Table of Contents

Advertisement

Operating Instruction
Maintenance Instruction
Original Operating Instructions
BW 124 PDH-5
S/N 101 586 85 1001>
Single drum roller
008 202 90 EN
© 01/2019

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BOMAG BW 124 PDH-5 and is the answer not in the manual?

Questions and answers

Summary of Contents for Fayat BOMAG BW 124 PDH-5

  • Page 1 Operating Instruction Maintenance Instruction Original Operating Instructions BW 124 PDH-5 S/N 101 586 85 1001> Single drum roller 008 202 90 EN © 01/2019...
  • Page 2 WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system.
  • Page 3: Table Of Contents

    Table of contents Table of contents Introduction.................... 9 1.1 Foreword..................10 1.2 Machine type plate and engine type plate......... 12 Technical data..................13 2.1 Noise and vibration data.............. 16 2.1.1 Noise data................... 17 2.1.2 Vibration data................17 Concerning your safety..............19 3.1 Basic prerequisites..............
  • Page 4 Table of contents 3.4.6 Safety regulations and environmental protection regulations for handling battery acid..............39 3.5 Load/transport the machine............41 3.6 Starting up the machine.............. 43 3.6.1 Prior to start-up................43 3.6.2 Starting the engine..............44 3.6.3 Starting the engine with jump leads..........44 3.7 Driving the machine;...
  • Page 5 Table of contents 4.1.3 Travel lever.................. 77 4.1.4 Travel lever with dozer blade control........... 78 4.1.5 Main battery switch..............79 4.1.6 12 V DIN socket................80 4.1.7 ECONOMIZER display..............80 4.1.8 Rotary switch ECONOMIZER............. 80 Checks prior to start up..............81 5.1 Notes on safety................
  • Page 6 Table of contents 6.8.3 Towing the machine..............112 6.8.4 After towing................114 Loading / transporting the machine..........119 7.1 Preparation for transport............120 7.2 Loading the machine..............121 7.3 Lashing the machine to the transport vehicle......123 7.4 Loading by crane................ 124 7.5 After transport................
  • Page 7 Table of contents 8.8.5 Checking the oil level in the drive axle........149 8.8.6 Check the oil level in the bevel gear housing......150 8.8.7 Checking the oil level in the wheel hubs........151 8.8.8 Checking the oil level in the drum drive reduction gear..... 151 8.8.9 Check the parking brake............
  • Page 8 Table of contents 8.12.2 Cleaning the DPF..............184 8.12.3 Checking the exhaust gas recirculation system...... 184 8.13 As required................185 8.13.1 Air filter maintenance............... 185 8.13.2 Checking and cleaning the water separator......188 8.13.3 Adjusting the scrapers............. 189 8.13.4 Cleaning the machine.............. 190 8.13.5 Draining the fuel tank sludge...........
  • Page 9: Introduction

    Introduction Introduction BW 124 PDH-5...
  • Page 10: Foreword

    Introduction – Foreword Foreword BOMAG manufactures machines for earth, asphalt and refuse compaction, stabilizers/ recyclers as well as planers and pavers. BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all impor- tant components and highest quality demands guarantee maximum reliability of your machine.
  • Page 11 Introduction – Foreword A description of all necessary maintenance work, maintenance intervals as well as informa- tion on fuels and lubricants can be found in the Ä Chapter 8 „Mainte- chapter “Maintenance” nance“ on page 127. Do not service or repair your machine by your- self to avoid harming persons or damaging material or environment.
  • Page 12: Machine Type Plate And Engine Type Plate

    Introduction – Machine type plate and engine type plate Machine type plate and engine type plate Please enter here: Machine type (1): Serial number (2): Fig. 1: Machine type plate (example) Please enter here: Engine type (Fig. 1) Engine number (2): Fig.
  • Page 13: Technical Data

    Technical data Technical data BW 124 PDH-5...
  • Page 14 Technical data Dimensions Fig. 3 1815 1310 1850 2520 3520 1200 (71) (52) (37.8) (73) (99) (12.6) (139) (2.2) (0.59) (47) Dimensions in millimetres (Dimensions in inch) Weights Max. operating weight 4000 (8818) (lbs) Operating weight (CECE) 3390 (7474) (lbs) Axle load, drum (CECE) 1660 (3660)
  • Page 15 Technical data Travel characteristics 0 - 9 Travel speed km/h (0 - 5.5) (mph) Max. gradeability without/with vibration (soil 55/55 dependent) Drive Engine manufacturer Kubota Type V2403-CR-E4 Cooling system Water Number of cylinders Rated power ISO 3046 Rated power SAE J 1995 Nominal speed 2400 Electric system...
  • Page 16: Noise And Vibration Data

    Technical data – Noise and vibration data Steering Type of steering Oscill.-articul. Steering angle +/- 35 ° Oscillation angle +/- 12 ° Inner track radius 2260 (89) (in) Exciter system Drive system hydrostatic Frequency (2460) (vpm) Amplitude (1/2) 1.60/0.80 (0.063/0.031) (in) Centrifugal force (1/2) 85/43...
  • Page 17: Noise Data

    Technical data – Noise and vibration data 2.1.1 Noise data Sound pressure level at = 87 dB(A), determined acc. to ISO 11201 the operator's stand and EN 500. WARNING! Loss of hearing caused by too high noise burdens! – Wear your personal protective equipment (ear protection).
  • Page 18 Technical data – Noise and vibration data BW 124 PDH-5...
  • Page 19: Concerning Your Safety

    Concerning your safety Concerning your safety BW 124 PDH-5...
  • Page 20: Basic Prerequisites

    Concerning your safety – Basic prerequisites Basic prerequisites 3.1.1 General This machine has been built in compliance with the latest technical standard and complies with the applicable regulations and technical rules. However, dangers for persons and property may arise from this machine, if: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel,...
  • Page 21: Explanation Of Signal Words Used

    Concerning your safety – Basic prerequisites 3.1.2 Explanation of signal words used: DANGER! Danger to life if failing to comply! Sections marked accordingly indi- cate an extremely dangerous situa- tion that could lead to fatal or severe injuries, if this warning is dis- regarded.
  • Page 22: Personal Protective Equipment

    Concerning your safety – Basic prerequisites Sections marked accordingly indi- cate technical information or notes on using the machine or its compo- nents. ENVIRONMENT! Environmental damage if failing to comply! Paragraphs marked accordingly indicate practices for safe and envi- ronment-friendly disposal of fuels and lubricants as well as replace- ment parts.
  • Page 23: Intended Use

