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Fayat BOMAG BW 124 PDH-5, Operating Instruction, Maintenance Instruction

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Fayat BOMAG BW 124 PDH-5 Operating Instruction, Maintenance Instruction Download Page 196

9.1 

Preliminary remarks

Malfunctions are frequently caused by incorrect

operation of the machine or insufficient mainte-

nance. Whenever a fault occurs you should

therefore thoroughly read these instructions on

correct operation and maintenance.
If you cannot locate the cause of a fault or rec-

tify it yourself by following the trouble shooting

chart, you should contact our customer service

department.

Troubleshooting – Preliminary remarks

 

BW 124 PDH-5

 

196

Summary of Contents for BOMAG BW 124 PDH-5

Page 1: ...BW 124 PDH 5 Single drum roller Operating Instruction Maintenance Instruction Original Operating Instructions S N 101 586 85 1001 01 2019 008 202 90 EN ...

Page 2: ...uding 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 ou...

Page 3: ...ndamentals 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 hand...

Page 4: ...n 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 tyr...

Page 5: ... 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...

Page 6: ... 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 ...

Page 7: ...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 ...

Page 8: ... 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...

Page 9: ...1 Introduction Introduction BW 124 PDH 5 9 ...

Page 10: ...enance 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 operati...

Page 11: ...ved 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...

Page 12: ...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 BW 124 PDH 5 12 ...

Page 13: ...2 Technical data Technical data BW 124 PDH 5 13 ...

Page 14: ... 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 BW 124 PDH 5 14 ...

Page 15: ...R 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 BW 124 PDH 5 15 ...

Page 16: ...al 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 n EU Machine Directive edition 2006 42 EU n Noise Emission Directive 2000 14 EU Noise Protection Directive 2003 10 EU n Vibration Protection Directive 2002 44 EU During operation these values may ...

Page 17: ...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 BW...

Page 18: ...Technical data Noise and vibration data BW 124 PDH 5 18 ...

Page 19: ...3 Concerning your safety Concerning your safety BW 124 PDH 5 19 ...

Page 20: ...ly with these safety regula tions If necessary the operating company must obtain the relevant signatures as confir mation Furthermore the following obviously also applies n applicable accident prevention instructions n generally accepted safety and road traffic regulations n country state specific safety regulations It is the duty of the operator to be acquainted with the safety regulations and to...

Page 21: ...tions marked accordingly indi cate a dangerous situation that could lead to fatal or severe injuries if this warning is disregarded CAUTION Danger of injury if failing to comply Sections marked accordingly indi cate a dangerous situation that could lead to fatal or severe injuries if this warning is disregarded NOTICE Danger of material damage if failing to comply Sections marked accordingly indi ...

Page 22: ...quip ment is required to be provided by the operating company Working clothes Tight fitting working clothes with low tear resistance tight sleeves and without any projecting parts protect against being caught by moving components Safety shoes To protect against heavy falling parts and slipping on slippery ground Protective gloves To protect the hands against excoria tion punctures or deep injuries...

Page 23: ...ine must only be used for n Compaction work in earth construction and road bases n Compaction of bituminous material e g road surface layers Intended use also includes compliance with the specified operating maintenance and repair measures 3 1 5 Improper use Dangers may arise with the machine if it is used other than for its intended purpose Any danger caused by improper use is the sole responsibi...

Page 24: ...il or inad equate contact areas danger of tilting n Using the machine for towing n Using to pull down walls or demolish build ings Transporting persons except the machine driver is prohibited Starting and operating the machine in explo sive environments and in underground mining is prohibited Concerning your safety Basic prerequisites BW 124 PDH 5 24 ...

Page 25: ...ut any remaining dangers The operating company must determine whether there are special operational hazards such as a toxic atmosphere or limiting soil con ditions Such conditions require special addi tional measures to remove or reduce the hazard The operating company must make sure that all users read and understand the information concerning safety The operating company is responsible for the p...

Page 26: ...ny aged 18 or more Observe your local laws and regulations Rights obligations and rules of conduct for driver or operator The driver or operator must n be instructed about his rights and obliga tions n wear protective equipment as appropriate for the application n have read and understood the operating instructions n have made himself familiar with the opera tion of the machine n be physically and...

Page 27: ...e actual danger zone of the machine Persons remaining in this area must pay partic ular attention to the machine so that they can react immediately in case of a possible mal function an incident or failure etc All persons remaining in the area of the machine must be informed about the dangers that arise from the operation of the machine 3 3 2 Regular safety inspections Have the machine inspected b...

Page 28: ...nor must they be made ineffective 3 3 5 Roll Over Protective Structure ROPS On machines with cab the ROPS is an integral part of the cab The frame of the machine must not be warped bent or cracked in the area of the ROPS fas tening The ROPS must not show any rust damage hairline cracks or open fractures The real machine weight must never exceed the testing weight for the ROPS No accessories may be...

Page 29: ...A defect ROPS must generally be replaced with an original spare part in close coordination with the manufacturer Concerning your safety Fundamentals for safe operation BW 124 PDH 5 29 ...

Page 30: ...ame of substance n possible dangers n composition information on constituents n first aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitation and monitoring of exposure per sonal protective equipment n physical and chemical properties n stability and reactivity n toxicological data n environmental data n notes on waste disposal n informati...

Page 31: ...d Wear your personal protective equipment protective gloves protective clothing CAUTION Health hazard caused by contact with diesel fuel Wear your personal protective equipment protective gloves protective clothing Do not inhale any fuel fumes Avoid contact CAUTION Danger of slipping on spilled diesel fuel Immediately bind spilled diesel fuel with an oil binding agent Fig 4 Concerning your safety ...

Page 32: ... Always keep diesel fuel in proper containers Immediately bind spilled diesel fuel with an oil binding agent and dispose of properly Dispose of diesel fuel and fuel fil ters according to regulations Concerning your safety Handling fuels and lubricants BW 124 PDH 5 32 ...

Page 33: ...tective clothing CAUTION Health hazard caused by contact with oil Wear your personal protective equipment protective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil Immediately bind spilled oil with an oil binding agent ENVIRONMENT Oil is an environmentally haz ardous substance Always keep oil in proper con tainers Continued on the n...

Page 34: ... Immediately bind spilled oil with an oil binding agent Dispose of oil and oil filter according to regulations Concerning your safety Handling fuels and lubricants BW 124 PDH 5 34 ...

Page 35: ...nal protective equipment protective gloves protective clothing goggles Should pressure fluid penetrate the skin immediate medical help is required WARNING Danger of burning by ignited hydraulic oil Do not allow hydraulic oil to come into contact with hot com ponents Smoking and open fire is pro hibited Wear your personal protective equipment protective gloves protective clothing Fig 6 Concerning y...

Page 36: ...tact CAUTION Danger of slipping on spilled oil Immediately bind spilled oil with an oil binding agent ENVIRONMENT Oil is an environmentally haz ardous substance Always keep oil in proper con tainers Immediately bind spilled oil with an oil binding agent Dispose of oil and oil filter according to regulations Concerning your safety Handling fuels and lubricants BW 124 PDH 5 36 ...

Page 37: ...sed by contact with coolant and coolant addi tives Wear your personal protective equipment protective gloves protective clothing Do not inhale any fumes Avoid contact CAUTION Danger of slipping on spilled coolant Immediately bind spilled coolant with an oil binding agent ENVIRONMENT Coolant is an environmentally hazardous substance Always keep coolant and coolant additives in proper containers Con...

Page 38: ...tely bind spilled coolant with an oil binding agent and dis pose of it according to regula tions Dispose of coolant according to regulations Concerning your safety Handling fuels and lubricants BW 124 PDH 5 38 ...

