Fayat Group Bomag MPH 122-2 Operating & Maintenance Instructions Download

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Operating instructions

Maintenance instructions

Original operating instructions

Catalogue No.

008 061 61

05/2011

MPH 122-2

S/N 101 590 06 .... S/N 101 590 07 ....

Soil Stabilizer

Asphalt Recycler

Summary of Contents for Bomag MPH 122-2

Page 1: ...Operating instructions Maintenance instructions Original operating instructions Catalogue No 008 061 61 05 2011 MPH 122 2 S N 101 590 06 S N 101 590 07 Soil Stabilizer Asphalt Recycler...

Page 2: ......

Page 3: ...rom l operating errors l insufficient maintenance and l wrong fuels and lubricants Please note This manual was written for operators and mainte nance personnel on construction sites Always keep this m...

Page 4: ...3 Motor number Fig 3 i Note Supplement the above data together with the com missioning protocol During commissioning our organisation will in struct you in the operation and maintenance of the machin...

Page 5: ...e cutting depth 65 4 14 Adjusting the tailgate 68 4 15 Steering the rear axle 69 4 16 Adjusting the oscillation angle of the rotor cross slope 69 4 17 Mixing water connection preparing for operation 7...

Page 6: ...cking the spraying sections for leaks 123 6 23 Lubricating the machine 125 6 24 Cleaning front radiator water hydraulics 127 6 25 Checking cleaning the additional fuel filter water separator 129 6 26...

Page 7: ...170 6 61 Changing the injection valve 171 6 62 Replacing the crankcase ventilation valve 173 6 63 Changing the coolant pump 173 6 64 Changing the pressure retaining valve on te injection pump 174 6 65...

Page 8: ...Table of Contents BOMAG 8 MPH 122 2...

Page 9: ...BOMAG 9 MPH 122 2 1 Technical Data...

Page 10: ...ting weight kg 28000 Dimensions Track radius inner outer mm 3500 6300 Travel characteristics Travel speed 1 km h 0 2 7 Travel speed 2 km h 0 12 Max gradability depending on soil 40 Drive Engine manufa...

Page 11: ...iculated rear Steering operation hydraulic Rotor Rotor width mm 2330 Outer rotor diameter mm 1225 Rotor speed rpm 110 160 Rotor oscillation angle 5 Max working depth mm 500 Number of teeth 208 Height...

Page 12: ...because of the existing operating conditions Noise value Sound pressure level on the place of the operator LpA 84 dB A determined acc to ISO 11204 and EN 500 Guaranteed sound power level LWA 114 dB A...

Page 13: ...BOMAG 13 MPH 122 2 2 Safety regulations...

Page 14: ...y arise from the machine when it is used for purposes other than the one it is intended for Any danger caused by intended use is the sole re sponsibility of the customer or driver operator the manufac...

Page 15: ...ot safe to operate or in traffic must be immediately taken out of service and shall not be used until these deficiencies have been properly rectified Safety installations and switches must neither be...

Page 16: ...ing Use only machines which are serviced at regular intervals Become acquainted with the equipment the con trol elements the working principle of the machine and the working area Wear your personal pr...

Page 17: ...moke perform trouble shooting and have the fault corrected Driving on inclinations and slopes Do not drive on gradients exceeding the maximum gradability of the machine On slopes drive extremely caref...

Page 18: ...buckling or damage In case of fire call fire fighters immediately Switch off heating pumps etc If possible close valves to prevent the fire from spreading Fight the fire with powder extinguishers foam...

Page 19: ...ne is running danger to life due to high pressures l Wait approx 5 minutes after the engine has stopped l Keep out of the danger zone during the initial test rung l In case of leaks return to the work...

Page 20: ...Do not use gasoline or other easily inflammable substances for cleaning When cleaning with steam cleaning equipment do not subject electrical parts and insulation material to the direct jet of water...

Page 21: ...Indicating sticker Rotor hood opening 8 Information sticker Heating operation 9 Information sticker Lashing point 10 Information sticker Guaranteed sound capac ity level 11 Warning sticker Danger of b...

Page 22: ...BOMAG 22 MPH 122 2 Fig 6 1 Warning sticker Hot surface 2 Warning sticker Danger of spray 3 Warning sticker Warning of dangerous spot 4 Warning sticker Bitumen temperature and pressure Stickers on bin...

Page 23: ...Safety regulations BOMAG 23 MPH 122 2 Fig 7 Instruction sticker Always wear your seat belt Fig 8 Information sticker fire extinguisher S_0027...

Page 24: ...Safety regulations BOMAG 24 MPH 122 2...

Page 25: ...BOMAG 25 MPH 122 2 3 Indicators and Controls...

Page 26: ...Indicators and Controls BOMAG 26 MPH 122 2...

