Fayat BOMAG BW 120 AD-5 User manual

BW 120 AD-5
Tandem vibratory roller
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 961 880 42 2507>
© 05/2020008 202 53 EN

terminals, tank trucks and other facilities and equipment.
plants, transport and storage operations such as pipelines, marine
For more information go to www.P65Warnings.ca.gov/petroleum.
These exposures can occur in and around oil fields, refineries, chemical
WARNING: Crude oil, gasoline, diesel fuel and other petroleum
products can expose you to chemicals including toluene and benzene,
which are known to the State of California to cause cancer and birth
defects or other reproductive harm.
WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
2

Table of contents
1 Introduction............................................................................................ 9
1.1 Foreword....................................................................................... 10
1.2 Machine type plate and engine type plate................................. 12
2 Technical data...................................................................................... 13
2.1 Noise and vibration data.............................................................. 17
2.1.1 Noise data................................................................................... 17
2.1.2 Vibration data.............................................................................. 18
3 Concerning your safety...................................................................... 19
3.1 Basic prerequisites...................................................................... 20
3.1.1 General........................................................................................ 20
3.1.2 Explanation of signal words used:............................................... 21
3.1.3 Personal protective equipment.................................................... 22
3.1.4 Intended use................................................................................ 23
3.1.5 Improper use............................................................................... 23
3.1.6 Estimated service life of the machine.......................................... 24
3.2 Definition of responsible persons.............................................. 25
3.2.1 Operating company..................................................................... 25
3.2.2 Expert / qualified person.............................................................. 25
3.2.3 Driver / operator.......................................................................... 26
3.3 Fundamentals for safe operation................................................ 27
3.3.1 Remaining dangers, remaining risks........................................... 27
3.3.2 Regular safety inspections.......................................................... 27
3.3.3 Modifications and alterations to the machine.............................. 27
3.3.4 Damage, defects, misuse of safety devices................................ 28
3.3.5 Roll Over Protective Structure (ROPS)....................................... 28
3.4 Handling fuels and lubricants..................................................... 29
3.4.1 Preliminary remarks.................................................................... 29
3.4.2 Safety regulations and environmental protection regulations for
handling diesel fuel...................................................................... 30
3.4.3 Safety regulations and environmental protection regulations for
handling oil.................................................................................. 32
3.4.4 Safety regulations and environmental protection regulations for
handling hydraulic oil................................................................... 33
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3.4.5 Safety regulations and environmental protection regulations for
handling coolants........................................................................ 35
3.4.6 Safety regulations and environmental protection regulations for
handling battery acid................................................................... 37
3.5 Loading/transporting the machine............................................. 39
3.6 Starting up the machine.............................................................. 41
3.6.1 Prior to commissioning................................................................ 41
3.6.2 Starting the engine...................................................................... 42
3.6.3 Starting the engine with jump leads............................................ 42
3.7 Driving the machine; working operation.................................... 44
3.7.1 Driving the machine..................................................................... 44
3.7.2 Driving up and down slopes........................................................ 45
3.7.3 Cross slope................................................................................. 45
3.7.4 Working with vibration................................................................. 46
3.7.5 Parking the machine.................................................................... 46
3.8 Refuelling...................................................................................... 47
3.9 Emergency procedures............................................................... 48
3.9.1 Actuating the emergency stop switch.......................................... 48
3.9.2 Disconnecting the battery............................................................ 48
3.9.3 Towing the machine..................................................................... 48
3.10 Maintenance work...................................................................... 50
3.10.1 Preliminary remarks.................................................................. 50
3.10.2 Working on hydraulic lines........................................................ 50
3.10.3 Working on the engine.............................................................. 51
3.10.4 Maintenance work on electric components and battery............ 52
3.10.5 Cleaning work............................................................................ 52
3.10.6 Measures for longer shut-down periods.................................... 53
3.10.7 After maintenance work............................................................. 53
3.11 Repair.......................................................................................... 54
3.12 Signage....................................................................................... 55
3.13 Danger zones.............................................................................. 63
4 Indicators and control elements........................................................ 65
4.1 Operating console........................................................................ 66
4.1.1 Rotary switch for direction indicators........................................... 67