Page 39: ...n or eyes immediately with lots of clean water Immediately call for medical advice in case of cauterization WARNING Danger of injury caused by exploding gas mixture Remove the plugs before starting to recharge the battery Ensure adequate ventilation Smoking and open fire is pro hibited Do not lay any tools or other metal objects on the battery Do not wear jewellery watch bracelets etc when working...

Page 40: ...ENVIRONMENT Battery acid is an environmen tally hazardous substance Dispose of battery and battery acid according to regulations Concerning your safety Handling fuels and lubricants BW 124 PDH 5 40 ...

Page 41: ...nts Always use appropriate lifting and lashing means on the lifting and lashing points Use lifting and lashing gear only in the pre scribed direction of load application Lifting tackle must not be damaged by machine components Secure the machine on the transport vehicle against rolling slipping and turning over Loads must only be attached and hoisted by an expert capable person Use only lifting ge...

Page 42: ...After the transport loosen the articulation lock again as otherwise the machine wouild not be steerable Concerning your safety Load transport the machine BW 124 PDH 5 42 ...

Page 43: ...nting the machine check whether n persons or obstructions are beside or under the machine n the machine is free of oily and combustible materials n all access steps grips and platforms are free of obstacles grease oils fuel dirt snow and ice n all safety elements are in place n all maintenance flaps and doors are closed and locked Climb onto or off the machine only when the machine is standing Use...

Page 44: ... start pilot or ether The machine must not be operated with dam aged missing or non functional safety installa tions After starting check all display instruments Do not inhale exhaust fumes because they contain toxic substances which could cause damage to health unconsciousness or even death For operation in closed or partly closed rooms ensure adequate ventilation 3 6 3 Starting the engine with j...

Page 45: ...Do not start the engine by shorting the electric terminals on the starter motor because the machine may start to drive immediately Concerning your safety Starting up the machine BW 124 PDH 5 45 ...

Page 46: ...ing Do not climb onto or off the machine while the machine is driving Do not use the machine to transport persons In case of unusual noises and development of smoke perform trouble shooting to determine the cause and have the fault corrected Match the speed to the working conditions Do not make extreme steering movements when driving with high speed danger of tipping over Always give way to loaded...

Page 47: ...Increased danger of accident 3 7 3 Cross slope The tipping angle was measured on level hard ground with the machine stopped and without steering The max permissible cross slope of the machine may be limited by the max permis sible slanted position of the engine The specified angle must not be exceeded With loose soil acceleration deceleration run ning vibration steering or attached accessories the...

Page 48: ...horizontal level firm ground Before leaving the machine n shift all control levers to Neutral position Off or 0 n apply the parking brake n shut down the engine pull off the ignition key n pull off the main battery switch n secure the machine against unauthorized use 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 ...

Page 49: ...arging than diesel fuel with a higher sulphur content You should therefore always make sure that the filling system is properly grounded and that there is equipotential bonding to the machine If necessary use a connecting cable between filling system and vehicle ground Monitor the entire refuelling process Do not spill any fuel Collect leaking fuel do not let it seep into the ground Wipe off spill...

Page 50: ...s aftertreatment system get very hot Do not touch hot components or exhaust gases Ensure an adequate supply of fresh air Keep a safe distance to combustible or explo sive materials When performing regeneration at standstill park the machine outdoors at a safe distance from any combustible or explosive materials Concerning your safety Regeneration of exhaust gas aftertreatment system BW 124 PDH 5 5...

Page 51: ...ergency stop switch as a service brake 3 10 2 Disconnecting the battery In events of emergency e g in case of a cable fire disconnect the battery from the vehicle network Pull out the main battery switch or lift off the battery pole to do so 3 10 3 Towing the machine Tow the machine only in a case of emergency or to avoid an accident Before releasing the parking brake apply suit able measures to s...

Page 52: ...eans are able to withstand the load and are fastened at the points pro vided for this purpose Before removing the towing facility apply appropriate measures to secure the machine against unintended rolling Concerning your safety Emergency procedures BW 124 PDH 5 52 ...

Page 53: ...ieve hydraulic pressures before working on hydraulic lines Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury Immediately call for medical assistance if injured by hydraulic oil Do not step in front of or behind the machine when performing adjustment work in the hydraulic system Do not change the setting of pressure relief valves Drain the hydraulic oil at operati...

Page 54: ...res Wait until the engine has stopped then wait approx another 15 minutes Keep out of the danger zone during the initial test run In case of leaks return to the workshop immedi ately Drain the engine oil at operating temperature danger of scalding Wipe off spilled oil collect leaking oil and dis pose of it in an environmentally friendly way Store used filters and other oil contaminated materials i...

Page 55: ...ng or open fire is prohibited Do not lay any tools or other metal objects on the battery Do not wear jewellery watch bracelets etc when working on the battery The connection cables of the battery must not touch or rub against machine parts 3 11 5 Working on wheels and tyres Explosion like bursting of tyres or parts of tyres and rims can cause most severe or even fatal injuries Do not drive with da...

Page 56: ...otor is running Allow the engine to cool down before starting cleaning work on engine and exhaust system Never use gasoline or other easily inflammable substances for cleaning When cleaning with a high pressure cleaner do not subject electrical parts and insulation mate rial to the direct jet of water or cover them beforehand Do not guide the water jet into the exhaust pipe and into the air filter...

Page 57: ...arning sign Only operate the machine after it has been repaired Repairs must only be performed by an expert qualified person When replacing safety relevant components only original spare parts must be used Concerning your safety Repair BW 124 PDH 5 57 ...

Page 58: ... meaning Replace damaged and illegible stickers or sig nage immediately Hydraulic Oil 12 Volt WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that are reproductive toxicants B 586 0477 Fig 10 Concerning your safety Signage BW 124 PDH 5 58 ...

Page 59: ...586 0328 Diesel ULTRA LOW SULFUR FUEL ONLY Part No 009 920 09 20 l 009 920 10 5 l Part No 009 940 03 20 l Engine Coolant Spec MB 325 5 Deutz DQC CC 14 Fig 11 Concerning your safety Signage BW 124 PDH 5 59 ...

Page 60: ...cker California Proposition 65 Prohibition sticker High pressure cleaning Fig 12 Fig 13 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that are reproductive toxicants B DEC 0316 Fig 14 Fig 15 Concerning your safety Signage BW 124 PDH 5 60 ...

Page 61: ...ticker Always wear your seat belt Instruction sticker Wear ear defenders Information sticker Lashing point Information sticker Lifting point Fig 16 Fig 17 Fig 18 Fig 19 Concerning your safety Signage BW 124 PDH 5 61 ...

Page 62: ...rmation sticker travel lever control Information sticker Filler opening for hydraulic oil Information sticker Disconnecting the battery Fig 20 B DEC 0228 Fig 21 B DEC 0214 Hydraulic Oil Fig 22 B DEC 0219 Fig 23 Concerning your safety Signage BW 124 PDH 5 62 ...

Page 63: ...y switch plus side Information sticker Vehicle voltage 12 V Information sticker Hydraulic oil drain Information sticker Engine oil drain Fig 24 Fig 25 B DEC 0210 Fig 26 B DEC 0211 Fig 27 Concerning your safety Signage BW 124 PDH 5 63 ...

Page 64: ...oil Information sticker Filler opening for diesel Information sticker Ultra low sulphur fuel B DEC 0221 Part No 009 940 03 20 l Engine Coolant Spec MB 325 5 Deutz DQC CC 14 Fig 28 Fig 29 B DEC 0215 Diesel Fig 30 Fig 31 Concerning your safety Signage BW 124 PDH 5 64 ...

Page 65: ...rol and dozer blade push button assignment Information sticker travel lever control and tilt blade push button assignment Machine type plate example B DEC 0229 Fig 32 B DEC 0230 Fig 33 Fig 34 Concerning your safety Signage BW 124 PDH 5 65 ...