Page 27: ...Indicators and Controls BOMAG 27 MPH 122 2 Fig 9 Fig 10...

Page 28: ...itch attachment plate up down 14 24 V sockets 15 12 V sockets 16 Water flow meter 17 Instrument cluster machine functions 18 Travel lever right 19 Rotary switch for automatic power limit control 20 En...

Page 29: ...ncise de scriptions of the individual operating steps 3 2 Description of indicators and control elements Fig 11 No 1 Rotary switch rear working light and rotor Position left Working light off Position...

Page 30: ...Flashes when the engine oil pressure is too low the warning buzzer sounds the engine is shut down after 20 seconds Check engine oil level repair the en gine if necessary b red Coolant temperature warn...

Page 31: ...s when the hydraulic circuit is contaminated the warning buzzer sounds the engine is shut down after approx 2 minutes Flush the hydraulic circuit change hydraulic oil and filter j yellow Warning light...

Page 32: ...arious types of applications Position left Working range for milling Position mid dle Transport range I for driving on the construction site Position right Transport range II to travel to and from wor...

Page 33: ...ry parking brake switch to position Right before shutting the engine down Fig 22 No 12 Rotary switch for vibration of attach ment plate Position left Vibration off Position right Vibration on Fig 23 N...

Page 34: ...g buzzer sounds the engine is shut down after approx 2 minutes b red Charge pressure warning light rotor II Lights if the charge pressure on rotor II is too low the warning buzzer sounds the engine is...

Page 35: ...e operating hours while the engine is running All maintenance work must be per formed according to the indicated op erating hours n RPM meter Fig 28 No 18 Travel lever right Position 0 Zero position P...

Page 36: ...itch in position I the control light lights for about 2 seconds function check permanent light A fault message is present the engine can be started and the vehicle is still operable with limitations I...

Page 37: ...nd off i Note In automatic mode the actual travel speed of the machine is taken into account When stopping the machine the injection of water is also stopped i Note In case of a lack of water or if th...

Page 38: ...g work Do not rev up a cold engine to high idle speed full load speed Do not shut down the engine all of a sudden from full load speed but let it idle for about 2 minutes Fig 36 No 26 Fuses l Fold dow...

Page 39: ...d travel Position middle Stop position after operation the lever will automatically re turn to 0 position Position right Close the tailgate Position left Open the tailgate Fig 40 No 29 Steering lever...

Page 40: ...at can be swivelled and locked to left and right by 15 to 90 i Note The seat control panel a may be fastened to the other side of the seat if required Danger Danger of squashing When swivelling the se...

Page 41: ...back Fig 45 e Adjust the seat height Lift the seat and lock it in the next de tent When lifting the seat completely it will sink down to lowest position Fig 46 No 33 Cross slope indicator spirit leve...

Page 42: ...purpose of an emergency pump in case of hydraulic electrics failures The cabin can be lifted the parking brake released and the rotor raised in dependence on the position of the ball valves i Note The...

Page 43: ...ntact switch windscreen wiper front No 42 Toggle switch momentary contact switch windscreen wiper front No 43 Toggle switch for flashing beacon No 44 Switch for cabin light Fig 54 No 45 Fuse box cabin...

Page 44: ...ration of the air conditioning system the warning buzzer sounds with a continuous tone switch the air conditioning off and check the pres sure No 47 Rotary switch for air conditioning fan i Note Turni...

Page 45: ...y stop switch has been eliminated The machine is braked immediately the engine is shut down actuate Press the button completely down it automatically locks in fully pressed position switch off un lock...

Page 46: ...r switched on f Burner switch To switch the burner on off g Lack of thermal oil warning light Lights red if the thermal oil pressure is too low Check the thermal oil level h Temperature gauge for bind...

Page 47: ...safety thermostat responds the burner will be shut down Do not start operation of the system before the cause has been found To unlock remove the grey cap and operate the button under the cap c After...

Page 48: ...emperature gauge for thermal oil f Thermal oil temperature Fig 63 No 57 Temperature gauge for binder tank Fig 64 No 58 Water level gauge for reaction water tank Fig 65 No 59 Ventilation lever Fig 66 N...

Page 49: ...BOMAG 49 MPH 122 2 4 Operation...

Page 50: ...k l fuel tank and fuel lines for leaks l screw joints for tight fit l function of steering l function of brakes l function of emergency stop l hydraulic oil tank and lines for leaks l engine and machi...

Page 51: ...elements on the machine Fig 67 l Insert the main battery switch Fig 67 and switch to position I Fig 68 l Turn the rotary switch for free wheeling of ro tor a Fig 68 to position Left free wheel ing of...

Page 52: ...heck whether the travel lever Fig 73 is in neutral position Fig 74 l Set the engine speed potentiometer Fig 74 to position MIN idle speed Fig 75 l Turn the ignition key Fig 75 to position I Fig 76 All...

