. If necessary, this must be con-
firmed by obtaining the signature of the cus-
tomer.
Furthermore, the following obviously also applies:
lapplicable accident prevention instructions,
lgenerally accepted safety and road traffic reg-
ulations,
lcountry specific safety regulations. It is the
duty of the operator to be acquainted with
these instructions and to apply these accord-
ingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instruc-
tions be different from the regulations valid in
your country, you must comply with the safety
regulations valid in your country.
Intended use
This machine must only be used for:
lStabilizing in road construction to improve and
reinforce existing soil materials by mixing in
lime, fly ash or cement.
lMilling and pulverizing old, damaged bitumen
road surface layers and road reinforcements,
lMetered application of water, bitumen emul-
sion or foam bitumen*.
Unintended 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 intended use is the sole re-
sponsibility of the customer or driver/operator, the
manufacturer cannot be made liable.
Examples for unintended use are:
lusing the machine as recovery vehicle
lusing the machine as towing vehicle for trans-
ports
ldriving on surfaces with insufficient load bear-
ing capacity or on hard shoulders - danger of
slipping down embankments
lconnection of accompanying vehicles (water
or bitumen) without tow bar
lconversion from emulsion operation to bitu-
men operation without cleaning the sywstem -
danger of explosion
Climbing onto or off the machine while driving is
prohibited.
Transporting persons, except the machine driver,
is prohibited.
Starting and operation of the machine in explosive
environments and in underground mining is pro-
hibited.
Remaining dangers, remaining risks
Despite careful work and compliance with stand-
ards and regulations it cannot be ruled out that fur-
ther dangers may arise when working with and
handling the machine.
Both the machine as well as all other system com-
ponents comply with the currently valid safety reg-
ulations. Nevertheless, remaining risks cannot be
ruled out completely, even when using the ma-
chine for the purpose it is intended for and follow-
ing 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.
* Optional equipment

Safety regulations
BOMAG 15MPH 122-2
Regular safety inspections
Have the machine inspected by an expert (capa-
ble person) as required for the conditiosn the ma-
chine is working under, but at least once every
year.
Who is allowed to operate the ma-
chine?
Only trained, instructed and authorized persons of
at least 18 years of age are permitted to drive and
operate this machine. For operation of the ma-
chine 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 re-
pair the machine.
Maintenance and repair work requires specific
knowledge and must therefore only be performed
by trained specialists.
Conversions and alterations to the ma-
chine
Unauthorized conversions to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
pressly clear that we have not tested or authorized
any original parts or special equipment not sup-
plied by us. The installation and/or use of such
products can impair the active and/or passive driv-
ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
Damage, deficiencies, misuse of safety
installations
Machines which are not safe to operate or in traffic
must be immediately taken out of service and shall
not be used, until these deficiencies have been
properly rectified.
Safety installations and switches must neither be
removed nor must they be made ineffective.
Safety notes in the operating and main-
tenance instructions:
!Danger
Sections marked like this point out possible
dangers for persons.
!
Caution
Sections marked like this point out possible
dangers for the machine or for parts of the ma-
chine.
i
Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
Observe all environment protection regula-
tions.
Conduct in events of emergency
Use the middle rear cabin window as emergency
exit!
Loading the machine
During demonstration and when loading the ma-
chine do not remain in the danger zone of the ma-
chine.
Use only stable loading ramps of sufficient load
bearing capacity.
Make sure that persons are not endangered by the
machine tipping or sliding off.
Always switch the rotor off.
Always turn the rotary switch to transport range "I"
to drive the machine onto the transport vehicle.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
Always use shackles on the lifting points for load-
ing or tying the machine down.
Check all lifting and lashing points for damage be-
fore lashing down the machine.

Safety regulations
BOMAG16 MPH 122-2
Lifting the machine is not permitted.
Use a flat container with collapsible front walls for
sea transport, so that the machine can be driven
onto the container.
Towing the machine
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.
Checking the Roll Over Protective
Structure (ROPS)
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, hair-
line cracks or open fractures.