    Concerning your safety – Basic prerequisites Face protection To protect the face against airborne par- ticles and squirting fluids. Hard hat To protect the head against falling parts and to protect against injuries. Hearing protection To protect hearing against excessive noise.
  • Page 24 Concerning your safety – Basic prerequisites Examples of improper use are: Work with vibration on hard concrete, cured bitumen layers or extremely frozen ground Driving on non-load-bearing subsoil or inad- equate contact areas (danger of tilting) Using the machine for towing Using to pull down walls or demolish build- ings Transporting persons, except the machine...
  • Page 25: Definition Of Responsible Persons

    Concerning your safety – Definition of responsible persons Definition of responsible persons 3.2.1 Operating company The operating company is the natural or jurid- ical person who uses the machine or in who's name the machine is used. The operating company must make sure that the machine is only used for the purpose it is intended for and in strict compliance with the safety regulations mentioned in these operating...
  • Page 26: Driver / Operator

    Concerning your safety – Definition of responsible persons This person is acquainted with the applicable governmental industrial safety regulations, accident prevention instructions, guidelines and generally acknowledged technical rules and regulations (standards, directives, technical rules of other member states of the European Union or other contractual states concerning the agreement about the European Economic Area) in as far as is necessary to be able to...
  • Page 27: Fundamentals For Safe Operation

    Concerning your safety – Fundamentals for safe operation Fundamentals for safe operation 3.3.1 Remaining dangers, remaining risks Despite careful work and compliance with standards and regulations it cannot be ruled out that further dangers may arise when working with and handling the machine. Both the machine as well as all other system components comply with the currently valid safety regulations.
  • Page 28: Damage, Defects, Misuse Of Safety Devices

    Concerning your safety – Fundamentals for safe operation We wish to make explicitly clear that we have not tested or approved any parts or accesso- ries not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive safety.
  • Page 29 Concerning your safety – Fundamentals for safe operation A defect ROPS must generally be replaced with an original spare part in close coordination with the manufacturer. BW 124 PDH-5...
  • Page 30: Handling Fuels And Lubricants

    Concerning your safety – Handling fuels and lubricants Handling fuels and lubricants 3.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the indi- vidual fuels and lubricants. Safety data sheets provide valuable informa- tion about the following characteristics: name of substance...
  • Page 31: Safety Regulations And Environmental Protection Regulations For Handling Diesel Fuel

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.2 tions for handling diesel fuel WARNING! Danger of burning by ignited diesel fuel! – Do not allow diesel fuel to come into contact with hot compo- nents.
  • Page 32 Concerning your safety – Handling fuels and lubricants ENVIRONMENT! Diesel fuel is an environmentally hazardous substance! – 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.
  • Page 33: Safety Regulations And Environmental Protection Regulations For Handling Oil

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.3 tions for handling oil WARNING! Danger of burning by ignited oil! – Do not allow oil to come into con- tact with hot components. – Smoking and open fire is pro- hibited! –...
  • Page 34 Concerning your safety – Handling fuels and lubricants – Immediately bind spilled oil with an oil-binding agent. – Dispose of oil and oil filter according to regulations. BW 124 PDH-5...
  • Page 35: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic Oil

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.4 tions for handling hydraulic oil WARNING! Danger of injury caused by escaping pressure fluid! – Always depressurize the hydraulic system before starting work in the hydraulic system. –...
  • Page 36 Concerning your safety – Handling fuels and lubricants CAUTION! Health hazard caused by contact with hydraulic 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! –...
  • Page 37: Safety Regulations And Environmental Protection Regulations For Handling Coolants

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.5 tions for handling coolants WARNING! Danger of scalding by hot fluid! – Open the compensation tank only when the engine is cold. – Wear your personal protective equipment (protective gloves, protective clothing, goggles).
  • Page 38 Concerning your safety – Handling fuels and lubricants – Immediately bind spilled coolant with an oil-binding agent and dis- pose of it according to regula- tions. – Dispose of coolant according to regulations. BW 124 PDH-5...
  • Page 39: Safety Regulations And Environmental Protection Regulations For Handling Battery Acid

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.6 tions for handling battery acid WARNING! Danger of cauterization with acid! – Wear your personal protective equipment (protective gloves, protective clothing, goggles). – Do not allow clothes, skin or eyes to come into contact with acid.
  • Page 40 Concerning your safety – Handling fuels and lubricants ENVIRONMENT! Battery acid is an environmen- tally hazardous substance! – Dispose of battery and battery acid according to regulations. BW 124 PDH-5...
  • Page 41: Load/Transport The Machine

    Concerning your safety – Load/transport the machine Load/transport the machine Use only stable loading ramps of sufficient load bearing capacity. Loading ramps and transport vehicle must be free of grease, oil, snow and ice. The ramp inclination must be less than the gradability of the machine.
  • Page 42 Concerning your safety – Load/transport the machine After the transport loosen the articulation lock again, as otherwise the machine wouild not be steerable. BW 124 PDH-5...
  • Page 43: Starting Up The Machine

    Concerning your safety – Starting up the machine Starting up the machine 3.6.1 Prior to start-up Only use machines which have been serviced at regular intervals. Become acquainted with the equipment, the indicators and control elements, the working principle of the machine and the working area. Use your personal protective equipment (hard hat, safety boots, if necessary also goggles and ear protection).
  • Page 44: Starting The Engine

    Concerning your safety – Starting up the machine If the tests reveal damages or other defects, the machine must not be operated, until these deficiencies have been corrected. Do not operate the machine with defective indi- cators and control elements. 3.6.2 Starting the engine The machine must only be started and oper-...
  • Page 45 Concerning your safety – Starting up the machine Do not start the engine by shorting the electric terminals on the starter motor, because the machine may start to drive immediately. BW 124 PDH-5...
  • Page 46: Driving The Machine; Working Operation

    Concerning your safety – Driving the machine; working operation Driving the machine; working operation 3.7.1 Driving the machine Always wear the seat belt when driving. Only drive on load-bearing surfaces. Do not drive on ice and snow. If the machine has touched high-voltage power lines: do not leave the driver’s stand, warn others from coming close to or...
  • Page 47: Driving Up And Down Slopes

    Concerning your safety – Driving the machine; working operation Always keep a sufficient distance when passing through subways, under bridges, tun- nels, electric power lines etc. 3.7.2 Driving up and down slopes Do not drive on gradients or slopes exceeding the maximum gradeability of the machine Ä...
  • Page 48: Working With Vibration

    Concerning your safety – Driving the machine; working operation 3.7.4 Working with vibration When compacting with vibration you must always check the effect of the vibration on nearby buildings and underground supply lines (gas, water, sewage, electric power). If neces- sary stop compacting with vibration.
  • Page 49: Refuelling

    Concerning your safety – Refuelling Refuelling Do not inhale any fuel fumes. Refuel only with the engine shut down. Do not refuel in closed rooms. No open fire, do not smoke. Static charges may be generated in the fuel as it passes through the filling system.
  • Page 50: Regeneration Of Exhaust Gas Aftertreatment System