Page 53: ...ol light for height shut down h with rotor in highest position and the parking brake warning light j stay on Caution Run the engine warm for a short while before starting work Do not rev up a cold eng...

Page 54: ...ositive poles af ter l Switch off the consumer i Note Run the engine warm for a short while 4 5 Driving the machine to work Danger Danger of accident Wet and loose soils considerably reduce the ground...

Page 55: ...down Fig 82 to such a height that the ma chine is safe to drive Fig 83 The height shut down control light h Fig 83 in the instrument cluster for machine functions lights up Fig 84 l Turn the rotary s...

Page 56: ...er Returning the travel lever towards neutral will brake the machine and in 0 position of the travel lever the machine will stop Notes on travel operation Caution When changing the travel direction ho...

Page 57: ...Note The parking brake must only be operated in ex ceptional cases e g when stopping on a slope or to hold the machine with the engine running The parking brake closes automatically when shutting the...

Page 58: ...case of frequent use the wear on the multi discs brakes will be very high i Note The machine is equipped with three emergency stop switches Fig 91 l Press the button of the emergency stop switch Fig...

Page 59: ...g 94 l Turn the rotary switch for the rotor Fig 94 to position 0 rotor off Fig 95 l Lower the rotor to the ground by operating the lever rotor up down Fig 95 Fig 96 l Set the engine speed potentiomete...

Page 60: ...ition key out lock the cabin door Pull out the main battery switch at the earliest 40 seconds after switching off the ignition except in cases of emergency Caution If the thermal oil in vehicle with b...

Page 61: ...er the rotor to the ground by operating the lever rotor up down Fig 100 Fig 101 l Before shutting the engine down turn the rota ry switch for parking brake Fig 101 to posi tion Right parking brake app...

Page 62: ...l clothes Working clothes and respiratory equipment should not be stored together with normal clothes Dust covered working clothes must be cleaned at regular intervals Checking the condition of the cu...

Page 63: ...Danger Danger of accident Always secure the hood gate with the bolt when working on the rotor Fig 109 l Take bolt 4 and spring pin 2 Fig 109 from the securing rod of the cab Fig 110 l Insert bolt 4 F...

Page 64: ...113 Round shank cutting tools must be free to turn in the sleeve l If necessary replace the cutting teeth Caution If necessary check the condition of the cutting teeth several times a day in order to...

Page 65: ...speed depends on cutting depth ro tor speed type of soil particle size required mixing ratio selected travel range If the power limit control interfers actively with the machine operation the machine...

Page 66: ...300 mm above ground level the rotor is automatically switched on again Fig 121 l Switch the rotor on with rotary switch for rotor speed Fig 121 and set it to the specified range Fig 122 i Note The con...

Page 67: ...ontroller l Shift the travel lever Fig 124 slowly to travel direction I forward until the max travel speed is reached Fig 125 l Set the desired max travel speed on the speed controller Fig 125 Fig 126...

Page 68: ...apidly the machine has reached its load limit Reduce the load by manual intervention 4 14 Adjusting the tailgate i Note Adjust the tailgate only when driving forward Fig 128 l Operate lever Fig 128 to...

Page 69: ...he lever for rear frame steering Fig 131 forward or backward until the wheels are in straight ahead direction 4 16 Adjusting the oscillation an gle of the rotor cross slope Fig 132 l Operate the lever...

Page 70: ...ition 4 17 Mixing water connection preparing for operation Caution You should generally use a tow bar Fig 135 l Remove the tow bar Fig 135 from the hood flap Fig 136 l Couple the MPH to the tanker Fig...

Page 71: ...the shut off lever for the cleaning port a Fig 139 to position 0 locked i Note The shut off cock is used to drain all water off if there is a risk of frost or to connect a hose to clean the machine Fi...

Page 72: ...ons Fig 143 lights up and the warning buzzer sounds Check water supply bleed Clean the water filter at regular intervals 4 18 Water dosing system noz zle change i Note In water dosing systems with 160...

Page 73: ...uspension Remember that the plates will swing out when cornering Lower the plates Fig 145 l Operate the rotary button to lift lower the plate Fig 145 to move the attachment plat to the desired positio...

Page 74: ...ion 0 Fig 149 l Shift the travel lever Fig 149 slowly to posi tion neutral position The machine is automatically braked hydrostati cally Fig 150 l Lift the rotor by operating the lever for rotor up do...

Page 75: ...ction l Check the cutting teeth replace if necessary see corresponding section 4 21 Raising lowering the cabin i Note Under normal conditions the cabin only needs to be lifted for repair work Fig 153...

Page 76: ...clip l Assemble the support rod 1 Fig 156 and secure it with bolt and spring clip l Remove the support rod and store it in the cor responding bracket before lowering the cabin Fig 157 l Turn the leve...