Page 66: ...is a danger zone Before starting the machine and during opera tion the driver operator must ensure that nobody is in the danger zone Give warning signals if necessary Stop work immediately if persons are in the danger zone Concerning your safety Danger zones BW 124 PDH 5 66 ...

Page 67: ...ty Components 1 2 4 5 3 11 9 8 7 6 10 B 586 0459 Fig 36 1 ROPS FOPS 2 Exhaust gas aftertreatment system 3 Engine hood 4 Fan protection 5 Backup protection Concerning your safety Safety Components BW 124 PDH 5 67 ...

Page 68: ...6 Safety belt 7 Main battery switch 8 Articulation lock 9 Operator detection system 10 Emergency stop switch 11 Control system Concerning your safety Safety Components BW 124 PDH 5 68 ...

Page 69: ...4 Indicators and control elements Indicators and control elements BW 124 PDH 5 69 ...

Page 70: ...ight Lights up when the driver s seat is not occu pied If the machine is travelling the warning buzzer will sound and the engine is shut down after 2 seconds If the travel lever is shifted out of parking brake position the engine is immediately shut down Regeneration con trol light Lights up if regeneration at high exhaust gas temperatures is necessary Also lights up during regeneration Control an...

Page 71: ...ort while Check the engine oil level if necessary repair the engine Coolant temperature warning light Lights up when the engine overheats Warning buzzer sounds The engine power is reduced after a short while Run the engine with idle speed or if necessary shut it down and clean the radiator if neces sary repair the engine Charge control light Lights up if the battery is not being charged Check V be...

Page 72: ...ice Coolant level warning light Lights up if the coolant level is too low Warning buzzer sounds The engine is shut down after a short while Check coolant level check cooling system for leaks repair if necessary Function key F1 is used to toggle between the operating hour meter and the fault code dis play Function key F2 is not assigned Display field 60 80 100 120 140 160 140 176 212 248 284 320 C ...

Page 73: ...y switch for working lights 3 Rotary button for regeneration 4 Rotary switch for engine speed 5 Push button for warning horn 6 Rotary switch for flashing beacon optional equipment 7 Rotary switch for amplitude pre selection 8 Starter switch Indicators and control elements Driver s stand BW 124 PDH 5 73 ...

Page 74: ...diately The engine is shut down switch off unlock Turn the Emergency Stop switch clockwise and let it go NOTICE In case of frequent use the wear on the multi discs brakes will be very high Do not use the emergency stop switch as service brake 4 1 2 2 Rotary switch for working lights Position Left Working lights off Position Right Working light on Fig 40 Fig 41 Indicators and control elements Drive...

Page 75: ...n of the operating sequences and operating possibili ties Ä Chapter 6 7 Regeneration of exhaust gas aftertreatment system on page 107 4 1 2 4 Rotary switch for engine speed Position Left Idle speed position MIN Position Middle ECO mode The engine speed automati cally adapts to the power requirements This enables economical operation Position Right Full load position MAX Fig 42 Fig 43 Indicators an...

Page 76: ...ashing beacon off Position Right Flashing beacon on Optional equipment 4 1 2 7 Rotary switch for amplitude pre selection Position Left low amplitude high fre quency Position Middle Vibration off Position Right high amplitude low fre quency Fig 44 Fig 45 Fig 46 Indicators and control elements Driver s stand BW 124 PDH 5 76 ...

Page 77: ...essure the engine starts Turn the ignition key back to position I when the engine starts The starter switch is designed with a re start lock The ignition key must first be turned back to position 0 before a new starting attempt can be made 4 1 3 Travel lever Shift forward Forward travel Pull back Backward travel Position Middle Service brake position Position Middle right Parking brake position Fi...

Page 78: ...lade are equipped with a different travel lever Shift forward Forward travel Pull back Backward travel Position Middle Service brake position Position Middle right Parking brake position Push button for vibration B ELE 0139 Fig 49 B ELE 0140 Fig 50 Indicators and control elements Driver s stand BW 124 PDH 5 78 ...

Page 79: ... switch Position on Main battery switch locked Normal position operation Turn anticlock wise Main battery switch can be pulled out Isolates the batteries from the on board electrics e g to protect against unauthorized use Individual control units may still be connected to the board electrics despite the main battery switch being pulled out B ELE 0141 5 6 1 2 3 4 Fig 51 B 596 0279 Fig 52 Indicators...

Page 80: ...page 105 Optional equipment 4 1 8 Rotary switch ECONOMIZER Position Left ECONOMIZER display for smooth drum Position Right ECONOMIZER display for attached padfoot shell seg ments The rotary switch for ECONOMIZER is located in the central electrics The rotary switch for ECONO MIZER is without function on machines with a padfoot drum Fig 53 Fig 54 B SWI 1479 Fig 55 Indicators and control elements Dr...

Page 81: ...5 Checks prior to start up Checks prior to start up BW 124 PDH 5 81 ...

Page 82: ...nd lubricants Safety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Ä Chapter 3 4 Handling fuels and lubri cants on page 30 WARNING Danger of injury caused by rotating parts Before starting work on the machine make sure that the engine can not be started CAUTION Danger of being injured by the engine hood dropping down Always secure an open...

Page 83: ...Open and secure the engine hood Close the engine hood again after work is com pleted Checks prior to start up Notes on safety BW 124 PDH 5 83 ...

Page 84: ...k the bolted connections are tight and secure 5 Check the engine and exhaust system for leaks 6 Check belt drive for damage 7 Check the machine for contamination and damage 8 Check function of steering 9 Check function of brake 10 Check emergency stop function 11 Check function of backup alarm system 12 Check function of seat contact switch Checks prior to start up Visual inspections and function ...

Page 85: ...oil If the engine oil level is higher than the MAX mark the engine oil is excessively diluted Immedi ately change the engine oil Protective equip ment n Working clothes n Protective gloves 1 Pull the dipstick out wipe it off with a lint free clean cloth and reinsert it to the end stop 2 Pull the dipstick out again ð The oil level must be between the MIN and MAX marks 3 For topping up clean the are...

Page 86: ...6 Push the dipstick in Checks prior to start up Checking the engine oil level BW 124 PDH 5 86 ...

Page 87: ...ever run the fuel tank empty as otherwise the fuel system needs to be bled Monitor the entire refuelling process Contaminated fuel can cause malfunction or even damage of the engine If necessary fill in fuel through a screen filter Use only fuel of the permitted specification Ä Chapter 8 3 2 Fuel on page 134 0 1 4 3 4 1 h 1 2 B DIS 0005 Fig 57 Checks prior to start up Checking the fuel level toppi...

Page 88: ...orking clothes n Protective gloves 1 Clean the area around the filler opening 2 Unscrew the cap and fill in fuel 3 Close the cap B 586 0280 Fig 58 Checks prior to start up Checking the fuel level topping up fuel BW 124 PDH 5 88 ...

Page 89: ...of the permitted specification Ä Chapter 8 3 4 Hydraulic oil on page 137 Protective equip ment n Working clothes n Protective gloves 1 Check the oil level in the inspection glass Normal level approx 3 cm 1 2 in below the top edge of the inspection glass Minimum level Middle of inspection glass 2 To refill remove the two rear screws from the seat console 3 Fold the seat console forward B 596 0281 F...

Page 90: ... the cap and fill in hydraulic oil 6 Close the cap 7 Push the seat console back again 8 Screw the two rear screws tightly into the seat console B 586 0283 Fig 61 B 586 0282 Fig 62 Checks prior to start up Checking the hydraulic oil level BW 124 PDH 5 90 ...