    Concerning your safety – Regeneration of exhaust gas aftertreatment system Regeneration of exhaust gas aftertreatment system During regeneration, the exhaust gas reaches very high temperatures and the exhaust gas quantity increases - fire hazard! Components of the exhaust gas aftertreatment system get very hot.
  • Page 51: Emergency Procedures

    Concerning your safety – Emergency procedures 3.10 Emergency procedures 3.10.1 Actuating the emergency stop switch In events of emergency and in case of danger actuate the emergency stop switch immedi- ately. The machine is braked immediately, the engine is shut down. Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.
  • Page 52 Concerning your safety – Emergency procedures Before starting towing operations make sure that the fastening means 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.
  • Page 53: Maintenance Work

    Concerning your safety – Maintenance work 3.11 Maintenance work 3.11.1 Preliminary remarks Adhere to the specified operating, maintenance and repair measures. The machine must only be serviced by quali- fied personnel authorised by the operating company. Keep unauthorised persons away from the machine.
  • Page 54: Working On The Engine

    Concerning your safety – Maintenance work Do not start the engine after draining off the hydraulic oil. Once all work is completed (with the system still depressurized!) check all con- nections and fittings for leaks. Hydraulic hoses must be visually inspected at regular intervals.
  • Page 55: Maintenance Work On Electric Components And Battery

    Concerning your safety – Maintenance work Engine and exhaust system work at high tem- peratures. Keep combustible materials away and do not touch any hot surfaces. Check and change coolant only when the engine is cold. Collect coolant and dispose of it in an environmentally friendly way.
  • Page 56: Cleaning Work

    Concerning your safety – Maintenance work When checking the tyre pressure stand in the extended path of the tyre track. Use an at least 6 meter air hose, so that you can keep a safe distance to the tyre. Always consider the heavy weight of a wheel during disassembly and assembly.
  • Page 57: Repair

    Concerning your safety – Repair 3.12 Repair Identify a defective machine with a warning 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. BW 124 PDH-5...
  • Page 58: Signage

    Concerning your safety – Signage 3.13 Signage Keep stickers and signage in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or sig- nage immediately. Hydraulic Oil WARNING California Proposition 65 Warning This product contains chemicals that cause cancer + chemicals that are reproductive toxicants 12 Volt...
  • Page 59 Concerning your safety – Signage Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) Part No.: 009 920 09 (20 l) / 009 920 10 (5 l) Diesel ULTRA LOW SULFUR FUEL ONLY B-586-0328 Fig.
  • Page 60 Concerning your safety – Signage Warning sticker - Danger of crushing Fig. 12 Warning sticker - Follow operating instructions Fig. 13 Warning sticker – California Proposition 65 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer + chemicals that are reproductive toxicants B-DEC-0316 Fig.
  • Page 61 Concerning your safety – Signage Instruction sticker - Always wear your seat belt Fig. 16 Instruction sticker - Wear ear defenders Fig. 17 Information sticker - Lashing point Fig. 18 Information sticker - Lifting point Fig. 19 BW 124 PDH-5...
  • Page 62 Concerning your safety – Signage Information sticker - Guaranteed sound capacity level Fig. 20 Information sticker - travel lever control B-DEC-0228 Fig. 21 Information sticker - Filler opening for hydraulic Hydraulic Oil B-DEC-0214 Fig. 22 Information sticker - Disconnecting the battery B-DEC-0219 Fig.
  • Page 63 Concerning your safety – Signage Information sticker - Main battery switch plus side Fig. 24 Information sticker - Vehicle voltage 12 V Fig. 25 Information sticker - Hydraulic oil drain B-DEC-0210 Fig. 26 Information sticker - Engine oil drain B-DEC-0211 Fig.
  • Page 64 Concerning your safety – Signage Information sticker - Coolant Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) B-DEC-0221 Fig. 28 Information sticker - Low ash engine oil Fig. 29 Information sticker - Filler opening for diesel Diesel B-DEC-0215 Fig.
  • Page 65 Concerning your safety – Signage Information sticker - travel lever control and dozer blade push button assignment B-DEC-0229 Fig. 32 Information sticker - travel lever control and tilt blade push button assignment B-DEC-0230 Fig. 33 Machine type plate (example) Fig. 34 BW 124 PDH-5...
  • Page 66: Danger Zones

    Concerning your safety – Danger zones 3.14 Danger zones B-586-0460 Fig. 35 The area around the machine 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.
  • Page 67: Safety Components

    Concerning your safety – Safety Components 3.15 Safety Components B-586-0459 Fig. 36 1 ROPS/FOPS 2 Exhaust gas aftertreatment system 3 Engine hood 4 Fan protection 5 Backup protection BW 124 PDH-5...
  • Page 68 Concerning your safety – Safety Components 6 Safety belt 7 Main battery switch 8 Articulation lock 9 Operator detection system 10 Emergency stop switch 11 Control system BW 124 PDH-5...
  • Page 69: Indicators And Control Elements

    Indicators and control elements Indicators and control elements BW 124 PDH-5...
  • Page 70: Driver's Stand

    Indicators and control elements – Driver’s stand Driver’s stand 4.1.1 Instrument cluster 1/ 2 1/ 2 1/ 2 1/ 4 1/ 4 1/ 4 3/ 4 3/ 4 3/ 4 100 120 140 160 °C 140 176 212 248 284 320 °F B-DIS-0516 Fig.
  • Page 71 Indicators and control elements – Driver’s stand Designation Note Flashes when regeneration at standstill is required. Carry out regeneration at standstill. Exhaust gas tem- Lights up when the exhaust gas temperature is perature control light too high during regeneration. Water in fuel Lights up when there is excessive water con- warning light tent in the fuel pre-filter.
  • Page 72 Indicators and control elements – Driver’s stand Designation Note Parking brake Lights up when the parking brake is applied. warning light Warning light for Lights up or flashes in case of a fault in the engine control unit engine control unit or in the exhaust gas after- treatment.
  • Page 73: Operating Console

    Indicators and control elements – Driver’s stand 4.1.2 Operating console B-586-0278 Fig. 39 1 Emergency stop switch 2 Rotary 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...
  • Page 74 Indicators and control elements – Driver’s stand 4.1.2.1 Emergency stop switch press In events of emergency and in case of danger actuate the emergency stop switch immediately by pressing it fully down. It automatically locks in end position. The machine will be braked immediately.
  • Page 75 Indicators and control elements – Driver’s stand 4.1.2.3 Rotary button for regeneration actuate to the Suppress regeneration left Position Regeneration active “Middle” Regeneration is automati- cally executed, if required. Turn clockwise To activate regeneration at for 3 seconds standstill Fig. 42 Description of the operating sequences and operating possibili- Ä...
  • Page 76 Indicators and control elements – Driver’s stand 4.1.2.5 Push button for warning horn Press. Warning horn sounds Fig. 44 4.1.2.6 Rotary switch for flashing beacon Position “Left” Flashing beacon off Position “Right” Flashing beacon on Optional equipment Fig. 45 4.1.2.7 Rotary switch for amplitude pre-selection Position “Left”...
  • Page 77: Travel Lever