Page 77: ...ine only after releasing the park ing brake Towing speed 1 km h max towing distance 500 m Releasing the multi disc brake with the hydraulic hand pump Fig 159 l Turn the lever 1 on the hydraulic hand p...

Page 78: ...operating the pump lever until the rotor has reached transport position Fig 164 l Slacken both high pressure relief valves Fig 164 on the travel pump for approx two turns Fig 165 Caution Generally use...

Page 79: ...ne tipping or sliding off Always switch the rotor off Always switch to transport range I to drive the machine onto the transport vehicle Lash the machine down so that it is secured against rolling sli...

Page 80: ...iving the machine onto the transport vehicle swing the articulation lock 1 Fig 168 out of its receptacle and fasten to the eye on the cross member Secure the bolt 2 with the cotter pin 3 Fig 169 l Ope...

Page 81: ...ine can no longer be used and needs to be finally shut down you must carry out the follow ing work and have the machine disassembled by an approved specialist workshop Environment Catch all fuels and...

Page 82: ...Operation BOMAG 82 MPH 122 2...

Page 83: ...BOMAG 83 MPH 122 2 5 Operation of binder dosing system...

Page 84: ...r screw fit tings and couplings l Check for leakages on components of the binder thermal oil and reaction water circuits l Check the reaction water level top up if neces sary l Check the oil level in...

Page 85: ...w rate n to position 0 Setting the thermal oil temperature Fig 176 l Set the thermal oil temperature by the working thermostat Fig 176 l Emulsion max 80 C l Bitumen max 200 C i Note With emulsion the...

Page 86: ...e possible Hitch up the tanker Fig 179 l Remove the tow bar Fig 179 from the hood flap Fig 180 l Couple the MPH to the tanker Fig 180 Danger Danger of burning The suction hose is hot Wear heat proof g...

Page 87: ...se of auf the fault has been determined and rectified Venting the system Fig 181 l Main switch b Fig 181 in On position l Set the selector switch for foam bitumen emul sion d to position Emulsion Fig...

Page 88: ...n Spraying l If necessary regulate the medium flow with the binder quantity potentiometer m Interrupting work l Set the selector switch for spraying circulation k to position Circulation All nozzles o...

Page 89: ...use of auf the fault has been determined and rectified Venting the system Fig 186 l Main switch b Fig 186 in On position l Set the selector switch for foam bitumen emul sion d to position Bitumen Fig...

Page 90: ...praying circulation k to position Spraying Fig 191 l Close the spraying sections n Fig 190 when the reaction water pressure gauge b Fig 191 has reached a pressure of at least 4 bar l Set the selector...

Page 91: ...n the spray bar needs to be completely emptied before hand l Completely drain the bitumen system see chapter Blowing out bitumen system and spray bar 5 5 Changing the bitumen tank Fig 193 When the bit...

Page 92: ...nd use the clamp ing bracket to secure it against twisting l Open the Peet valve 2 l Open the shut off tap 1 on the tanker 5 6 Finishing work Fig 196 Danger Danger of burning The suction hose is hot W...

Page 93: ...switch the main battery switch to position 0 after the fan on the thermal oil heater burn er has stopped running Heat exchanger and burner may otherwise be destroyed 5 7 Blowing out bitumen sys tem an...

Page 94: ...ig 201 l Set the selector switch for spraying circulation k Fig 201 to position Circulation l Switch on the compressor c l Set the binder quantity potentiometer m to medium flow Fig 202 l Open the bal...

Page 95: ...BOMAG 95 MPH 122 2 6 Maintenance...

Page 96: ...he trouble shooting chart you should contact the service departments at our branch offices or dealers Notes on the fuel system The lifetime of the diesel engine depends to a great extent on the cleanl...

Page 97: ...ot leave the tank opening unnecessarily open but cover it so that nothing can fall in 6 2 Fuels and lubricants Engine oil Quality For use in DEUTZ engines the lubrication oils are classified in DEUTZ...

Page 98: ...fect on the oil change intervals The fuel level should always be topped up in due time so that the fuel tank is never run dry as oth erwise filter and injection lines need to be bled Quality The follo...

Page 99: ...e for any important reasons you may in excep tional cases use products that have been approved by the engine manufacturer The list of approved cooling system protection agents is also available in the...

Page 100: ...aulic oil to an ester based biologically degradable oil you should consult the lubrication oil service of the oil manufacturer for details Caution Check the filter more frequently after this change Pe...

Page 101: ...Maintenance BOMAG 101 MPH 122 2 Compressor service unit Use only acid free pneumatic oil STASTO HP 32...