Page 91: ...ow is indicated by the coolant level warning light Protective equip ment n Working clothes n Protective gloves n Safety goggles 1 WARNING Danger of scalding by hot fluid Open the compensation tank only when the engine is cold Wear your personal protec tive equipment protective gloves protective clothing goggles Check the coolant level in the compensa tion tank 2 To refill remove the cover and fill...

Page 92: ...3 Close the cap Checks prior to start up Checking the coolant level BW 124 PDH 5 92 ...

Page 93: ...th a length of min 6 meters Never exceed the permitted max imum pressure The tire pressure can be adapted to the operating conditions within the specified limits A reduced tire pressure improves the traction especially on sandy soils Higher tires pressures improve the driving stability of the machine The total height of the machine can also be influenced by changing the tire pressure Checks prior ...

Page 94: ...ition on page 106 3 Check the tyres for cuts bulges damaged rims missing wheel studs or nuts 4 Have damaged wheels or tyres replaced immediately 5 Unscrew the valve caps and check the front and rear tire pressure correct if nec essary Ensure equal pressure in all tires Tire pressure nominal value Ä Chapter 2 Technical data on page 13 6 Screw the valve caps back on again Fig 65 Checks prior to star...

Page 95: ...6 Operation Operation BW 124 PDH 5 95 ...

Page 96: ...2 Adjust the seat in longitudinal direction dis engage lever b and push the seat forward or back to do so 3 Adjust to the weight of the operator using lever a The adjustment lever a is locked in upwards direction To release the lock press the lever down against the end stop Then adjust to the weight of the operator by sliding the lever down Fig 66 a Weight adjustment b Longitudinal adjustment c Ba...

Page 97: ...Main battery switch switched on n Emergency stop switch unlocked n Travel lever in position Middle right parking brake closed 1 Turn the rotary switch for engine speed to position Middle ECO mode 2 Turn the ignition key to position I ð All control and warning lights in the instrument cluster light up for a moment B SWI 1089 Fig 67 B ELE 0070 Fig 68 Operation Starting the engine BW 124 PDH 5 97 ...

Page 98: ...tarting process for max imum 20 seconds without inter ruption and pause for a minute between starting attempts If the engine has not started after two attempts determine the cause 4 Turn the ignition key through position II to position III ð The starter cranks the engine NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under...

Page 99: ...exhaust gas temperatures result in increased soot loads in the DPF Short engine running times low engine loads or excessively long engine idle times should be avoided Operation Starting the engine BW 124 PDH 5 99 ...

Page 100: ...e gradeability of the machine Wet and loose soil considerably reduces trac tion of the machine on inclinations and slopes Increased danger of accident If the operator leaves his seat while travelling the driver s seat warning light lights up The warning buzzer sounds After approx 3 seconds the machine brakes to a standstill Before being able to drive again the travel lever must first be shifted to...

Page 101: ...rking brake position and move it slowly to the desired travel direction ð The further the travel lever is moved for wards or backwards the faster the machine will travel 4 Set the travel lever to Middle position to stop the machine ð The machine decelerates to a standstill B SWI 1089 Fig 72 B ELE 0138 Fig 73 B ELE 0142 Fig 74 Operation Travel operation BW 124 PDH 5 101 ...

Page 102: ...5 Always apply the parking brake when stop ping on inclinations or slopes B ELE 0143 Fig 75 Operation Travel operation BW 124 PDH 5 102 ...

Page 103: ...und supply lines gas water sewage elec tric power If necessary stop compacting with vibration NOTICE Components may get damaged Do not activate the vibration on hard frozen concrete ground Vibration at standstill causes transverse marks n Switch the vibration on only after shifting the travel lever to the desired travel direction n Switch the vibration off before stopping the machine Operation Wor...

Page 104: ...Press the vibration push button on the travel lever ð Vibration is switched on 4 Press the vibration push button on the travel lever once again to switch off vibra tion ð Vibration is switched off 5 After finishing work turn the rotary switch for amplitude pre selection back to position 0 B SWI 1083 Fig 76 B ELE 0144 Fig 77 B SWI 1084 Fig 78 Operation Working with vibration BW 124 PDH 5 104 ...

Page 105: ...ay value does not increase any further no further compaction can be ach ieved with this machine The maximum dis play value 10 is not always reached n If the drum is in jump operation the display a flashes In order to achieve the desired soil stiffness one must always perform a suitable reference measurement before compaction is started The reference measurement is used to deter mine which display ...

Page 106: ... ð The parking brake warning light lights up NOTICE Danger of engine damage Do not shut down the engine all of a sudden from full load speed but let it idle for about two minutes 3 Turn the ignition key to position 0 and pull it out 4 Turn the main battery switch anticlockwise and pull it out B ELE 0122 Fig 80 B ELE 0069 Fig 81 B SWI 0079 Fig 82 Operation Parking the machine in secured condition B...

Page 107: ...n in normal operation required Is carried out automatically As long as there is no danger do not stop or sup press regeneration flashes off Regeneration at stand still required Perform regeneration at standstill as soon as pos sible Ä Chapter 6 7 3 Running regeneration at standstill on page 110 flashes lights up Regeneration at stand still is urgently required Reduced engine power Perform regenera...

Page 108: ...haust gas reaches very high temperatures and the exhaust gas quantity increases warning light for exhaust gas temperature lights up WARNING Danger of burning by ignited materials Keep a safe distance to combus tible or explosive materials If the interval for regeneration drops to under five hours find out why and rectify the cause e g DPF overloaded Then change the engine oil Ä Chapter 8 9 1 Chang...

Page 109: ... suppress regeneration As soon as there is danger due to high exhaust gas temperatures and quantities the operator has to suppress regeneration 1 Actuate the rotary button for regeneration to the left ð Regeneration is suppressed 2 To disable suppression actuate the rotary button briefly to the right After restarting the engine the suppression is automatically disabled Fig 84 Operation Regeneratio...

Page 110: ...stible or explosive mate rials Stop the machine in open terrain 2 Engage the travel lever to the right parking brake position When the travel lever is disen gaged out of parking brake position to the left regeneration at standstill will be aborted 3 Turn the rotary switch for engine speed to position Middle ECO mode Fig 85 Fig 86 Fig 87 Operation Regeneration of exhaust gas aftertreatment system B...

Page 111: ...regeneration warning light lights up Regeneration at standstill runs automati cally and takes up to 30 minutes The increased exhaust gas temperature is indicated by the exhaust gas tempera ture warning light 5 After regeneration has finished the warning lights go out Fig 88 Fig 89 Fig 90 Operation Regeneration of exhaust gas aftertreatment system BW 124 PDH 5 111 ...

Page 112: ...anticlockwise and pull it out or pull the battery terminal off the bat tery 6 8 3 Towing the machine Tow the machine only in case of emergency or to prevent an accident Towing distance max 500 m 1600 ft towing speed max 1 km h 55 ft min Before towing make sure that n the tractor vehicle has sufficient traction and braking power for the non braking towed load n lifting tackle is of sufficient stren...

Page 113: ...by uncontrolled machine movement Always secure the machine against unintended rolling 1 Fasten the towing device reliably to the towing points 2 Remove the two rear screws from the seat console 3 Fold the seat console forward B 586 0324 Fig 93 B 586 0310 Fig 94 Operation Emergency procedures BW 124 PDH 5 113 ...

Page 114: ...9 Insert a suitable pump lever extension and operate the pump until the brake is released ð The machine can now be towed 6 8 4 After towing WARNING Danger of injury caused by uncontrolled machine movement Always secure the machine against unintended rolling 1 If the engine cannot be started pull the emergency operation button completely out after towing After starting the engine the emergency oper...

Page 115: ...h pressure limiting valves of the travel pump 3 Unscrew the socket head cap screws 2 against the end stop 4 Tighten the counter nuts tightening torque 22 Nm 16 ft lbf 2 3 1 1 B 586 0478 Fig 98 Operation Emergency procedures BW 124 PDH 5 115 ...