    Indicators and control elements – Driver’s stand 4.1.2.8 Starter switch Position “P”/“0” Switch the ignition off Ignition key can be removed Position “I”/“II” Ignition on All control and warning lights light up for a moment (test function). At low temperatures the pre- Fig.
  • Page 78: Travel Lever With Dozer Blade Control

    Indicators and control elements – Driver’s stand Push button for vibration Press Vibration on Press again Vibration off B-ELE-0139 Fig. 49 4.1.4 Travel lever with dozer blade control Machines with dozer blade are equipped with a different travel lever. Shift forward Forward travel Pull back Backward travel...
  • Page 79: Main Battery Switch

    Indicators and control elements – Driver’s stand Designation Note Tilt the tilt blade to Optional equipment the left Vibration Vibration on/off Raise the dozer blade Dozer blade floating position Tilt the tilt blade to Optional equipment the right Lower the dozer blade B-ELE-0141 Fig.
  • Page 80: Din Socket

    Indicators and control elements – Driver’s stand 4.1.6 12 V DIN socket Permanent current, loadable up to 20 A. Fig. 53 4.1.7 ECONOMIZER display The ECONOMIZER displays the compaction status of the layer to be compacted. Description of display possibilities Ä...
  • Page 81: Checks Prior To Start Up

    Checks prior to start up Checks prior to start up BW 124 PDH-5...
  • Page 82: Notes On Safety

    Checks prior to start up – Notes on safety Notes on safety If the following tests reveal damages or other defects, the machine must not be operated, until these deficiencies have been corrected. Do not operate the machine with defective indi- cators and control elements.
  • Page 83 Checks prior to start up – Notes on safety Open and secure the engine hood. Close the engine hood again after work is com- pleted. BW 124 PDH-5...
  • Page 84: Visual Inspections And Function Tests

    Checks prior to start up – Visual inspections and function tests Visual inspections and function tests 1. Check hydraulic oil tank and lines for con- dition and leaks. 2. Check fuel tank and lines for condition and leaks. 3. Check cooling system for contamination, damage and leaks.
  • Page 85: Checking The Engine Oil Level

    Checks prior to start up – Checking the engine oil level Checking the engine oil level NOTICE! Danger of engine damage! – If the engine is warm, shut it down and check the oil level after five minutes. With a cold engine the oil level can be checked immediately.
  • Page 86 Checks prior to start up – Checking the engine oil level 6. Push the dipstick in. BW 124 PDH-5...
  • Page 87: Checking The Fuel Level, Topping Up Fuel

    Checks prior to start up – Checking the fuel level, topping up fuel Checking the fuel level, topping up fuel 5.4.1 Checking the fuel level 1. Check the filling level on the fuel gauge. 1/ 2 2. Refuel if required, after first shutting down 1/ 4 3/ 4 the engine.
  • Page 88 Checks prior to start up – Checking the fuel level, topping up fuel Protective equip- Working clothes ment: 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.
  • Page 89: Checking The Hydraulic Oil Level

    Checks prior to start up – Checking the hydraulic oil level Checking the hydraulic oil level NOTICE! Components may get damaged! – Check the hydraulic oil level at room temperature (approx. 20 °C (68 °F)). – If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components...
  • Page 90 Checks prior to start up – Checking the hydraulic oil level 4. Clean the area around the filler opening. 5. Remove the cap and fill in hydraulic oil. 6. Close the cap. 7. Push the seat console back again. B-586-0283 Fig.
  • Page 91: Checking The Coolant Level

    Checks prior to start up – Checking the coolant level Checking the coolant level NOTICE! Danger of engine damage! – If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks. –...
  • Page 92 Checks prior to start up – Checking the coolant level 3. Close the cap. BW 124 PDH-5...
  • Page 93: Checking Wheels And Tyres

    Checks prior to start up – Checking wheels and tyres Checking wheels and tyres WARNING! Danger of being injured by bursting tyres! – Wear your personal protective equipment (safety shoes, gloves, goggles, hard hat). – When checking the tyre pressure stand in the extended path of the tyre track.
  • Page 94 Checks prior to start up – Checking wheels and tyres Protective equip- Safety shoes ment: Protective gloves Safety goggles Hard hat 1. Move the machine until the tire inflation valve (1) is in top position. 2. Park the machine in secured condition Ä...
  • Page 95: Operation

    Operation Operation BW 124 PDH-5...
  • Page 96: Setting Up The Work Place

    Operation – Setting up the work place Setting up the work place 1. Park the machine in secured condition Ä Chapter 6.6 „Parking the machine in secured condition“ on page 106. 6.1.1 Adjust the driver’s seat 1. To adjust the inclination of the backrest operate lever (c) and tilt the backrest for- ward or back.
  • Page 97: Starting The Engine

    Operation – Starting the engine Starting the engine WARNING! Loss of hearing caused by too high noise burdens! – Wear your personal protective equipment (ear protection). Protective equip- Hearing protection ment: Prerequisites: Main battery switch switched on Emergency stop switch unlocked Travel lever in position “Middle right”...
  • Page 98 Operation – Starting the engine 3. If the pre-heating control light lights up, wait until it goes out before you start the engine. B-SYM-0010 The starter switch is designed with Fig. 69 a re-start lock. The ignition key must first be turned back to position “0”...
  • Page 99 Operation – Starting the engine NOTICE! Low 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. BW 124 PDH-5...
  • Page 100: Travel Operation

    Operation – Travel operation Travel operation 6.3.1 Preliminary remarks and safety notes Driving up and down DANGER! slopes Danger to life caused by the machine turning over! – Never drive across a slope. – Always drive straight up or down a slope.
  • Page 101: Driving The Machine

    Operation – Travel operation 6.3.2 Driving the machine 1. Fasten your seat belt. 2. Turn the rotary switch for engine speed to position “Middle” (ECO mode). B-SWI-1089 Fig. 72 3. Disengage the travel lever to the left out of parking brake position and move it slowly to the desired travel direction.
  • Page 102 Operation – Travel operation 5. Always apply the parking brake when stop- ping on inclinations or slopes. B-ELE-0143 Fig. 75 BW 124 PDH-5...
  • Page 103: Working With Vibration