Page 102: ...es Coolant Mixture of water and anti freeze agent Specification see Fuels and lubricants coolant approx 50 litres Hydraulic system Hydraulic oil ISO HLP 46 BOMAG PN 009 930 09 20 l or ester based biod...

Page 103: ...sure grease lithium saponified as required Air conditioning system Refrigerant R134a approx 2400 g Exciter shaft housing at tachment plate SAE 75W 90 API GL 5 BOMAG PN 009 925 05 20 l approx 2 7 l eac...

Page 104: ...50 operating hours l Change engine oil and oil filter cartridge l Change all fuel filters l Retighten bolted connections on intake and exhaust tubes oil sump and engine mounts l Retighten all bolted c...

Page 105: ...level Instrument clus ter X 6 10 Check the condition of the cutters X 6 11 Check front and rear tire pressures X 6 12 Visual inspection for leakages and damage clean the machine X 6 13 Clean the later...

Page 106: ...rvice the air conditioning X 6 27 Check the oil level in the front right left hand travel gear X 6 28 Check the oil level in the rear axle reduction gear X 6 29 Clean the ventilation valve on the rear...

Page 107: ...eplacing the fuel pre filter car tridge bleed the fuel system X 6 44 Check the anti freeze concentration and the condition of the coolant X 6 45 Intercooler drain lubricating oil condensation water mi...

Page 108: ...2 years see foot note X 6 57 Change the hydraulic oil fine fil ter see foot note X 6 58 Changing the coolant min every 2 years X 6 59 Retighten the screws on the articu lated joint X 6 60 Check the f...

Page 109: ...een washer tank X 6 71 Change the tires X 6 72 Lubricate the attachment plate ad justment spindles X 6 73 Clean the bitumen filter only with binder metering sys tem X 6 74 Reaction water tank maintena...

Page 110: ...Maintenance BOMAG 110 MPH 122 2 oil change after 250 and 1000 operating hours then every 1000 operating hours Also after repairs in the hydraulic system...

Page 111: ...tick until it bottoms and pull it out again l The oil level must always be between the MIN and MAX marks fill up oil if neces sary 6 7 Checking the fuel level Caution Do not drive the fuel tank dry as...

Page 112: ...l Caution In hydraulic systems filled with Panolin HLP Synth 46 use always the same oil to top up With other ester based oils consult the lubrica tion oil service of the respective oil manufac turer C...

Page 113: ...engine for leaks Do not use radiator sealant to seal leaks For coolant refer to the table of fuels and lu bricants Fig 208 i Note A too low coolant level is indicated by the coolant level warning ligh...

Page 114: ...t damage to the rotor Change damaged cutting teeth immediately see chapter Replacing cutting teeth holders l Start the engine and run it at idle speed Fig 210 l Turn the rotary switch for parking brak...

Page 115: ...nsert bolt 4 Fig 215 taken off the cab se curing rod into the opening in hood 3 and tail gate and secure it from the inside of the tailgate with a spring pin 2 Fig 216 l Turn the rotary switch for fre...

Page 116: ...ger Danger of bursting Take care of the air pressure when inflating tires Excessive pressure causes the risk of bursting Caution Mitas tires are filled with a water anti freeze mixture water You shoul...

Page 117: ...ine Deposits accumulations of combustible mate rials especially on or near components with higher temperatures e g exhaust pipes must be cleaned off at regular intervals If you clean the machine with...

Page 118: ...3 l Remove left and right hand service doors Fig 223 l Remove loose and dried on dirt with a strong water jet from both sides of the rotor hood 6 14 Cleaning the dirt scrapers on the hydraulic cylinde...

Page 119: ...ontamination spray the parts with cold cleansing agent and spray it off with a water jet after s sufficient soaking time l If steam cleaning equipment is available this should preferably be used l Aft...

Page 120: ...ll completely with water Fig 230 before starting work 6 17 Checking the oil level for the reaction water pump Caution For quality and quantity of oil refer to the table of fuels and lubricants Fig 231...

Page 121: ...l Check the oil level in the sight glass 2 of the service unit fill up oil if necessary l If necessary drain the water from the service unit inspection bowl 3 6 19 Checking the thermal oil level Caut...

Page 122: ...the binder pump for leaks Fig 235 l Check the binder pump Fig 235 for leaks at operating temperature l If necessary retighten the stuffing boxes even ly on both sides Caution Do not over tighten the...

Page 123: ...operating temperature l If necessary retighten the stuffing boxes even ly on both sides Caution Do not over tighten the stuffing boxes During operation a small quantity of fluid must leak out of the...

Page 124: ...Every 10 operating hours BOMAG 124 MPH 122 2...

Page 125: ...of high pressure grease from the grease gun Greasing articulated joint and steering cylinder bearings Fig 237 l Clean and lubricate the right hand grease nip ple Fig 237 Fig 238 l Clean and lubricate...