Page 116: ...e solenoid valve for the parking brake to prevent the parking brake from opening 3 Close the engine hood 4 Turn the rotary switch for engine speed to position Left 5 Start the engine and shut it down again after approx 2 3 seconds 6 Repeat this process after a short break 7 Pull off the ignition key Bleeding the hydraulic circuit B 586 0326 1 Fig 99 1 Plug Y04 B SWI 1469 Fig 100 Operation Emergenc...

Page 117: ...8 Open the engine hood and reconnect the plug Y04 to the solenoid valve for the parking brake 9 Close the engine hood B 586 0326 1 Fig 101 1 Plug Y04 Operation Emergency procedures BW 124 PDH 5 117 ...

Page 118: ...Operation Emergency procedures BW 124 PDH 5 118 ...

Page 119: ...7 Loading transporting the machine Loading transporting the machine BW 124 PDH 5 119 ...

Page 120: ...eparation for transport 1 Close all flaps 2 Remove all loose objects from the machine or the driver s stand or fasten them securely Loading transporting the machine Preparation for transport BW 124 PDH 5 120 ...

Page 121: ...or down from the transport vehicle The instructing person should not be inside the travel range of the machine Distance from middle of drum mm Height mm 925 100 680 70 DANGER Danger to life caused by the machine slipping or turning over Make sure that no persons are in the danger zone 1 Drive the machine carefully onto the trans port vehicle 2 Observe the centre of gravity 3 Shut down the engine p...

Page 122: ...4 Engage the articulation lock Ä Chapter 8 2 2 1 Engaging the articulation lock on page 130 Loading transporting the machine Loading the machine BW 124 PDH 5 122 ...

Page 123: ... lifting and lashing points Use lifting tackle only in the prescribed direc tion of load application Lifting tackle must not be damaged by machine components 1 Fasten the lashing tackle at the marked lashing points 2 Lash the machine securely to the transport vehicle Fig 103 Loading transporting the machine Lashing the machine to the transport vehicle BW 124 PDH 5 123 ...

Page 124: ...only in the prescribed direc tion of load application Lifting tackle must not be damaged by machine components When lifting the machine avoid uncontrolled movements of the load If necessary hold the load with guide ropes 1 Shut down the engine 2 Engage the articulation lock Ä Chapter 8 2 2 1 Engaging the articulation lock on page 130 3 Fasten the lashing tackle at the marked lifting points 4 Use a...

Page 125: ...o life caused by sus pended loads Do not step or stand under sus pended loads 6 Lift the machine carefully and lower it again at the intended location Loading transporting the machine Loading by crane BW 124 PDH 5 125 ...

Page 126: ...east 2 metres while the machine is driven onto or down from the transport vehicle The instructing person should not be inside the travel range of the machine 1 Loosen the articulation lock Ä Chapter 8 2 2 2 Disengaging the articulation lock on page 131 2 DANGER Danger to life caused by the machine slipping or turning over Make sure that no persons are in the danger zone Drive the machine carefully...

Page 127: ...8 Maintenance Maintenance BW 124 PDH 5 127 ...

Page 128: ...bricants Safety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Ä Chapter 3 4 Handling fuels and lubri cants on page 30 CAUTION Danger of being injured by the engine hood dropping down Always secure an opened engine hood Wear your personal protective equipment Do not touch hot components Park the machine on horizontal level firm ground Perf...

Page 129: ...hine parts which are not intended for this purpose Always attach the articulation lock when working in the area of the articulated joint Do not leave any tools or other objects that could cause damage in or on the machine After maintenance work has been completed dispose of fuels and lubricants filters sealing elements and cleaning cloths in an environ mentally friendly way After all maintenance w...

Page 130: ...2 1 Opening closing the engine hood 1 Shift the lever sideways ð The hood is raised by the gas springs 2 To close the hood push it back into locked position 8 2 2 Articulation lock 8 2 2 1 Engaging the articulation lock WARNING Danger of crushing by the articu lating machine Do not step into the articulation area of the machine while the engine is running 1 Move the steering to middle position and...

Page 131: ... 2 2 Disengaging the articulation lock WARNING Danger of crushing by the articu lating machine Do not step into the articulation area of the machine while the engine is running 1 Pull the split pin out of the locking bolt for the articulation lock 2 Remove the locking bolt B 586 0286 Fig 106 B 586 0287 Fig 107 B 586 0287 Fig 108 Maintenance Preparations concluding work BW 124 PDH 5 131 ...

Page 132: ...vers can be removed for better access during maintenance work 1 Remove the two star bolts from each side cover and take off the covers 2 Place the covers in the mounting position after the maintenance work and secure with the star bolts B 586 0286 Fig 109 B 586 0288 Fig 110 Maintenance Preparations concluding work BW 124 PDH 5 132 ...

Page 133: ...oosing the viscosity class SAE class The temperature data of the SAE class always refer to fresh oils In travel operation engine oil ages because of soot and fuel residues This adversely affects the properties of the engine oil especially under low ambient temperatures Optimal operating conditions can be achieved by using the following oil viscosity chart as a reference Ambient temperature Oil vis...

Page 134: ...ed with an exhaust gas after treatment system must only be operated with sulphur free diesel fuel The following fuel specifications are permitted n EN 590 n ASTM D975 Grade No 1 D S15 and 2 D S15 The recommended Cetan index number is 45 A Cetan index number higher than 50 should preferably be used especially at ambient tem peratures below 20 C 4 F and when working at altitudes of 1500 m 4921 ft an...

Page 135: ...stems and fuel lines are not permitted Copper containing materials copper lines brass items should be avoided because they can cause catalytic reactions in the fuel with subsequent depositing in the injection system 8 3 3 Coolant Always use a mixture of anti freeze agent and clean dehardened water with a mixing ratio of 1 1 Under particularly extreme temperature condi tions you should consult our ...

Page 136: ...ends on the brand of the anti freeze agent see standard SAE J1034 and also standard SAE J814c Add anti freeze agent n If the coolant level drops because of evapo ration only clean water is to be used for top ping up n In case of leakages you must always fill in anti freeze agents of the same brand and the same mixing ratio Do not use any radiator cleaning agent after the anti freeze agent has been...

Page 137: ...aulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil The biodegradable hydraulic oil Panolin HLP Synth 46 or Plantohyd 46 S meets all the requirements of a mineral oil based hydraulic oil according to DIN 51524 In hydraulic systems filled with biodegradable hydraulic oil always use the same oil to top up and do not mix oil types When changing...

Page 138: ... tent and mineral oil Replace the hydraulic oil filter at the latest after 500 operating hours 8 3 5 Gear oil SAE 80W 140 Use a fully synthetic gear oil in accordance with SAE 80W 140 API GL5 with a kinematic vis cosity of at least 20 mm2 s at 100 C 212 F It is a hypoid lubricant of highest quality class for transmissions under extreme strain Maintenance Fuels and lubricants BW 124 PDH 5 138 ...

Page 139: ...Mixture of water and anti freeze agent Specification Ä Chapter 8 3 3 Coolant on page 135 009 940 03 20 l 7 0 l 1 8 gal us Hydraulic system Hydraulic oil ISO HVLP 46 Specification Ä Chapter 8 3 4 1 Mineral oil based hydraulic oil on page 137 009 930 09 20 l 45 l 12 gal us or ester based biodegradable hydraulic oil Specification Ä Chapter 8 3 4 2 Bio degradable hydraulic oil on page 137 Drum drive g...