    Operation – Working with vibration Working with vibration 6.4.1 Preliminary remarks and safety notes NOTICE! Possible damage to neigh- bouring buildings! – When compacting with vibration you must always check the effect of the vibration on nearby build- ings and underground supply lines (gas, water, sewage, elec- tric power).
  • Page 104: Switching The Vibration On And Off

    Operation – Working with vibration 6.4.2 Switching the vibration on and off 1. Preselect the desired amplitude with the rotary switch for amplitude pre-selection. B-SWI-1083 Fig. 76 2. Shift the travel lever slowly in the desired travel direction. 3. Press the vibration push button on the travel lever.
  • Page 105: Economizer

    Operation – ECONOMIZER ECONOMIZER Optional equipment The ECONOMIZER continuously informs the driver about the compaction status of the layer being compacted and enables the detection and targeted post-compaction of local weak spots. The acceleration sensor on the drum measures the reaction of the road subbase. With the vibration switched on, the meas- uring value for the soil stiffness or the asphalt density is shown on a scale (LED 1 -...
  • Page 106: Parking The Machine In Secured Condition

    Operation – Parking the machine in secured condition Parking the machine in secured condition 1. Drive the machine onto level and firm ground. 2. To stop the machine return the travel lever to “Middle” position and shift it to the right to lock (parking brake position).
  • Page 107: Regeneration Of Exhaust Gas Aftertreatment System

    Operation – Regeneration of exhaust gas aftertreatment system Regeneration of exhaust gas aftertreatment system 6.7.1 Preliminary remarks and safety notes As the soot load in the DPF increases, the deposited particles must be burned (regenera- tion). Depending on the soot load, the engine control requests a certain regeneration level.
  • Page 108 Operation – Regeneration of exhaust gas aftertreatment system Warning light Description Measures flashes lights up Regeneration by Inform our service depart- authorised service per- ment. sonnel required. Engine power dramati- cally reduced. flashes lights up DPF overloaded. Inform our service depart- ment.
  • Page 109: Suppressing Regeneration

    Operation – Regeneration of exhaust gas aftertreatment system NOTICE! Low 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. 6.7.2 Suppressing regeneration As long as there is no danger, do not stop or suppress regeneration.
  • Page 110: Running Regeneration At Standstill

    Operation – Regeneration of exhaust gas aftertreatment system 6.7.3 Running regeneration at standstill Regeneration at standstill must be carried out if the warning light for regeneration flashes. Fig. 85 WARNING! Danger of burning by ignited materials! – Keep a safe distance to com- bustible or explosive mate- rials.
  • Page 111 Operation – Regeneration of exhaust gas aftertreatment system 4. Hold the rotary button for regeneration for approx. 3 seconds in position “Right”. Fig. 88 ð As soon as regeneration at standstill starts, the engine speed will increase. The regeneration warning light lights up. Regeneration at standstill runs automati- Fig.
  • Page 112: Emergency Procedures

    Operation – Emergency procedures Emergency procedures 6.8.1 Actuating the emergency stop switch 1. In events of emergency and in case of danger actuate the emergency stop switch immediately. ð The engine is shut down and the parking brake is closed. Fig.
  • Page 113 Operation – Emergency procedures Protective equip- Working clothes ment: Safety shoes Protective gloves WARNING! Danger of injury caused by uncontrolled machine movement! – Always secure the machine against unintended rolling. 1. Fasten the towing device reliably to the towing points. B-586-0324 Fig.
  • Page 114: After Towing

    Operation – Emergency procedures 4. To by-pass both travel pumps undo the locknuts (3) on the high pressure limiting valves (1). 5. Tighten the socket head cap screws (2) until the screw touches the spring cup (increased resistance). 6. Tighten the socket head cap screws B-586-0478 another half turn.
  • Page 115 Operation – Emergency procedures 2. Loosen the counter nuts (3) on the high 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). B-586-0478 Fig.
  • Page 116 Operation – Emergency procedures Bleeding the hydraulic circuit Protective equip- Working clothes ment: Protective gloves The hydraulic circuit needs to be filled and bled before the machine can be put back into opera- tion (e.g. following repair). 1. Open the engine hood. 2.
  • Page 117 Operation – Emergency procedures 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 Fig. 101 1 Plug (Y04) BW 124 PDH-5...
  • Page 118 Operation – Emergency procedures BW 124 PDH-5...
  • Page 119: Loading / Transporting The Machine

    Loading / transporting the machine Loading / transporting the machine BW 124 PDH-5...
  • Page 120: Preparation For Transport

    Loading / transporting the machine – Preparation for transport Preparation for transport 1. Close all flaps. 2. Remove all loose objects from the machine or the driver's stand or fasten them securely. BW 124 PDH-5...
  • Page 121: Loading The Machine

    Loading / transporting the machine – Loading the machine Loading the machine Use only stable loading ramps of sufficient load bearing capacity. Loading ramps and transport vehicle must be free of grease, oil, snow and ice. The ramp inclination must be less than the gra- deability of the machine.
  • Page 122 Loading / transporting the machine – Loading the machine Ä Chapter 4. Engage the articulation lock 8.2.2.1 „Engaging the articulation lock“ on page 130. BW 124 PDH-5...
  • Page 123: Lashing The Machine To The Transport Vehicle

    Loading / transporting the machine – Lashing the machine to the transport vehicle Lashing the machine to the transport vehicle Do not use damaged or in any other way impaired lifting points. Always use appropriate lifting and lashing tackle on the lifting and lashing points. Use lifting tackle only in the prescribed direc- tion of load application.
  • Page 124: Loading By Crane

    Loading / transporting the machine – Loading by crane Loading by crane Loads may only be attached and hoisted by an expert/qualified person. Do not use lifting points that are damaged or impaired in any other way. Only use lifting and lashing tackle with suffi- cient load bearing capacity for the weight to be loaded.
  • Page 125 Loading / transporting the machine – Loading by crane DANGER! Danger to 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. BW 124 PDH-5...
  • Page 126: After Transport

    Loading / transporting the machine – After transport After transport Use only stable loading ramps of sufficient load bearing capacity. Loading ramps and transport vehicle must be free of grease, oil, snow and ice. The ramp inclination must be less than the gra- deability of the machine.
  • Page 127: Maintenance

    Maintenance Maintenance BW 124 PDH-5...
  • Page 128: Preliminary Remarks And Safety Notes

    Maintenance – Preliminary remarks and safety notes Preliminary remarks and safety notes DANGER! Danger to life caused by an operationally unsafe machine! – The machine must only be serv- iced by qualified and authorized personnel. – Follow the safety regulations for Ä...
  • Page 129 Maintenance – Preliminary remarks and safety notes Make sure that the engine cannot be acciden- tally started during maintenance work. Thoroughly clean machine and engine before starting maintenance work. Before mounting the machine, check whether all access steps, grips and platforms are free of obstacles, grease, oils, fuel, dirt, snow and ice.
  • Page 130: Preparations/Concluding Work

