Fayat BOMAG BW 124 PDH-5 Instructions for use

BW 124 PDH-5
Single drum roller
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 586 85 1001>
© 01/2019008 202 90 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.
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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.............................................................. 16
2.1.1 Noise data................................................................................... 17
2.1.2 Vibration data.............................................................................. 17
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
3.2 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..................................................... 30
3.4.1 Preliminary remarks.................................................................... 30
3.4.2 Safety regulations and environmental protection regulations for
handling diesel fuel...................................................................... 31
3.4.3 Safety regulations and environmental protection regulations for
handling oil.................................................................................. 33
3.4.4 Safety regulations and environmental protection regulations for
handling hydraulic oil................................................................... 35
3.4.5 Safety regulations and environmental protection regulations for
handling coolants........................................................................ 37
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3.4.6 Safety regulations and environmental protection regulations for
handling battery acid................................................................... 39
3.5 Load/transport the machine........................................................ 41
3.6 Starting up the machine.............................................................. 43
3.6.1 Prior to start-up............................................................................ 43
3.6.2 Starting the engine...................................................................... 44
3.6.3 Starting the engine with jump leads............................................ 44
3.7 Driving the machine; working operation.................................... 46
3.7.1 Driving the machine..................................................................... 46
3.7.2 Driving up and down slopes........................................................ 47
3.7.3 Cross slope................................................................................. 47
3.7.4 Working with vibration................................................................. 48
3.7.5 Parking the machine.................................................................... 48
3.8 Refuelling...................................................................................... 49
3.9 Regeneration of exhaust gas aftertreatment system................ 50
3.10 Emergency procedures............................................................. 51
3.10.1 Actuating the emergency stop switch........................................ 51
3.10.2 Disconnecting the battery.......................................................... 51
3.10.3 Towing the machine................................................................... 51
3.11 Maintenance work...................................................................... 53
3.11.1 Preliminary remarks................................................................... 53
3.11.2 Working on hydraulic lines......................................................... 53
3.11.3 Working on the engine............................................................... 54
3.11.4 Maintenance work on electric components and battery............ 55
3.11.5 Working on wheels and tyres..................................................... 55
3.11.6 Cleaning work............................................................................ 56
3.11.7 After maintenance work............................................................. 56
3.12 Repair.......................................................................................... 57
3.13 Signage....................................................................................... 58
3.14 Danger zones.............................................................................. 66
3.15 Safety Components.................................................................... 67
4 Indicators and control elements........................................................ 69
4.1 Driver’s stand............................................................................... 70
4.1.1 Instrument cluster........................................................................ 70
4.1.2 Operating console....................................................................... 73
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4.1.3 Travel lever.................................................................................. 77
4.1.4 Travel lever with dozer blade control........................................... 78
4.1.5 Main battery switch...................................................................... 79
4.1.6 12 V DIN socket.......................................................................... 80
4.1.7 ECONOMIZER display................................................................ 80
4.1.8 Rotary switch ECONOMIZER..................................................... 80
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.................................... 87
5.4.1 Checking the fuel level................................................................ 87
5.4.2 Refuelling.................................................................................... 87
5.5 Checking the hydraulic oil level.................................................. 89
5.6 Checking the coolant level.......................................................... 91
5.7 Checking wheels and tyres......................................................... 93
6 Operation.............................................................................................. 95
6.1 Setting up the work place............................................................ 96
6.1.1 Adjust the driver’s seat................................................................ 96
6.2 Starting the engine....................................................................... 97
6.3 Travel operation.......................................................................... 100
6.3.1 Preliminary remarks and safety notes....................................... 100
6.3.2 Driving the machine................................................................... 101
6.4 Working with vibration............................................................... 103
6.4.1 Preliminary remarks and safety notes....................................... 103
6.4.2 Switching the vibration on and off............................................. 104
6.5 ECONOMIZER............................................................................. 105
6.6 Parking the machine in secured condition.............................. 106
6.7 Regeneration of exhaust gas aftertreatment system.............. 107
6.7.1 Preliminary remarks and safety notes....................................... 107
6.7.2 Suppressing regeneration......................................................... 109
6.7.3 Running regeneration at standstill............................................. 110
6.8 Emergency procedures.............................................................. 112
6.8.1 Actuating the emergency stop switch........................................ 112
6.8.2 Disconnecting the battery.......................................................... 112
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6.8.3 Towing the machine................................................................... 112
6.8.4 After towing................................................................................ 114
7 Loading / transporting the machine................................................. 119
7.1 Preparation for transport........................................................... 120
7.2 Loading the machine................................................................. 121
7.3 Lashing the machine to the transport vehicle......................... 123
7.4 Loading by crane........................................................................ 124
7.5 After transport............................................................................ 126
8 Maintenance....................................................................................... 127
8.1 Preliminary remarks and safety notes..................................... 128
8.2 Preparations/concluding work.................................................. 130
8.2.1 Opening/closing the engine hood.............................................. 130
8.2.2 Articulation lock......................................................................... 130
8.2.3 Side engine covers.................................................................... 132
8.3 Fuels and lubricants.................................................................. 133