Page 140: ... gear housing Gear oil SAE 80W 140 Specification Ä Chapter 8 3 5 Gear oil SAE 80W 140 on page 138 009 925 07 20 l 0 45 l 0 1 gal us Wheel hubs Gear oil SAE 80W 140 Specification Ä Chapter 8 3 5 Gear oil SAE 80W 140 on page 138 009 925 07 20 l 0 4 l each 0 1 gal us Tyres Water calcium chloride 35 l 20 kg 9 2 gal us 44 lbs or water magnesium chloride 43 l 12 kg 11 4 gal us 26 5 lbs Maintenance List ...

Page 141: ...perating hours 8 5 2 After 50 operating hours 1 Check the engine for leaks 2 Tighten all bolted connections on air intake exhaust oil sump and engine mounts 3 Retighten the bolted connections on the machine 8 5 3 After 250 operating hours 1 Retighten the wheel nuts Ä Chapter 8 10 11 Retightening the wheel nuts on page 175 2 Oil and filter change on diesel engine Ä Chapter 8 9 1 Change engine oil a...

Page 142: ...drum drive reduction gear Ä Chapter 8 10 9 Change the oil in the drum drive reduction gear on page 173 8 5 5 After 1000 operating hours 1 Retighten the wheel nuts Ä Chapter 8 10 11 Retightening the wheel nuts on page 175 2 Oil change in drive axle Ä Chapter 8 10 6 Change the oil in the drive axle on page 169 3 Oil change in bevel gear housing Ä Chapter 8 10 7 Changing the oil in the bevel gear hou...

Page 143: ...rum drive reduction gear 151 8 8 9 Check the parking brake 152 Every 500 operating hours 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 con dition of the coolant 159 8 9 5 Checking the hydraulic lines 159 8 9 6 Servicing the battery checking the mai...

Page 144: ...nging 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 Every 3000 operating hours 8 12 1 Checking the turbo charger 184 8 12 2 Cleaning the DPF 184 8 12 3 Checking the exhaust gas recirculation system 184 As required 8 13 1 Air filter maintenance 185 8 13 2 Checki...

Page 145: ... page 106 2 Allow the engine to cool down 3 Check the condition and tight fit of all fuel lines and hose clamps 4 If fuel lines or hose clamps are found to be damaged the corresponding parts must be immediately repaired or replaced by authorized service personnel NOTICE Danger of engine damage After work on the fuel system bleed the system perform a test run and check for leaks Maintenance Every 5...

Page 146: ...clamps are found to be damaged the corresponding parts must be immediately replaced 8 8 2 Checking radiator hoses and hose clamps Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 2 Allow the engine to cool down 3 Check the condition and tight fit of all radi ator hoses and hose cla...

Page 147: ...elt Ä Chapter 8 9 3 Replacing the V belt on page 158 5 Check with thumb pressure whether the V belt can be depressed more than 7 to 9 mm 0 28 0 35 inch between the V belt pulleys retighten if necessary 8 8 3 2 Tightening the V belt Protective equip ment n Working clothes n Protective gloves 1 Loosen the tensioning screw 1 and the screw 2 on the generator 2 Press the generator towards the outside u...

Page 148: ...ow the engine to cool down Protective equip ment n Working clothes n Protective gloves n Safety goggles CAUTION Danger of eye injuries caused by particles flying around Wear your personal protective equipment safety gloves protec tive working clothes goggles 1 Blow the radiator out with compressed air from inside the engine compartment Cleaning with com pressed air B 586 0289 LUFT AIR Fig 113 Main...

Page 149: ...water jet 1 Spray engine and radiator with a suitable cleansing agent let it soak in for a while and then wash off with a strong water jet 2 Warm up the engine for a while to avoid corrosion 8 8 5 Checking the oil level in the drive axle NOTICE Components may get damaged Use only gear oil of the permitted specification Ä Chapter 8 3 5 Gear oil SAE 80W 140 on page 138 B 586 0290 LUFT AIR Fig 114 Cl...

Page 150: ...ly 8 8 6 Check the oil level in the bevel gear housing NOTICE Components may get damaged Use only gear oil of the permitted specification Ä Chapter 8 3 5 Gear oil SAE 80W 140 on page 138 Protective equip ment n Working clothes n Protective gloves 1 Clean the area around the oil level inspec tion plug 2 Unscrew the oil level inspection plug ð The oil level must reach the bottom edge of the level bo...

Page 151: ...rking the machine in secured condition on page 106 3 Clean the area around the oil level inspec tion plug 4 Unscrew the oil level inspection plug ð The oil level must reach the bottom edge of the level bore 5 Top up oil if necessary 6 Turn the oil level inspection plug tightly back in 7 Change the oil in both wheel hubs 8 8 8 Checking the oil level in the drum drive reduction gear NOTICE Component...

Page 152: ... area around the oil level inspec tion plug and unscrew the plug ð The oil level must reach the bottom edge of the level bore 4 For topping up clean the area around the filler plug 5 Unscrew the filler screw 6 Refill with oil until it reaches the bottom edge of the inspection bore 7 Retighten the oil level inspection and filler plug 8 8 9 Check the parking brake This work must only be performed by...

Page 153: ...est after one year NOTICE Danger of engine damage Change the oil only with the engine at operating temperature Use only oil of the permitted specification Ä Chapter 8 3 1 Engine oil on page 133 Filling quantity Ä Chapter 8 4 List of fuels and lubri cants on page 139 Maintenance Every 500 operating hours BW 124 PDH 5 153 ...

Page 154: ...omponents 2 Unscrew the drain plug and collect any oil running out 3 Screw the drain plug back in tightly 4 Thoroughly clean the outside of the oil filter cartridge 5 Unscrew the oil filter cartridge using an appropriate strap wrench 6 Remove any dirt from the sealing face of the filter carrier 7 Thinly apply oil to the rubber seal of the new oil filter cartridge 8 Screw on the new oil filter cart...

Page 155: ...ge Ensure strict cleanliness Thor oughly clean the area around the fuel filters Air in the fuel system causes irregular running of the engine a drop in engine power stalls the engine and makes starting impossible After work on the fuel system bleed the system perform a test run and check for leaks Additional bleeding of the fuel system by a 5 minute test run in idle speed or low load is manda tory...

Page 156: ...d take off the fuel pre cleaner 3 5 Clean the sealing face on the filter carrier from any dirt 6 NOTICE Danger of engine damage Never fill filters beforehand to avoid the entry of dirt into the clean side Slightly oil the rubber seal on the new fuel pre filter 7 Attach the fuel pre filter 1 with quick lock and ensure correct coding 8 Close the quick lock 2 so that it engages noticeably 9 Screw in ...

Page 157: ...6 Attach the fuel filter 1 with quick lock and ensure correct coding 17 Close the quick lock 2 so that it audibly engages 18 Screw in the drain plug 3 19 Loosen the hose clamps on the fuel filter and pull off the hoses 20 Install the new line filter and observe the flow direction arrow 21 Connect the hoses to the line filter with hose clamps 22 Dispose of fuel and filter in an environmen tally fri...

Page 158: ... engine and run it for 5 minutes at idle speed 5 Shut down the engine and check the fuel filter and fuel pre filter for leaks 8 9 3 Replacing the V belt Perform this maintenance work at the latest after two years Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 2 Allow the engine t...

Page 159: ...k the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 2 Allow the engine to cool down 3 Remove the cap and check the coolant level and anti freeze concentration with a conventional tester 4 Check the condition of the coolant 5 Thoroughly flush the cooling system if the coolant is contaminated by corrosion resi dues or other suspended matter Ä Chapter...

Page 160: ... tion formation of blisters crushed spots buckling n leaks on hose socket or fitting n the hydraulic hose has separated from the fitting n fittings are damaged or deformed whereby the function and strength of the hose fitting connection is impaired n the fitting shows corrosion that impairs both function and strength n incorrect installation squeezing shearing or chafing points n paint covered hyd...