    Maintenance – Preparations/concluding work Preparations/concluding work Certain maintenance tasks require prepara- tions and concluding activities. This includes e.g. opening and closing mainte- nance flaps and maintenance doors as well as securing certain components. After this work close all maintenance flaps and doors again and return all components to their operating condition.
  • Page 131 Maintenance – Preparations/concluding work 3. Pull the split pin out of the locking bolt for the articulation lock. 4. Remove the locking bolt. B-586-0286 Fig. 106 5. Insert the locking bolt into the articulation lock and secure it with the split pin. B-586-0287 Fig.
  • Page 132: Side Engine Covers

    Maintenance – Preparations/concluding work 3. Engage the articulation lock in the holding fixture and secure it with the split pin. B-586-0286 Fig. 109 8.2.3 Side engine covers The side engine covers can be removed for better access during maintenance work. 1.
  • Page 133: Fuels And Lubricants

    Maintenance – Fuels and lubricants Fuels and lubricants 8.3.1 Engine oil 8.3.1.1 Oil quality The following lubrication oil specifications are permitted: Low-ash engine oils acc. to API-classifica- tion CJ-4. Avoid mixing of engine oils. 8.3.1.2 Oil viscosity Since engine oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class...
  • Page 134: Fuel

    Maintenance – Fuels and lubricants 8.3.1.3 Oil change intervals If the oil change intervals are not reached over a period of one year, the oil change should be performed at least 1 x per year, irrespective of the operating hours reached. However, engine oil must also be changed when the maintenance interval for regeneration of the exhaust gas aftertreatment system has...
  • Page 135: Coolant

    Maintenance – Fuels and lubricants Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are available for Arctic climates. NOTICE! Danger of engine damage! – The admixture of petroleum and the addition of “flow enhancing additives” (fuel additives) is not permitted.
  • Page 136 Maintenance – Fuels and lubricants Before filling in the coolant mixed with anti- freeze agent the radiator must be flushed with clean water. This procedure should be repeated two to three times to clean the inside of radiator and engine block. NOTICE! Danger of engine damage! –...
  • Page 137: Hydraulic Oil

    Maintenance – Fuels and lubricants 8.3.4 Hydraulic oil 8.3.4.1 Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm /s at 40 °C (104 °F) and 8 mm /s at 100 °C (212 °F).
  • Page 138: Gear Oil Sae 80W-140

    Maintenance – Fuels and lubricants NOTICE! Danger of damage to the hydraulic system! – After the changeover check the hydraulic oil filters increasingly for contamination. – Have regular oil analyses per- formed regarding the water con- tent and mineral oil. –...
  • Page 139: List Of Fuels And Lubricants

    Maintenance – List of fuels and lubricants List of fuels and lubricants Assembly Fuel or lubricant Spare Filling group parts quantity number Summer Winter Observe the level mark! Engine oil SAE 15W-40 009 920 09 8.5 l Ä Chapter 8.3.1 Specification: 20 l (2.2 gal us)
  • Page 140 Maintenance – List of fuels and lubricants Assembly Fuel or lubricant Spare Filling group parts quantity number Summer Winter Observe the level mark! Drive axle Gear oil SAE 80W-140 009 925 07 3.4 l Ä Chapter 8.3.5 Specification: 20 l (0.9 gal us) „Gear oil SAE 80W-140“...
  • Page 141: Running-In Instructions

    Maintenance – Running-in instructions Running-in instructions 8.5.1 General The following maintenance work must be per- formed when running in new machines or over- hauled engines. NOTICE! Danger of engine damage! – Up to approx. 250 operating hours check the engine oil level twice every day.
  • Page 142: After 500 Operating Hours

    Maintenance – Running-in instructions 4. Oil change in bevel gear housing Ä Chapter 8.10.7 „Changing the oil in the bevel gear housing“ on page 171. Ä Chapter 8.10.8 5. Oil change in wheel hubs „Changing the oil in the wheel hubs“...
  • Page 143: Maintenance Table

    Maintenance – Maintenance Table Maintenance Table Maintenance works Page Every 50 operating hours 8.7.1 Checking radiator hoses and hose clamps Every 250 operating hours 8.8.1 Check the air intake lines 8.8.2 Checking radiator hoses and hose clamps 8.8.3 Checking, tensioning the V-belt 8.8.4 Cleaning the radiator module 8.8.5...
  • Page 144 Maintenance – Maintenance Table Maintenance works Page 8.10.6 Change the oil in the drive axle 8.10.7 Changing the oil in the bevel gear housing 8.10.8 Changing the oil in the wheel hubs 8.10.9 Change the oil in the drum drive reduction gear 8.10.10 Retightening the fastening of the axle on the frame 8.10.11...
  • Page 145: Every 50 Operating Hours

    Maintenance – Every 50 operating hours Every 50 operating hours 8.7.1 Checking radiator hoses and hose clamps Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.6 „Parking the machine in secured condition“ on page 106. 2.
  • Page 146: Every 250 Operating Hours

    Maintenance – Every 250 operating hours Every 250 operating hours 8.8.1 Check the air intake lines Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.6 „Parking the machine in secured condition“ on page 106. 2.
  • Page 147: Checking, Tensioning The V-Belt

    Maintenance – Every 250 operating hours 8.8.3 Checking, tensioning the V-belt 8.8.3.1 Checking the V-belt Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.6 „Parking the machine in secured condition“ on page 106. 2.
  • Page 148: Cleaning The Radiator Module

    Maintenance – Every 250 operating hours 8.8.4 Cleaning the radiator module NOTICE! Components may get damaged! – Do not bend or damage cooling fins. – Do not clean with high pressure. 1. Park the machine in secured condition Ä Chapter 6.6 „Parking the machine in secured condition“...
  • Page 149: Checking The Oil Level In The Drive Axle

    Maintenance – Every 250 operating hours 2. Blow the radiator out with compressed air LUFT from the outside. B-586-0290 Fig. 114 Cleaning with cold Protective equip- Working clothes cleansing agent ment: Protective gloves NOTICE! Electric components can be dam- aged by water entering into the system! –...
  • Page 150: Check The Oil Level In The Bevel Gear Housing

    Maintenance – Every 250 operating hours Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.6 „Parking the machine in secured condition“ on page 106. 2. Clean the area around the oil level inspec- tion plug and unscrew the plug.
  • Page 151: Checking The Oil Level In The Wheel Hubs