The real machine weight must never exceed the
testing weight for 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 specifi-
cations and should be absolutely tight (observe
the tightening 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 con-
sent of the manufacturer, since this will impair the
strength of the unit.
The ROPS must therefore also not be straight-
ened or repaired if it is damaged.
A defect ROPS must generally be replaced with an
original spare part in close coordination with the
manufacturer.
Starting the machine
Before starting
Use only machines which are serviced at regular
intervals.
Become acquainted with the equipment, the con-
trol elements, the working principle of the machine
and the working area.
Wear your personal protective outfit (hard hat,
safety boots, etc.).
Before mounting the machine check whether:
lpersons or obstructions are beside or under
the machine
lthe machine is free of oily and combustible
material
lall grips, steps and platforms are free of
grease, oils, fuel, dirt, snow and ice
lengine compartment doors are closed and
locked
Use steps and grips to mount the machine.
Before starting the machine check whether:
lthe machine shows any obvious faults
lall guards and safety elements are in place
lsteering, brakes, control elements, light sys-
tem and warning horn work correctly
lthe seat is correctly adjusted
Do not start the machine with defective gauges,
control lights or control elements.
Do not take any loose objects with you or fasten
them to the machine.
On machines with roll over protection system you
must always wear your seat belt!
When checking the condition of the cutting teeth
the rotary switch for free-wheeling of rotor must be
switched on.
Starting
Start and operate the machine only from the driv-
er’s seat.
For starting set all control levers to 'neutral posi-
tion'.
After starting check all gauges and control lights.
Starting with jump wires
When using external starting aid two external bat-
teries are required, one for each on-board battery.
Connect positive with positive and negative with
negative (ground cable) – always connect the
ground strap last and disconnect it first! A wrong
connection will cause severe damage in the elec-
tric system.

Safety regulations
BOMAG 17MPH 122-2
Starting in closed rooms
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Driving the machine
Persons in the danger area
Before taking up work, also after breaks, you
should always convince yourself that the danger
zone is free of persons or obstructions, especially
when driving in reverse.
Give warning signals, if necessary. Stop work im-
mediately if persons 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
In events of emergency and in case of danger ac-
tuate one of the emergency stop buttons immedi-
ately. Do not use the emergency stop switch as
service brake. Restart the machine only after the
danger that caused the actuation of the emergen-
cy stop switch has been eliminated.
If the machine has contacted high-voltage power
lines:
ldo not leave the operator’s stand
lwarn others from coming close to or touching
the machine
lif possible drive the machine out of the danger
zone
lhave the power switched off
Operate the machine only from the operator’s
stand.
Keep the cabin doors closed.
Do not adjust the driver’s seat while driving.
Do not climb onto or off the machine while the ma-
chine is driving.
Do not use the machine to transport persons.
Do not make any major steering movements at in-
appropriate speed.
In case of unusual noises and development of
smoke perform trouble shooting and have the fault
corrected.
Driving on inclinations and slopes
Do not drive on gradients exceeding the maximum
gradability of the machine.
On slopes drive extremely careful and always di-
rectly up or down the slope. Change to a lower
gear before starting to drive.
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations
and slopes. Higher risk of accident!
Behaviour in traffic
Match the speed to the working conditions.
Always give way to loaded transport vehicles.
Switch the lights on if the visibility is poor.
Keep away from edges and embankments.
Always comply with the applicable highway code
when driving on public roads.
Work
When milling road covering layers harmful dusts
may be released.
In order to avoid any damage to health the ma-
chine operator and other persons, who have to
work in the immediate vicinity of the milling ma-
chine, should wear breathing masks (half mask
with exhalation valve or respirator) to reduce the
dust particles, when a development of dust is no-
ticed.
Contaminated parts of the body should be thor-
oughly washed before breaks and at the end of
work.
After work the dust covered working clothes
should be replaced by normal clothes.
Working clothes and respiratory equipment should
not be stored together with normal clothes. Dust
covered working clothes must be cleaned at regu-
lar intervals.