Page 161: ...e to the bat tery as a result of exhaustive dis charge Exhausted batteries batteries with formation of sulphate on the plates are not covered under warranty Protective equip ment n Working clothes n Protective gloves n Safety goggles 1 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 2 Remove the two rear screws from the seat console 3 Fold t...

Page 162: ...f necessary top up to the filling mark with distilled water 9 Push the seat console back again 10 Screw the two rear screws tightly into the seat console 8 9 6 2 Checking the main battery shutoff 1 Turn the main battery switch counter clock wise and pull it out 2 Check by turning the ignition key whether the battery is disconnected from the elec tric system of the machine B 586 0300 Fig 132 B 586 ...

Page 163: ...l down for at least 30 minutes The engine oil temperature must be below 80 C 176 F Valve clearance Intake exhaust valve 0 18 mm to 0 22 mm 0 007 in to 0 009 in Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 2 Allow the engine to cool down 3 Remove the valve cover Fig 135 Maintena...

Page 164: ...te the flywheel by another 360 6 Check the valve clearance on the valves marked black adjust if necessary 7 Rotate the flywheel by another 360 8 Check the valve clearance on the valves marked black adjust if necessary Fig 136 Fig 137 I Intake valve E Exhaust valve Fig 138 Maintenance Every 1000 operating hours BW 124 PDH 5 164 ...

Page 165: ...too narrow or too wide for the feeler gauge adjust the valve clearance 8 10 2 Checking the lines on the diesel engine This work must only be performed by authorized service personnel Perform this maintenance work at the latest after one year Check the following lines n Lines of the exhaust gas recirculation system n DPF lines n lines of the lubrication system Fig 139 Checking the valve clear ance ...

Page 166: ...on on page 106 2 Allow the engine to cool down 3 Check air intake and exhaust manifold fas tenings for tight fit 4 Check sockets and clamps between air filter exhaust turbocharger and charge air line as well as the engine oil lines for tight fit and leaks 5 Check fastening screws on the engine oil sump and engine mounts for tight fit 6 Check condition and tight fit of engine pillow blocks 8 10 5 R...

Page 167: ... change intervals the filter element must also be changed after major repairs in the hydraulic system Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 2 Allow the engine to cool down 3 Unscrew filter bowl 4 and take it off with filter element 3 B 586 0301 1 2 3 4 Fig 141 Maintenanc...

Page 168: ...e or repair the defec tive components if necessary Do not clean or reuse the filter element 4 Take out the old filter element and clean the filter bowl 5 Clean the thread on the filter bowl 6 Reassemble the filter bowl with a new filter element and new O rings 1 2 7 After a short test run check the filter for leaks 8 Dispose of oil and filter in an environmen tally friendly way Maintenance Every 1...

Page 169: ...n page 139 Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 WARNING Danger of burning on hot compo nents Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components 2 Clean the area around the oil level inspec tion plug and unscrew th...

Page 170: ...ection bore until it has reached the bottom edge of the bore 7 After filling with oil wait until the oil has evenly distributed itself inside the axle if necessary fill with some more oil 8 Screw the oil level inspection plug back in tightly 9 Dispose of oil in an environmentally friendly way B 586 0302 Fig 143 B 586 0291 Fig 144 Maintenance Every 1000 operating hours BW 124 PDH 5 170 ...

Page 171: ...n plug 2 Unscrew the oil drain screw and collect any oil running out 3 Screw the drain plug back in 4 Clean the area around the oil level inspec tion plug 5 Unscrew the oil level inspection plug 6 Fill with new oil through the oil level inspec tion plug until the oil level reaches the bottom edge of the bore 7 Screw the oil level inspection plug back in tightly 8 Dispose of oil in an environmental...

Page 172: ...otective gloves 1 Move the drum until the oil level inspection plug is in bottom position 2 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 WARNING Danger of burning on hot compo nents Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components 3 Clean the area around the oil level inspec tion ...

Page 173: ... Change the oil in both wheel hubs 9 Dispose of oil in an environmentally friendly way 8 10 9 Change the oil in the drum drive reduction gear NOTICE Components may get damaged Drain gear oil only at operating temperature Use only gear oil of the permitted specification Ä Chapter 8 3 5 Gear oil SAE 80W 140 on page 138 Filling quantity Ä Chapter 8 4 List of fuels and lubri cants on page 139 Fig 148 ...

Page 174: ... oil level inspection plug and catch any oil running out 5 Once all oil has been drained off move the machine until the oil level inspection plug 1 is in a horizontal position and the filler screw is in 2 top position 6 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 7 Clean the area around the filler plug and unscrew the filler plug 8 Fill ...

Page 175: ...orking clothes n Protective gloves 1 Tighten the wheel nuts cross wise tight ening torque 550 Nm 405 ft lbf 8 10 12 Checking the ROPS All bolted connections must comply with the specifications and should be absolutely tight observe the tightening torques Screw and nuts must not be damaged bent or deformed Unusual movements and noises vibrations during operation are signs for damage or loos ened fa...

Page 176: ...ng of the seat belts 8 10 13 Checking the travel lever control 1 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 2 Move the travel lever forward backwards and to braking position Thereby check for function light movement clearance and damage 3 In case of malfunction perform trouble shooting and replace the corresponding parts 4 Only operate ...

Page 177: ...draulic oil Do not use any detergents to clean the system Use only lint free cleaning cloths for cleaning When changing from mineral oil based hydraulic oil to an ester based biologically degradable hydraulic oil you should consult the lubrication oil service of the oil manufac turer or our customer service for details NOTICE Risk of damage Perform the oil change when the hydraulic oil is warm Use...

Page 178: ...he area around the filler opening and remove the cap WARNING Danger of burning on hot compo nents Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components 5 Connect the drain hose and collect running out oil ð The drain valve opens when the drain hose is screwed on 6 Unscrew the drain hose again B 586 0310 Fig 154 B 586 0283 Fig 155 B 586 0306 Fig...

Page 179: ...ted in the cap you must therefore replace the complete cap Close the tank with a new cap 9 Check the oil level in the inspection glass Normal level approx 3 cm 1 2 in below the top edge of the inspection glass Minimum level Middle of inspection glass 10 Push the seat console back again 11 Screw the two rear screws tightly into the seat console 12 Dispose of oil in an environmentally friendly way B...

Page 180: ...tem If oil has entered you must add a cleansing agent in order to remove any residues from the system Follow the instructions of the manufac turer If in doubt consult your Customer Service or the engine manufacturer When changing the coolant without any signs of contamination cleaning of the cooling system is not necessary NOTICE Danger of engine damage Use only coolant of the permitted specificat...

Page 181: ... Connect the drain hose and collect leaking coolant ð The drain valve opens when the drain hose is screwed on 5 Unscrew the drain hose again 6 Check the condition of the coolant 7 Thoroughly flush the cooling system if the coolant is contaminated by corrosion resi dues or other suspended matter 8 Remove the thermostat 9 Fill in clean water B 586 0284 Fig 160 B 586 0307 Fig 161 Maintenance Every 20...

Page 182: ...nger of engine damage The anti freeze concentration additive must be at least 35 Vol and maximum 45 Vol Open the cover and top up with coolant 17 Close the cap 18 Start the engine and run to operating tem perature 19 Allow the engine to cool down and refill if necessary 20 Check the coolant level and refill if neces sary 21 Dispose of coolant in an environmentally friendly way B 586 0284 Fig 162 B...

Page 183: ...ble the oil separator 6 Dispose of the oil separator element envi ronmentally 8 11 4 Checking the exhaust gas recirculation cooler This work must only be performed by authorized service personnel 8 11 5 Replacing hoses This work must only be performed by authorized service personnel Perform this maintenance work at the latest after two years The following hoses need to be renewed n fuel hoses n ai...