Page 126: ...Clean and lubricate the front grease nipple Fig 241 Fig 242 l Clean and lubricate the rear grease nipple Fig 242 Greasing the oscillating joint Fig 243 l Clean and lubricate the grease nipple Fig 243...

Page 127: ...uce the cooling effect You should therefore immediately seal any oil or fuel leaks near cooling fan cylinder or oil cooler and subsequently clean the cooling fins Danger Danger of injury Perform clean...

Page 128: ...After cleaning the coolers it is mandatory to clean the engine Cover all parts of the electrical system do not subject to the direct water jet Fig 249 l Blow the engine dry with compressed air Flush l...

Page 129: ...not spill any fuel Shut down the engine Danger Health hazard Do not inhale any fuel fumes Environment Catch running out fuel do not let it seep into the ground l Open the right hand service door Fig...

Page 130: ...Every 50 operating hours BOMAG 130 MPH 122 2...

Page 131: ...nser Danger Danger of accident Do not clean with a hot water jet Heat will cause extreme overpressure which could cause damage or explosion of the system Use access steps and grips to mount and dis mo...

Page 132: ...g fan Fig 256 to position 2 l Open the air outlet nozzles Fig 257 l Turn the rotary thermostat switch Fig 257 clockwise The air flow cools down i Note The adjusted temperature must be below the actu a...

Page 133: ...g season Checking the condition of the drier col lector unit Caution According to the regulation for pressure reser voirs all pressure reservoirs must be repeated ly inspected by a specialist In this...

Page 134: ...of the bore top up oil if neces sary For quality and quantity of oil refer to the table of fuels and lubricants l Clean the oil filler and inspection plug and screw it back in tightly 6 28 Checking th...

Page 135: ...jet Water may enter 6 30 Check the oil level in the rear axle i Note The rear axle must be horizontally on level ground Fig 265 l Clean and unscrew the oil filler and level con trol plug on left and r...

Page 136: ...water jet Water may enter 6 32 Check the oil level in the rear planetary gear Caution Check the oil level in both planetary drives For quality of oil refer to the table of fuels and lubricants Fig 267...

Page 137: ...cartridge Fig 268 l Unscrew the cap from the oil drain socket Fig 268 l Drain off and catch the engine oil l Screw the cap back on after the oil has run out Fig 269 l Loosen and unscrew the engine oi...

Page 138: ...l initially every day later as required for signs of water If a too high quantity is drained off the filter needs to be bled see section Replacing the fuel pre cleaner cartridge Fig 271 Caution If the...

Page 139: ...belt tension Fig 274 l Lover the indicator arm 1 Fig 274 into the measuring unit l Rest the guide 3 on the V belt 2 between two belt pulleys The stop should abut against the side l Evenly press the bu...

Page 140: ...ng time of 15 minutes 6 36 Servicing the air condition ing compressor V belt Danger Danger of injury Work on the V belt must only be performed with the engine shut down Check the V belt Fig 276 l Insp...

Page 141: ...en working on the battery do not use open fire do not smoke The battery contains acid Wear protective clothing Do not let acid come in contact with skin or clothes Do not lay any tools on the battery...

Page 142: ...ig 278 Fig 279 l Pull the carrier plate with batteries 2 Fig 279 completely out release the lock to do so l Turn the tommy screw 1 anti clockwise l Press the locking button and turn the tommy screw ba...

Page 143: ...in cases of emergency l Turn the main battery switch Fig 281 to po sition 0 and check by voltage measurement ignition key test whether the batteries are disconnected from the electric system of the ma...

Page 144: ...hange in rotor gearbox check rotor water level Danger Life hazard Do not lift and support the rotor hood with a jack or similar When working on the rotor keep all persons out of the cabin or off the o...

Page 145: ...or hood is in highest po sition Fig 286 l Hook the safety chains Fig 286 by the two large chain links into the hooks on the rotor hood Fig 287 l Lower the rotor to just above the ground by op erating...

Page 146: ...tailgate with a spring pin 2 Fig 291 l Turn the rotary switch for free wheeling of ro tor a Fig 291 to position Right Fig 292 l Turn the rotor further with the rotary switch for cutter change b Fig 29...

Page 147: ...ct the pressure relief valve to the oil fill ing hose Fig 294 and apply compressed air for about 10 minutes Caution Do not exceed a pressure of 1 0 bar in the oil filling hose as otherwise the seal ri...

Page 148: ...Fig 299 l Unscrew the oil drain plug Fig 299 for venti lation during filling Fig 300 l Use a gear oil pump Fig 300 to fill in oil Caution Make sure to fill in the exact quantity For quality and quant...

Page 149: ...sition l Unscrew the middle inspection plug and check the filling level Caution If the water level is not just below the opening you must fill up water For filling or topping up all three inspection p...