Make sure that persons keep a sufficient safety
distance (approx. 2 m) to the working range of the
rotor.
Parking the machine
Park the machine on level, firm ground.
Before leaving the machine:
lreturn the control lever to neutral position
lapply the parking brake
llower the rotor to the ground

Safety regulations
BOMAG18 MPH 122-2
lshut down the engine, pull off the ignition key
llock the cabin
lswitch the main battery switch to position "0"
and pull it out.
Do not jump off the machine, but use hand grips
and access steps.
Mark machines, which could be in the way, with a
clearly visible sign.
Parking on slopes and inclinations
Apply suitable measures to block the machine
against rolling away.
Always lower the rotor to the ground.
Refuelling
Do not inhale any fuel fumes.
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Monitor the entire refuelling process.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Wipe off spilled fuel.
Keep dirt and water away from the fuel.
A leaking fuel tank can cause an explosion. En-
sure tight fit of the fuel tank cover, if necessary re-
place immediately.
Fire protection measures
Familiarise yourself with the location and the oper-
ation of fire fighting equipment. Observe all fire re-
porting and fire fighting possibilities.
Working with hot bitumen
Do not exceed store temperatures of 200 °C. Dan-
ger of fire and explosion!
Prevent water from seeping into the storage tanks.
Storage tanks may foam over.
Do not inhale bitumen vapours.
Wear hard hat with neck protection and visor.
Wear heat resistant gloves with arms covering the
cuffs
Wear safety shoes and overalls with trouser legs
covering the shoes.
Use only heat resistant hoses without twisting,
buckling or damage.
In case of fire call fire fighters immediately! Switch
off heating, pumps etc. If possible close valves to
prevent the fire from spreading. Fight the fire with
powder extinguishers, foam, CO2-extinguishers or
water mist. Do not use a water jet!
Maintenance work
Maintenance work must only be performed by
qualified and authorized persons.
Comply with the maintenance work described in
the operating and maintenance instructions, in-
cluding the specified replacement of parts.
For overhead maintenance and assembly work
use the access steps and working platforms pro-
vided or other secure means. Do not use machine
parts as access steps.
Keep unauthorized persons away from the ma-
chine.
Do not perform maintenance work while the ma-
chine is driving or the engine is running.
Park the machine on level, firm ground.
Pull the key out of the ignition switch.
pull the key off the main battery switch.
Secure the articulated joint with the articulation
lock.
When changing tires comply with all safety regula-
tions concerning the lifting of loads.
Tilting the cabin
Tilted cabins should always be secured with the
support bar, pin and spring clip.
Work on hydraulic lines
Relieve hydraulic pressures before working on hy-
draulic lines. Hydraulic oil escaping under pres-
sure can penetrate the skin and cause severe
injury. When being injured by hydraulic oil consult
a medical doctor immediately, as otherwise this
may cause severe infections.
Do not step in front of or behind the rubber wheels
when performing adjustment work in the hydraulic
system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature –
danger of scalding!

Safety regulations
BOMAG 19MPH 122-2
Any hydraulic oil must be caught and disposed of
in an environmentally friendly manner.
Always catch and dispose of hydraulic oils sepa-
rately.
Do not start the engine after draining the hydraulic
oil.
Once all work is completed (with the system still
depressurized!) check all connections and fittings
for leaks.
Wear protective clothing.
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at reg-
ular intervals.
Hydraulic hoses must be immediately replaced if:
lthe outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks),
lthe outer layer is brittle (formation of cracks in
the hose material)
lthe hose shows deformations in pressurized
and depressurized condition, which do not
comply with the genuine shape of the hydrau-
lic hose
lthe hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, forma-
tion of blisters,
lparts of the hose are leaking.
lhoses are not correctly installed,
lthe hydraulic hose has separated from the fit-
ting
lthe fitting shows corrosion that impairs both
function and strength.
lfittings are damaged or deformed, whereby
the function and strength of the hose - hose
connection is impaired
Only genuine BOMAG replacement hydraulic hos-
es ensure that the correct hose type (pressure
range) is used at the right location.
lhoses are mixed up by mistake.