Page 184: ...ed by authorized service personnel 8 12 2 Cleaning the DPF This work must only be performed by authorized service personnel 8 12 3 Checking the exhaust gas recirculation system This work must only be performed by authorized service personnel Maintenance Every 3000 operating hours BW 124 PDH 5 184 ...

Page 185: ...ment is covered with a sooty deposit Do not use gasoline or hot fluids to clean the filter element After cleaning the air filter must be inspected for damage using a torch Do not continue to use a dam aged air filter element If in doubt use a new air filter If the air filter is damaged the safety element must be replaced as well The safety element must not be cleaned We generally recommend to rene...

Page 186: ...ne year 2 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 3 Allow the engine to cool down 4 Loosen both locking hooks on the housing cover and take the cover off 5 Clean housing cover and dust discharge valve 6 Pull out the air filter with light turning move ments Fig 165 Fig 166 Fig 167 Maintenance As required BW 124 PDH 5 186 ...

Page 187: ...wn inside the element until it is free of dust 8 Examine the air filter with a torch for cracks and holes in the paper bellows 9 In case of damage replace the air filter and the safety element 10 Slide the air filter carefully into the housing NOTICE Danger of engine damage The dust discharge valve must point vertically downwards Make sure that the cover locks engage correctly 11 Reassemble the ho...

Page 188: ...ed 1 Remove the housing cover and pull the air filter element off 2 Pull the safety element out by turning it lightly 3 Push in a new safety element 4 Insert the air filter and reassemble the housing cover 8 13 2 Checking and cleaning the water separator The service intervals for the water separator depend on the water con tent in the fuel and can therefore not be determined precisely After taking...

Page 189: ...n plug tightly back in Check for leaks if necessary use a new seal ring ð Once the water separator is empty the warning light for water in fuel must go out 6 Dispose of collected fluid in an environ mentally friendly way 8 13 3 Adjusting the scrapers 1 Check adjustment and condition of scra pers adjust or replace the teeth if neces sary 2 In order to adjust the scrapers loosen the fastening screws...

Page 190: ...ure safe standing Protective equip ment n Working clothes n Protective gloves n Safety goggles 1 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 106 2 Allow the engine to cool down 3 When cleaning with a high pressure cleaner do not subject electrical parts and insulation material to the direct jet of water or cover them beforehand 4 If necessar...

Page 191: ...3 6 1 Measures before shutting down If the machine is shut down for a longer period of time e g winter season the following work must be carried out 1 Clean the machine thoroughly 2 Clean the water separator 3 Fill the fuel tank with diesel fuel to prevent the formation of condensation water in the tank 4 Change engine oil and oil filter if the oil has been changed more than 300 hours ago or if th...

Page 192: ...ibited Do not lay any tools or other metal objects on the battery Do not wear jewellery watch bracelets etc when working on the battery Wear your personal protective equipment protective gloves protective clothing goggles Protective equip ment n Working clothes n Protective gloves n Safety goggles 1 Switch off all consuming devices e g igni tion light 2 Measure the open circuit voltage of the batt...

Page 193: ...ect the battery Do not forget to perform regular open circuit voltage measurements 8 13 6 3 Measures before restarting 1 Replace the fuel filter 2 Replace the air filter 3 Change engine oil and oil filter 4 Check the coolant level 5 Check the charge condition of the bat teries recharge if necessary Check the battery fluid level before and after charging 6 Connect the ground straps to the cou pling...

Page 194: ...11 Check the oil levels 12 Check the function of electric system steering and brakes 13 Clean the machine thoroughly Maintenance As required BW 124 PDH 5 194 ...

Page 195: ...9 Troubleshooting Troubleshooting BW 124 PDH 5 195 ...

Page 196: ... Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance If you cannot locate the cause of a fault or rec tify it yourself by following the trouble shooting chart you should contact our customer service department Troubleshooting Preliminary remarks BW 124 PDH 5 196 ...

Page 197: ...ngine or chassis ground as far away from the bat tery as possible 3 Start the engine Ä Chapter 6 2 Starting the engine on page 97 NOTICE Danger of damage to the elec tronic system If no powerful consuming device is switched on voltage peaks may occur when separating the con necting cables between the bat teries which could damage elec trical components 4 Once the engine is running switch on a powe...

Page 198: ...tion F03 10 A Vibration F04 7 5 A Instrument cluster F05 10 A 12 V socket F11 15 A Working head lights rear F23 10 A Warning horn F48 40 A Preheating system F50 25 A BOMAG TELEMATIC potential 30 F68 10 A Reserve potential 30 F103 10 A Reserve potential 15 F119 10 A Engine control unit F139 30 A Engine control unit F153 10 A Control potential 15 F154 10 A BOMAG TELEMATIC potential 30 F156 15 A Work...

Page 199: ... Optional headlights F243 5 A BOMAG TELEMATIC potential 30 F275 5 A ECONOMIZER 9 3 3 Main fuse The main fuse is located underneath the driv er s seat Fuse Amperage Designation F00 80 A Main fuse for battery B 586 0398 Fig 177 Troubleshooting Fuse assignment BW 124 PDH 5 199 ...

Page 200: ...dized causing the starter to turn too slowly Check the battery charge condition clean the terminal clamps tighten and cover them with acid free grease Fuel supply too low fuel system clogged by paraffin separation during winter Replacing the fuel filter Check all line connections for leaks and tighten the fittings bleed the fuel system Use winter fuel in winter Engine oil with wrong SAE viscosity ...

Page 201: ...e radiator sealant to seal leaks Anti freeze concentration too high Use coolant with the speci fied mixing ratio Thermostat defective Check the thermostat replace if necessary Interior parts of radiator cor roded Clean or replace the radiator Insufficient cooling air supply to the cooling fan Remove any clogging from the cooling air duct Fan radiator or radiator cap defective Have examined by a sp...

Page 202: ... lights during operation the warning buzzer sounds Generator speed too low Check the generator belt for tension replace the belt if necessary Generator or regulator defec tive Have examined by a spe cialist Troubleshooting Engine faults BW 124 PDH 5 202 ...

Page 203: ...e display a and the LED 10 flash alternately for five seconds Then the four digits of the fault code are dis played in order via the LEDs 1 10 e g 4777 LED 10 corresponds to 0 Please contact our Customer Service with your fault codes Fig 178 Troubleshooting Trouble shooting ECONOMIZER BW 124 PDH 5 203 ...

Page 204: ...Troubleshooting Trouble shooting ECONOMIZER BW 124 PDH 5 204 ...

Page 205: ...10 Disposal Disposal BW 124 PDH 5 205 ...

Page 206: ...ron mental protection regulations must be followed when handling fuels and lubricants Ä Chapter 3 4 Handling fuels and lubri cants on page 30 Protective equip ment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Remove the batteries and dispose of in compliance with legal regulations 2 Empty the fuel tank 3 Drain the hydraulic oil tank 4 Drain coolant from cooling system an...

Page 207: ...11 List of special tools List of special tools BW 124 PDH 5 207 ...

Page 208: ...List of special tools BW 124 PDH 5 208 ...

Page 209: ......

Page 210: ...51 3470 6220 e mail brasil bomag com BOMAG CANADA INC 3455 Semenyk Court Missisauga Ontario L5C 4P9 CANADA Tel 1 905 361 9961 Fax 1 905 361 9962 e mail canada bomag com BOMAG China Construction Machinery Co Ltd No 2808 West Huancheng Road Shanghai Comprehensive Industrial Zone Fengxian Shanghai 201401 CHINA Tel 86 21 3365 5566 Fax 86 21 3365 5508 e mail china bomag com BOMAG France S A S 2 avenue ...

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