Page 150: ...Every 500 operating hours BOMAG 150 MPH 122 2 Fig 307 l Remove the bolt 4 Fig 307 from the hood tailgate l Close the tailgate...

Page 151: ...ng the intake cycle the exhaust valve opens for a short mo ment This must not be mistaken as overlapping of valves Fig 310 Check the valve clearance l Intake valves 0 25 mm l Exhaust valves 0 30 mm l...

Page 152: ...umes Caution Ensure strict cleanliness Thoroughly clean the area around the fuel filters After work on the fuel system bleed the sys tem perform a test run and check for leaks Additional bleeding of t...

Page 153: ...e bleed the fuel system Danger Fire hazard When working on the fuel system do not use open fire do not smoke and do not spill any fu el Danger Health hazard Do not inhale any fuel fumes Caution Ensure...

Page 154: ...cable of the water sensor back on Bleed the fuel system i Note Air in the fuel system causes irregular running of the engine a drop in engine power stalls the en gine and makes starting impossible The...

Page 155: ...In case of lubrication oil entering into the cool ing system or a suspicious turbidity caused by corrosion residues or other suspended matter the coolant must be drained off and the com plete cooling...

Page 156: ...hand engine compartment door Fig 316 l Unscrew the drain plug Fig 316 and catch running out fluid 6 46 Check the fastening of en gine turbocharger com bustion air hoses Fig 317 l Check charge air lin...

Page 157: ...gauge 1 Fig 317 to the oil dipstick opening using hose and hose clamps l Make sure that the connection is tightly sealed l Fill half of the U pipe pressure gauge with wa ter l Fasten the U pipe press...

Page 158: ...ch running out oil and dispose of environ mentally Fig 319 l Drive the machine until the drain plug 2 Fig 319 is at the deepest point l Clean and unscrew filler and level control plug 1 l Clean and un...

Page 159: ...e table of fuels and lubricants Environment Catch running out oil and dispose of environ mentally Fig 321 l Drive the machine until the drain plug Fig 321 is at the lowest point l Clean the plug and u...

Page 160: ...of environ mentally Fig 323 l Unscrew the oil filling and level inspection plug Fig 323 l Unscrew the oil drain plug and catch any oil running out l Clean and turn the oil drain plug back in tightly...

Page 161: ...n mentally Fig 326 l Unscrew the oil filler and oil level inspection plugs Fig 326 l Unscrew the oil drain plugs l Catch running out oil and dispose of environ mentally l Clean the oil drain plugs and...

Page 162: ...lubricants for oil grade and volume Environment Catch running out oil and dispose of environ mentally Fig 329 l Unscrew the oil drain plugs on both sides Fig 329 drain and catch running out old oil l...

Page 163: ...sen the hose clamp 2 and renew the fuel filter 2 l Tighten the hose clamp l Assemble and tighten fuel lines 6 54 Changing the thermal oil Fig 332 Caution Perform this maintenance work at the latest af...

Page 164: ...correct as necessary 6 55 Compressor oil change Caution Perform this maintenance work at the latest af ter one year For quality and quantity of oil refer to the table of fuels and lubricants Environme...

Page 165: ...r quality and quantity of oil refer to the table of fuels and lubricants When changing from mineral oil based hydrau lic oil to an ester based biologically degradable oil you should consult the lubric...

Page 166: ...and fill in new hydraulic oil through the screen filter l Screw the plug back in with a new seal and tighten it l Replace the breather filter 1 i Note We recommend to use the BOMAG filling and fil ter...

Page 167: ...tervals the fil ter element must also be changed after major re pairs in the hydraulic system l Open the right hand service door Fig 341 l Remove the locking wire if present l Unscrew the spigot nut F...

Page 168: ...se of environmentally Fig 342 l Unscrew the cap Fig 342 Fig 343 l Unscrew the plug from the drain cock Fig 343 and connect the drain hose l Guide the drain hose into a vessel of appropri ate size l Op...

Page 169: ...ose the compensation tank l For bleeding start the engine and run it warm l Allow the engine to cool down to approx 50 C l Check the coolant level top up if necessary l The coolant level must reach th...

Page 170: ...g hours BOMAG 170 MPH 122 2 6 60 Checking the fire extin guisher Fig 346 i Note This work must only be performed by a qualified person Fire extinguishers must be checked at the latest after two years...

Page 171: ...Every 4000 operating hours BOMAG 171 MPH 122 2 Every 4000 operating hours 6 61 Changing the injection valve i Note This work must only be performed by authorized service personnel...

Page 172: ...Every 4000 operating hours BOMAG 172 MPH 122 2...

Page 173: ...122 2 Every 6000 operating hours 6 62 Replacing the crankcase ventilation valve Fig 347 l Replace the crankcase ventilation valve Fig 347 6 63 Changing the coolant pump i Note This work must only be p...