    Maintenance – Every 250 operating hours 8.8.7 Checking the oil level in the wheel hubs NOTICE! Components may get damaged! – Use only gear oil of the permitted Ä Chapter 8.3.5 specification „Gear oil SAE 80W-140“ on page 138. Protective equip- Working clothes ment: Protective gloves...
  • Page 152: Check The Parking Brake

    Maintenance – Every 250 operating hours Protective equip- Working clothes ment: Protective gloves 1. Move the machine until the oil level inspec- tion plug (1) is horizontal and the filler plug (2) is in top position. 2. Park the machine in secured condition Ä...
  • Page 153: Every 500 Operating Hours

    Maintenance – Every 500 operating hours Every 500 operating hours 8.9.1 Change engine oil and oil filter cartridge Perform this maintenance work at the latest after one year. NOTICE! Danger of engine damage! – Change the oil only with the engine at operating temperature.
  • Page 154 Maintenance – Every 500 operating hours Protective equip- Working clothes ment: Safety shoes Protective gloves Ä Chapter 6.6 1. Park the machine safely „Parking the machine in secured condi- tion“ on page 106. WARNING! Danger of burning on hot compo- nents! –...
  • Page 155: Replacing The Fuel Filter, Bleeding The Fuel System

    Maintenance – Every 500 operating hours 9. Fill with new engine oil. 10. After a short test run check the oil level on the dipstick; if necessary, top up to the top dipstick mark. 11. Check the oil filter cartridge and drain plug for leaks.
  • Page 156 Maintenance – Every 500 operating hours 8.9.2.2 Replacing the fuel filter, fuel pre-filter and fuel line filter Perform this maintenance work at the latest after one year. Protective equip- Working clothes ment: Protective gloves Fuel pre-filter 1. Pull the plug-in connection off the fuel pre- filter sensor on the water separator.
  • Page 157 Maintenance – Every 500 operating hours Fuel filter 11. Place a collecting vessel under the drain bore. 12. Unscrew the drain plug (1) and collect leaking fuel. 13. Open the quick lock (2) and remove the fuel filter (3). 14. Clean the sealing face on the filter carrier B-586-0297 B-586-0298 from any dirt.
  • Page 158: Replacing The V-Belt

    Maintenance – Every 500 operating hours 8.9.2.3 Bleeding the fuel system Protective equip- Working clothes ment: Protective gloves 1. Unscrew the bleed screw (1) on the fuel filter and fuel pre-filter 2 to 3 turns. B-586-0329 Fig. 127 2. Hold the ignition key in position “I” until clean fuel starts to run out at the bleed screws.
  • Page 159: Checking The Anti-Freeze Concentration And The Condition Of The Coolant

    Maintenance – Every 500 operating hours 3. Loosen the tensioning screw (1) and the screw (2) on the generator. 4. Relieve and remove the V-belt. 5. Assemble a new V-belt at the generator. 6. Tension the V-belt to the specified value Ä...
  • Page 160 Maintenance – Every 500 operating hours 1. Park the machine in secured condition Ä Chapter 6.6 „Parking the machine in secured condition“ on page 106. 2. Check all hydraulic lines. Hydraulic hoses must be immediately replaced if: the outer layer is damaged down to the inlay (e.g.
  • Page 161: Servicing The Battery, Checking The Main Battery Shutoff

    Maintenance – Every 500 operating hours 8.9.6 Servicing the battery, checking the main battery shutoff 8.9.6.1 Battery service Maintenance free batteries also need care. Maintenance free only means that the fluid level does not need to be checked. Every battery has a self-discharge, which may, if not checked occasion- ally, even cause damage to the bat- tery as a result of exhaustive dis-...
  • Page 162 Maintenance – Every 500 operating hours 4. Remove the battery and clean the battery compartment. 5. Clean the outside of the battery. 6. Clean battery poles and pole clamps and grease them with pole grease (Vaseline). 7. Install the battery and check the battery fastening.
  • Page 163: Every 1000 Operating Hours

    Maintenance – Every 1000 operating hours 8.10 Every 1000 operating hours 8.10.1 Adjusting the valve clearance NOTICE! Danger of engine damage! We recommend to have this work carried out by trained personnel or our after sales service. – Before checking the valve clear- ance let the engine cool down for at least 30 minutes.
  • Page 164 Maintenance – Every 1000 operating hours 4. Align the marking “1TC” on the flywheel and the marking on the housing. Fig. 136 5. Check if cylinder 1 is overlapping, if neces- sary rotate the flywheel by another 360°. 6. Check the valve clearance on the valves marked black, adjust if necessary.
  • Page 165: Checking The Lines On The Diesel Engine

    Maintenance – Every 1000 operating hours 9. Install the cylinder head cover with a new gasket. 10. After a short test run check the engine for leaks. Fig. 139 Checking the valve clear- ance 1. Check valve clearance (A) between rocker arm and valve with a feeler gauge.
  • Page 166: Checking The Exhaust Manifold

    Maintenance – Every 1000 operating hours 8.10.3 Checking the exhaust manifold This work must only be performed by authorized service personnel. Perform this maintenance work at the latest after one year. 8.10.4 Checking the engine mounts Protective equip- Working clothes ment: Protective gloves 1.
  • Page 167 Maintenance – Every 1000 operating hours NOTICE! Components may get damaged! – If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the oil change and after the test run. – Do not use the oil in the filter bowl again.
  • Page 168 Maintenance – Every 1000 operating hours NOTICE! Negligence may cause destruc- tion to the entire hydraulic system! – Visible dirt may be an early sign for the failure of system compo- nents and indicate the possible failure of components. – In this case determine the cause and replace or repair the defec- tive components, if necessary.
  • Page 169: Change The Oil In The Drive Axle

    Maintenance – Every 1000 operating hours 8.10.6 Change the oil in the drive axle NOTICE! Components may get damaged! – Drain gear oil only at operating temperature. – Use only gear oil of the permitted Ä Chapter 8.3.5 specification „Gear oil SAE 80W-140“...
  • Page 170 Maintenance – Every 1000 operating hours 3. Clean the area around the drain plug. 4. Unscrew the drain plug and collect any oil running out. 5. Turn the drain plug tightly back in. B-586-0302 Fig. 143 6. Fill in fresh gear oil through the oil level inspection bore, until it has reached the bottom edge of the bore.
  • Page 171: Changing The Oil In The Bevel Gear Housing

    Maintenance – Every 1000 operating hours 8.10.7 Changing the oil in the bevel gear housing NOTICE! Components may get damaged! – Use only gear oil of the permitted Ä Chapter 8.3.5 specification „Gear oil SAE 80W-140“ on page 138. Protective equip- Working clothes ment: Protective gloves...
  • Page 172: Changing The Oil In The Wheel Hubs