4.1.2 Rotary switch for working lights................................................... 67
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4.1.3 Rotary switch for lighting............................................................. 67
4.1.4 Rotary switch for hazard light system.......................................... 68
4.1.5 Rotary switch for flashing beacon............................................... 68
4.1.6 Rotary switch for drum pre-selection........................................... 68
4.1.7 Rotary switch for vibration pre-selection..................................... 69
4.1.8 Emergency stop switch............................................................... 69
4.1.9 Instrument cluster........................................................................ 70
4.1.10 ECONOMIZER display.............................................................. 72
4.1.11 Rotary switch for water spraying system................................... 72
4.2 Driver’s stand............................................................................... 73
4.2.1 Starter switch............................................................................... 74
4.2.2 12 V DIN socket.......................................................................... 74
4.2.3 Travel lever.................................................................................. 75
4.2.4 Driver’s seat................................................................................ 77
4.2.5 Throttle lever............................................................................... 78
4.3 Engine compartment.................................................................... 79
4.3.1 Main battery switch...................................................................... 79
5 Checks prior to start up...................................................................... 81
5.1 Notes on safety............................................................................. 82
5.2 Visual inspections and function tests........................................ 84
5.3 Checking the engine oil level...................................................... 85
5.4 Checking the fuel level; topping up fuel.................................... 86
5.4.1 Checking the fuel level................................................................ 86
5.4.2 Refuelling.................................................................................... 86
5.5 Checking the hydraulic oil level.................................................. 88
5.6 Checking the coolant level.......................................................... 89
5.7 Checking the air filter................................................................... 90
5.8 Checking the water level, topping up......................................... 91
5.9 Checking and cleaning the scrapers.......................................... 93
5.10 Checking the hydraulic oil filter................................................ 94
6 Operation.............................................................................................. 97
6.1 Setting up the workplace............................................................. 98
6.2 Electronic immobilizer................................................................. 99
6.3 Starting the engine..................................................................... 100
6.4 Travel mode................................................................................ 103
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6.4.1 Preliminary remarks and safety notes....................................... 103
6.4.2 Driving the machine................................................................... 104
6.4.3 Stopping the machine, applying the parking brake................... 104
6.5 Driving the machine in public traffic........................................ 105
6.6 Working with vibration............................................................... 107
6.6.1 Preliminary remarks and safety notes....................................... 107
6.6.2 Preparing to work with vibration................................................ 108
6.6.3 Manual vibration........................................................................ 108
6.6.4 Vibration in automatic mode...................................................... 109
6.6.5 Stop working with vibration........................................................ 110
6.6.6 ECONOMIZER.......................................................................... 110
6.7 Water spraying system.............................................................. 113
6.8 Parking the machine in secured condition.............................. 114
6.9 Emergency procedures.............................................................. 116
6.9.1 Actuating the emergency stop switch........................................ 116
6.9.2 Disconnecting the battery.......................................................... 116
6.9.3 Towing the machine................................................................... 116
6.9.4 After towing................................................................................ 119
7 Loading / transporting the machine................................................ 123
7.1 Preparation for transport........................................................... 124
7.2 Loading the machine................................................................. 125
7.3 Lashing the machine to the transport vehicle......................... 126
7.4 Loading by crane........................................................................ 127
7.5 After transportation.................................................................... 129
7.6 Folding down and erecting the foldable ROPS....................... 130
7.6.1 Folding down the foldable ROPS.............................................. 130
7.6.2 Erecting the foldable ROPS...................................................... 130
8 Maintenance....................................................................................... 133
8.1 Preliminary remarks and safety notes..................................... 134
8.2 Preparations/concluding work.................................................. 136
8.2.1 Engine hood.............................................................................. 136
8.2.2 Articulation lock......................................................................... 137
8.3 Fuels and lubricants.................................................................. 139
8.3.1 Engine oil................................................................................... 139
8.3.2 Fuel........................................................................................... 140
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8.3.3 Coolant...................................................................................... 142
8.3.4 Hydraulic oil............................................................................... 143