Working on the engine
Shut the engine down before opening the service
doors.
Do not work on the fuel system while the engine is
running – danger to life due to high pressures!
lWait approx. 5 minutes after the engine has
stopped.
lKeep out of the danger zone during the initial
test rung.
lIn case of leaks return to the workshop imme-
diately.
lMake sure that the engine cannot be started
unintentionally during service and repair work.
Drain the engine oil at operating temperature –
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oil contaminated ma-
terials in a separate, specially marked container
and dispose of environmentally.
Do not leave any tools or other objects, that could
cause damage, in the engine compartment.
Check and change coolant only when the engine
is cold.
Catch coolant and dispose of environmentally.
Working on electric parts of the machine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire haz-
ard!
Working on the battery
When working on the battery do not smoke, do not
use open fire!
Do not let acid come in contact with hands or
clothes! When injured by acid flush off with clear
water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must
not come in contact with the battery poles – dan-
ger of short circuit and burning!
When recharging non-serviceable batteries re-
move all plugs, to avoid the accumulation of explo-
sive gases.
Observe the applicable instructions when starting
with an auxiliary battery.
Dispose of old batteries according to regulations.
Switch off the charging current before removing
the charging clamps.

Safety regulations
BOMAG20 MPH 122-2
Ensure sufficient ventilation, especially if the bat-
tery is to be charged in a closed room.
Working on the fuel system
Avoid open fire, do not smoke, do not spill any fuel.
Do not inhale any fuel fumes.
Catch running out fuel, do not let it seep into the
ground and dispose off environmentally.
Working on the rotor
Open the hood gate completely and secure it with
bolt and spring clip.
Do not prop the rotor hood with any means – dan-
ger to life!
For maintenance work on rotor and rotor hood, the
rotor hood must always be secured on both sides
with hood securing bolts.
Wear goggles and gloves to change the cutting
teeth, since hard metal chips may splinter off when
knocking the teeth in or out.
Working on the air conditioning
Faults on the air conditioning should only be rem-
edied by professional personnel.
According to the regulation for pressure reservoirs
all pressure reservoirs must be repeatedly inspect-
ed by a specialist.
In connection with this inspection the drier/collec-
tor unit must be visually examined twice every
year. During these inspections special attention
must be paid to corrosion and mechanical dam-
age.
Do not perform welding work in the vicinity of the
air conditioning. Danger of explosion!
Do not clean the condenser in the air conditioning
system with a hot water jet. Danger of explosion!
Do not release refrigerant into the atmosphere, but
dispose of environmentally.
Cleaning work
Do not perform cleaning work while the motor is
running.
Do not use gasoline or other easily inflammable
substances for cleaning.
When cleaning with steam cleaning equipment do
not subject electrical parts and insulation material
to the direct jet of water, or cover it beforehand.
Do not guide the water jet into the exhaust and into
the air filter.
When working with asphalt, bitumen or lime clean
engine and hydraulic oil coolers at regular inter-
vals.
After maintenance work
After all maintenance work is completed reinstall
all guards and safety installations.
Repair
Mark a defective machine by attaching a warning
tag to the steering wheel.
Repair work must only be performed by qualified
and authorized persons. Use our repair instruc-
tions for this work.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Do not work on the fuel system while the engine is
running - danger to life!
The system is under high pressure! Keep away
from leakages in the high pressure system, be-
cause fuel squirting out may cause severe injury.
After shutting down the engine wait for another
minute, until the pressure has dropped to a per-
missible level. In case of leakages you should con-
tact the Service Department of the engine
manufacturer and refrain from starting the engine.
Always remove the main battery switch before
starting welding work on the machine. Disconnect
the batteries and connect negative and positive
cables. Pull the plugs of ESX-control and Dios-
module (water injection).
Information and safety stickers/decals
on the machine
Keep stickers/decals in good and legible condition
(see spare parts catalogue) and comply with their
meaning.
Replace damaged and illegible stickers/decals im-
mediately.