8.3.1 Engine oil................................................................................... 133
8.3.2 Fuel........................................................................................... 134
8.3.3 Coolant...................................................................................... 135
8.3.4 Hydraulic oil............................................................................... 137
8.3.5 Gear oil SAE 80W-140.............................................................. 138
8.4 List of fuels and lubricants........................................................ 139
8.5 Running-in instructions............................................................. 141
8.5.1 General...................................................................................... 141
8.5.2 After 50 operating hours............................................................ 141
8.5.3 After 250 operating hours.......................................................... 141
8.5.4 After 500 operating hours.......................................................... 142
8.5.5 After 1000 operating hours........................................................ 142
8.6 Maintenance Table..................................................................... 143
8.7 Every 50 operating hours.......................................................... 145
8.7.1 Checking radiator hoses and hose clamps............................... 145
8.8 Every 250 operating hours........................................................ 146
8.8.1 Check the air intake lines.......................................................... 146
8.8.2 Checking radiator hoses and hose clamps............................... 146
8.8.3 Checking, tensioning the V-belt................................................. 147
8.8.4 Cleaning the radiator module.................................................... 148
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8.8.5 Checking the oil level in the drive axle...................................... 149
8.8.6 Check the oil level in the bevel gear housing............................ 150
8.8.7 Checking the oil level in the wheel hubs................................... 151
8.8.8 Checking the oil level in the drum drive reduction gear............. 151
8.8.9 Check the parking brake........................................................... 152
8.9 Every 500 operating hours........................................................ 153
8.9.1 Change engine oil and oil filter cartridge................................... 153
8.9.2 Replacing the fuel filter, bleeding the fuel system..................... 155
8.9.3 Replacing the V-belt.................................................................. 158
8.9.4 Checking the anti-freeze concentration and the condition of the
coolant....................................................................................... 159
8.9.5 Checking the hydraulic lines...................................................... 159
8.9.6 Servicing the battery, checking the main battery shutoff........... 161
8.10 Every 1000 operating hours.................................................... 163
8.10.1 Adjusting the valve clearance.................................................. 163
8.10.2 Checking the lines on the diesel engine.................................. 165
8.10.3 Checking the exhaust manifold............................................... 166
8.10.4 Checking the engine mounts................................................... 166
8.10.5 Replacing the hydraulic oil filter............................................... 166
8.10.6 Change the oil in the drive axle............................................... 169
8.10.7 Changing the oil in the bevel gear housing............................. 171
8.10.8 Changing the oil in the wheel hubs......................................... 172
8.10.9 Change the oil in the drum drive reduction gear..................... 173
8.10.10 Retightening the fastening of the axle on the frame.............. 175
8.10.11 Retightening the wheel nuts.................................................. 175
8.10.12 Checking the ROPS.............................................................. 175
8.10.13 Checking the travel lever control........................................... 176
8.11 Every 2000 operating hours.................................................... 177
8.11.1 Changing the hydraulic oil....................................................... 177
8.11.2 Changing the coolant............................................................... 180
8.11.3 Replacing the oil separator element........................................ 183
8.11.4 Checking the exhaust gas recirculation cooler........................ 183
8.11.5 Replacing hoses...................................................................... 183
8.12 Every 3000 operating hours.................................................... 184
8.12.1 Checking the turbo charger..................................................... 184
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8.12.2 Cleaning the DPF.................................................................... 184
8.12.3 Checking the exhaust gas recirculation system...................... 184
8.13 As required............................................................................... 185
8.13.1 Air filter maintenance............................................................... 185
8.13.2 Checking and cleaning the water separator............................ 188
8.13.3 Adjusting the scrapers............................................................. 189
8.13.4 Cleaning the machine.............................................................. 190
8.13.5 Draining the fuel tank sludge................................................... 191
8.13.6 Measures prior to extended shutdown period......................... 191
9 Troubleshooting................................................................................ 195
9.1 Preliminary remarks................................................................... 196
9.2 Starting the engine with jump leads......................................... 197
9.3 Fuse assignment........................................................................ 198
9.3.1 Notes on safety......................................................................... 198
9.3.2 Central electrics......................................................................... 198
9.3.3 Main fuse................................................................................... 199
9.4 Engine faults............................................................................... 200
9.5 Trouble shooting ECONOMIZER............................................... 203
10 Disposal.............................................................................................. 205
10.1 Final shut-down of machine.................................................... 206
11 List of special tools........................................................................... 207
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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 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 69.
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 95.
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 127.
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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Fig. 3
A B D H H2K L O1/2 S W
1815
(71)
1310
(52)
960
(37.8)
1850
(73)
2520
(99)
320
(12.6)
3520
(139)
55
(2.2)
15
(0.59)
1200
(47)
Dimensions in millimetres
(Dimensions in inch)
Weights
Max. operating weight 4000
(8818)
kg
(lbs)
Operating weight (CECE) 3390
(7474)
kg
(lbs)
Axle load, drum (CECE) 1660
(3660)
kg
(lbs)
Axle load, wheels (CECE) 1730
(3814)
kg
(lbs)
Dimensions
Technical data
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Travel characteristics
Travel speed 0 - 9
(0 - 5.5)
km/h
(mph)
Max. gradeability without/with vibration (soil
dependent)
55/55 %
Drive
Engine manufacturer Kubota
Type V2403-CR-E4
Cooling system Water
Number of cylinders 4
Rated power ISO 3046 34 kW
Rated power SAE J 1995 46 hp
Nominal speed 2400 min-1
Electric system
Voltage 12 V
Tyres
Tyre size 9.5-24/4PR
Air pressure, nominal value 1.8
(26)
bar
(psi)
Air pressure, range 0.8 - 1.8
(12 - 26)
bar
(psi)
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Technical data
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Steering
Type of steering Oscill.-articul.
Steering angle +/- 35 °
Oscillation angle +/- 12 °
Inner track radius 2260
(89)
mm
(in)
Exciter system
Drive system hydrostatic
Frequency 41
(2460)
Hz
(vpm)
Amplitude (1/2) 1.60/0.80
(0.063/0.031)
mm
(in)
Centrifugal force (1/2) 85/43
(16861/9217)
kN
(lbf)
Filling capacities
Fuel (diesel) 60
(16)
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.
Technical data – Noise and vibration data
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2.1.1 Noise data
LpA = 87 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
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 at
the operator'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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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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