8.4 List of fuels and lubricants........................................................ 144
8.5 Running-in instructions............................................................. 145
8.5.1 General...................................................................................... 145
8.5.2 After 50 operating hours............................................................ 145
8.6 Maintenance Table..................................................................... 146
8.7 Every 50 operating hours.......................................................... 148
8.7.1 Checking radiator hoses and hose clamps............................... 148
8.7.2 Checking and cleaning the water separator.............................. 148
8.8 Every 250 operating hours........................................................ 150
8.8.1 Change engine oil and oil filter cartridge................................... 150
8.8.2 Checking, tensioning the V-belt................................................. 151
8.8.3 Check the air intake lines.......................................................... 152
8.8.4 Checking radiator hoses and hose clamps............................... 153
8.8.5 Cleaning the radiator module.................................................... 153
8.8.6 Battery service........................................................................... 155
8.8.7 Check the parking brake........................................................... 156
8.9 Every 500 operating hours........................................................ 157
8.9.1 Replacing the fuel filter.............................................................. 157
8.9.2 Replacing the V-belt.................................................................. 158
8.9.3 Checking the anti-freeze concentration and the condition of the
coolant....................................................................................... 159
8.9.4 Checking the hydraulic lines...................................................... 160
8.10 Every 1000 operating hours.................................................... 161
8.10.1 Checking, adjusting the valve clearance................................. 161
8.10.2 Checking the engine mounts................................................... 163
8.10.3 Checking the ROPS................................................................ 163
8.10.4 Checking the travel lever control............................................. 164
8.10.5 Replacing the hydraulic oil filter............................................... 164
8.11 Every 2000 operating hours.................................................... 168
8.11.1 Changing the hydraulic oil....................................................... 168
8.11.2 Changing the coolant............................................................... 171
8.11.3 Replacing hoses...................................................................... 173
8.11.4 Check the injection valves....................................................... 174
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8.12 Every 3000 operating hours.................................................... 175
8.12.1 Checking the fuel injection pump............................................ 175
8.13 As required............................................................................... 176
8.13.1 Air filter maintenance............................................................... 176
8.13.2 Checking the water spraying system....................................... 180
8.13.3 Cleaning the water spraying system....................................... 183
8.13.4 Measures if there is a risk of frost........................................... 185
8.13.5 Draining the fuel tank sludge................................................... 186
8.13.6 Measures prior to extended shut-down period........................ 187
9 Setting up / refitting........................................................................... 191
9.1 Manually adjusting the crabwalk.............................................. 192
10 Troubleshooting................................................................................ 195
10.1 Preliminary remarks................................................................. 196
10.2 Starting the engine with jump leads....................................... 197
10.3 Fuse assignment...................................................................... 198
10.3.1 Notes on safety....................................................................... 198
10.3.2 Fuses in engine compartment................................................. 198
10.3.3 Central electrics....................................................................... 199
10.4 Engine faults............................................................................. 201
10.5 Trouble shooting ECONOMIZER............................................. 204
11 Disposal.............................................................................................. 207
11.1 Final shut-down of machine.................................................... 208
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1 Introduction
Introduction
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9

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 impor-
tant components and highest quality
demands guarantee maximum reliability of
your machine.
These operating and maintenance instructions
are part of your machine.
They provide necessary information to operate
your machine safely and properly.
They also contain information on required oper-
ating, maintenance and repair measures.
Carefully read the operating and maintenance
instructions before taking your machine into
operation.
Please observe the safety regulations strictly
and follow all instructions to ensure safe opera-
tion.
If you are not yet acquainted with the controls
and indicating elements on this machine, you
should thoroughly read the corresponding
chapter
Ä Chapter 4 ‘Indicators and control
elements’ on page 65.
The description of the individual operating
steps including the notes on safety to be fol-
lowed can be found in chapter “Operation”
Ä Chapter 6 ‘Operation’ on page 97.
Before every start up, carry out all required
visual inspections and function tests
Ä Chapter
5 ‘Checks prior to start up’ on page 81.
Ensure the compliance with the specified oper-
ating, maintenance and repair measures to
maintain the functional safety of your machine.
Introduction – Foreword
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A description of all necessary maintenance
work, maintenance intervals as well as informa-
tion on fuels and lubricants can be found in the
chapter “Maintenance”
Ä Chapter 8 ‘Mainte-
nance’ on page 133.
Do not service or repair your machine by your-
self to avoid harming persons or damaging
material or environment.
The machine must only be serviced and
repaired by qualified and authorized personnel.