Page 174: ...Every 6000 operating hours BOMAG 174 MPH 122 2 6 64 Changing the pressure re taining valve on te injection pump i Note This work must only be performed by authorized service personnel...

Page 175: ...ed until the end of the day Caution Do not clean the safety cartridge but replace immediately Fig 349 l Unscrew wing nut 1 Fig 349 remove cover 2 Fig 350 l Unscrew hexagon nut 1 Fig 350 and pull safet...

Page 176: ...not continue to run the machine with a damaged main filter element If in doubt use a new main filter element Cleaning the dust bowl Fig 353 l Remove the insert Fig 353 from the filter housing and cle...

Page 177: ...er on 6 66 Replacing the cutting teeth cutting tooth holders Danger Life hazard Do not lift and support the rotor hood with a jack or similar When working on the rotor keep all persons out of the cabi...

Page 178: ...is in highest po sition Fig 358 The height shut down control light h Fig 358 in the instrument cluster for machine functions lights up Fig 359 l Hook the safety chains Fig 359 by the two large chain l...

Page 179: ...g 363 l Insert bolt 4 Fig 363 taken off the cab se curing rod into the opening in hood 3 and tail gate and secure it from the inside of the tailgate with a spring pin 2 Fig 364 l Turn the rotary switc...

Page 180: ...OMAG No 591 701 38 Fig 367 Caution If the seat area is at one point smaller than the large diameter of the male gauge have a new holder assembled using the special tool kit BOMAG No 590 020 23 Fig 368...

Page 181: ...se curing rod l Close the tailgate 6 67 Grease the bearings of the lift cylinder for the cabin Fig 371 l Clean the grease nipples Fig 371 l Lubricate each grease nipple with approx 5 strokes of high...

Page 182: ...replace if necessary Caution In case of frost drain the complete system l Open the front service flap Fig 373 l Open the drain valve 1 Fig 373 on the wa ter pump and let all water flow out Fig 374 l...

Page 183: ...xhaust when hot Fig 375 l Unscrew six screws 1 Fig 375 from the cover and take off the cover l Remove and replace the filter mat 2 l Screw the cover back on 6 70 Fill the provision tank for the windsc...

Page 184: ...wheel nuts and take the wheel off Fig 377 l Attach the new wheel with the arrow profile in travel direction Fig 377 l Tighten the wheel nuts cross wise Tightening torques l front 463 Nm l rear 500 Nm...

Page 185: ...edure l Enter code 6 9 1 for standard tires l Enter code 6 9 2 for EM tires l Switch the ignition off and on again The set mode is now active l For checking the tire type setting enter code 1 2 9 anal...

Page 186: ...the bitumen filter must be un screwed before the bitumen has cooled down and solidified Wear heat proof gloves Fig 382 l Loosen four nuts Fig 382 and swing to the side Fig 383 l Assemble the plate Fig...

Page 187: ...c unified thread Fig 386 Strength classes for screws with untreated non lubricated surface The screw quality is stamped on the screw heads 8 8 8G 10 9 10K 12 9 12K The values result in a 90 utilizatio...

Page 188: ...il is distributed to all parts l After this engine run remove the cylinder head covers and the side cover of the injection pump spray rocker chambers as well as spring chamber in injection pump with a...

Page 189: ...BOMAG 189 MPH 122 2 7 Trouble shooting...

Page 190: ...Faults occur frequently due to the fact that the machine has not been properly operated or serv iced Therefore whenever a fault occurs read through these instructions on correct operation and mainten...

Page 191: ...eparation Change the filter use winter fuel Fuel lines leaking Check all line connections for leaks and tighten the fittings bleed the fuel system Air in the fuel system Bleed the fuel system Fuel lif...

Page 192: ...s defective Have examined by a specialist Dry air filter cartridge soiled engine air fil ter control light in monitoring board and central warning light are on replace Vacuum switch defective Check va...

Page 193: ...he cooling air duct Too high concentration of anti freeze and or coolant additives Use correct concentration Engine has too low oil pressure engine must be immediately shut down Coolant level too low...

Page 194: ...fault is eliminated the fault lamp will go out The diagnostic button provides the possibility to read out existing faults in form of flashing codes Example fault code 211 Fig 387 l Press the diagnose...

Page 195: ...ins System works switches off Overpressure because of high ambient temperatures Run the system until the pressure has sta bilized System does not work Vacuum drier clogged Replace the drier only by a...

Page 196: ...low Increase the engine speed Bitumen temperature too low The bitumen temperature must be min 180 C check the binder temperature check the thermal oil temperature Bitumen filter dirty Clean the bitum...

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Fayat Group Bomag MPH 122-2, Operating & Maintenance Instructions

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