Contact our Customer Service to carry out the
required maintenance work or necessary
repairs.
In case of operating errors, inadequate mainte-
nance or the use of unapproved fuels and lubri-
cants all warranty claims will become null and
void.
For your own personal safety you should only
use original parts from BOMAG.
For your machine we offer service kits to make
maintenance easier.
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 (Fig. 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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B-880-0001
Fig. 3
ABCDHH2
1752
(69)
1272
(50)
523
(20.6)
700
(27.6)
1808
(71)
2568
(101)
Dimensions in millimetres
(Dimensions in inches)
K L O S W
254
(10.0)
2529
(100)
36
(1.4)
13
(0.5)
1200
(47)
Dimensions in millimetres
(Dimensions in inches)
Height with protective roof and flashing beacon
(optional equipment)
2890
(114)
mm
(in)
Dimensions
Technical data
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Weights
Max. operating weight 3650
(8047)
kg
(lbs)
Operating weight with ROPS (CECE) 2700
(5953)
kg
(lbs)
Average static linear load (CECE) 11.3
(63)
kg/cm
(pli)
Travel characteristics
Travel speed 0 - 10
(0 - 6.2)
km/h
(mph)
Working speed with vibration 0 - 10
(0 - 6.2)
km/h
(mph)
Max. gradeability without/with vibration (soil
and weather dependent)
40/30 %
Drive
Engine manufacturer Kubota
Type D 1703-M-E3B
Cooling system Water
Number of cylinders 3
Rated power ISO 14396 24.3 kW
Rated power SAE J 1995 32.6 hp
Rated speed 2600 min-1
Fixed engine speed (1) 2500 min-1
Fixed engine speed (2) 2600 min-1
Driven drum front + rear
Technical data
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Electric system
Voltage 12 V
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering angle +/- 32 °
Oscillation angle +/- 10 °
Inner track radius 2450
(97)
mm
(in)
Crabwalk, lateral offsetting of drum right/left 50
(2.0)
mm
(in)
Exciter system
Vibrating drum front + rear
Frequency (1/2) 63/67
(3780/4020)
Hz
(vpm)
Amplitude 0.5
(0.02)
mm
(in)
Centrifugal force (1/2) 36/41
(8093/9217)
kN
(lbf)
Technical data
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Filling capacities
Fuel (diesel) 35
(9.2)
l
(gal us)
Water 205
(54)
l
(gal us)
2.1 Noise and vibration data
The following noise and vibration data were
determined in accordance with the following
guidelines under equipment specific conditions
and by using harmonized standards:
nEU Machine Directive edition 2006/42/EU
nNoise Emission Directive 2000/14/EU, Noise
Protection Directive 2003/10/EU
nVibration Protection Directive 2002/44/EU
During operation these values may vary
because of the prevailing operating conditions.
2.1.1 Noise data
LpA = 84 dB(A), determined acc. to ISO 11201
and EN 500.
WARNING!
Loss of hearing caused by too
high noise burdens!
– Wear your personal protective
equipment (ear protection).
LWA = 106 dB(A), determined acc. to ISO 3744
and EN 500
Sound pressure level at
the operator's stand
Guaranteed sound
power level
Technical data – Noise and vibration data
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2.1.2 Vibration data
The weighted effective acceleration value
determined according to ISO 2631 is ≤ 0.5
m/s2.
The weighted effective acceleration value
determined according to ISO 5349 is ≤ 2.5
m/s2.
Vibration of the entire
body (driver’s seat)
Hand-arm vibration
Technical data – Noise and vibration data
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3 Concerning your safety
Concerning your safety
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3.1 Basic prerequisites
3.1.1 General
This 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 unprofes-
sional way,
nthe 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 regula-
tions. If necessary, the operating company
must obtain the relevant signatures as confir-
mation.
Furthermore, the following obviously also
applies:
napplicable accident prevention instructions,
ngenerally accepted safety and road traffic
regulations,
ncountry/state specific safety regulations.
It is the duty of the operator to be acquainted
with the safety regulations and to apply these
accordingly. This also applies for local regula-
tions and regulations concerning different types
of handling activities. Should the recommenda-
tions in these instructions be different from the
regulations valid in your country, you must
comply with the safety regulations valid in your
country.
Concerning your safety – Basic prerequisites
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