    Maintenance – Every 1000 operating hours 8.10.8 Changing the oil in the wheel hubs NOTICE! Components may get damaged! – Drain gear oil only at operating temperature. – Use only gear oil of the permitted Ä Chapter 8.3.5 specification „Gear oil SAE 80W-140“...
  • Page 173: Change The Oil In The Drum Drive Reduction Gear

    Maintenance – Every 1000 operating hours 5. Move the drive wheel, until the oil level inspection plug (1) is in horizontal position. 6. Fill in fresh gear oil through the oil level inspection bore, until it has reached the bottom edge of the bore. 7.
  • Page 174 Maintenance – Every 1000 operating hours Protective equip- Working clothes ment: Protective gloves 1. Move the machine until the oil level inspec- tion plug (2) is in bottom position. 2. Park the machine in secured condition Ä Chapter 6.6 „Parking the machine in secured condition“...
  • Page 175: Retightening The Fastening Of The Axle On The Frame

    Maintenance – Every 1000 operating hours 8.10.10 Retightening the fastening of the axle on the frame Protective equip- Working clothes ment: Protective gloves 1. Check all fastening nuts on axle mounting bolts for tight fit, retighten if necessary, tightening torque: 463 Nm (341 ft·lbf). 463 Nm B-586-0305 Fig.
  • Page 176: Checking The Travel Lever Control

    Maintenance – Every 1000 operating hours 1. Inspect the cabin, especially the ROPS, for cracks, corrosion, damage and missing fastening parts. 2. Check the fastening screws for the cabin (ROPS) to the operator’s platform for tight fit. 3. Check the rubber buffers of the operator’s platform suspension for condition and tight fit.
  • Page 177: Every 2000 Operating Hours

    Maintenance – Every 2000 operating hours 8.11 Every 2000 operating hours 8.11.1 Changing the hydraulic oil Perform this maintenance work at the latest after two years. The hydraulic oil must also be changed after major repairs in the hydraulic system. Always replace the hydraulic oil filter after each hydraulic oil change.
  • Page 178 Maintenance – Every 2000 operating hours Protective equip- Working clothes ment: Protective gloves 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.
  • Page 179 Maintenance – Every 2000 operating hours We recommend to use our filling and filtering unit with fine filter to fill the system. This ensures finest fil- tration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system. 7.
  • Page 180: Changing The Coolant

    Maintenance – Every 2000 operating hours 8.11.2 Changing the coolant Perform this maintenance work at the latest after two years. Do not start the engine after draining off the coolant. In case of lubrication oil entering into the cooling system or a suspicious turbidity caused by corrosion residues or other suspended matter, the coolant must be drained off and the complete cooling system needs to be cleaned.
  • Page 181 Maintenance – Every 2000 operating hours Protective equip- Working clothes ment: Protective gloves 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.
  • Page 182 Maintenance – Every 2000 operating hours 10. Close the cap. 11. Start the engine and run to operating tem- perature. 12. Allow the engine to cool down to approx. 50 °C (122 °F). 13. Drain off all water. B-586-0284 14. When using a cleansing agent repeat the Fig.
  • Page 183: Replacing The Oil Separator Element

    Maintenance – Every 2000 operating hours 8.11.3 Replacing the oil separator element Protective equip- Working clothes ment: 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.
  • Page 184: Every 3000 Operating Hours

    Maintenance – Every 3000 operating hours 8.12 Every 3000 operating hours 8.12.1 Checking the turbo charger This work must only be performed 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.
  • Page 185: As Required

    Maintenance – As required 8.13 As required 8.13.1 Air filter maintenance NOTICE! Danger of engine damage! – Do not start the engine after having removed the air filter. – If necessary, the air filter may be cleaned up to six times. After one year at the latest it must be replaced together with the safety element.
  • Page 186 Maintenance – As required Protective equip- Working clothes ment: Protective gloves Safety goggles 1. Maintenance of the air filter is due when the air filter warning light lights up, but at the latest after one year. 2. Park the machine in secured condition Ä...
  • Page 187 Maintenance – As required CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protec- tive working clothes, goggles). 7. Blow the air filter out with dry compressed air (max. 2.1 bar (30 psi)) from inside to outside by moving the gun up and down inside the element, until it is free of dust.
  • Page 188: Checking And Cleaning The Water Separator

    Maintenance – As required 8.13.1.1 Replacing the safety element NOTICE! Danger of engine damage! The safety element must not be cleaned and should not be used again after it has been removed. The safety element must be replaced: – if the air filter is damaged. –...
  • Page 189: Adjusting The Scrapers

    Maintenance – As required Protective equip- Working clothes ment: Safety shoes Protective gloves 1. If the “water in fuel” warning light lights up when starting or during operation, drain the water from the fuel pre-filter immediately. Ä Chapter 6.6 2. Park the machine safely B-SYM-0011 „Parking the machine in secured condi- Fig.
  • Page 190: Cleaning The Machine

    Maintenance – As required 8.13.4 Cleaning the machine Clean the machine thoroughly at least once a week. If necessary, clean the machine daily for example when used on highly cohesive soils or cement. Do not climb on the machine to clean it. WARNING! Danger of injury caused by falling off the platform!
  • Page 191: Draining The Fuel Tank Sludge

    Maintenance – As required 8.13.5 Draining the fuel tank sludge Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.6 „Parking the machine in secured condition“ on page 106. 2. Disconnect the hose at the connection between the two fuel tanks and collect around 5 litres of fuel.
  • Page 192 Maintenance – As required 7. Disconnect the ground strap from the bat- tery (this avoids self-discharge caused by closed-circuit consuming devices). 8.13.6.2 Battery service during prolonged machine downtimes WARNING! Danger of injury caused by exploding gas mixture! – Remove the plugs before starting to recharge the battery.
  • Page 193 Maintenance – As required 3. Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform boost charging. ð The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge.
  • Page 194 Maintenance – As required 11. Check the oil levels. 12. Check the function of electric system, steering and brakes. 13. Clean the machine thoroughly. BW 124 PDH-5...
  • Page 195: Troubleshooting

    Troubleshooting Troubleshooting BW 124 PDH-5...
  • Page 196: Preliminary Remarks

    Troubleshooting – Preliminary remarks 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.
  • Page 197: Starting The Engine With Jump Leads

    Troubleshooting – Starting the engine with jump leads Starting the engine with jump leads NOTICE! A wrong connection will cause severe damage in the electric system. – Bridge the machine only with a 12 Volt auxiliary battery. 1. Connect the plus pole of the external bat- tery first with the plus pole of the vehicle battery using the first jump lead.
  • Page 198: Fuse Assignment

    Troubleshooting – Fuse assignment Fuse assignment 9.3.1 Notes on safety WARNING! Danger of injury by fire in the machine! – Do not use fuses with higher ampere ratings and do not bridge fuses. 9.3.2 Central electrics The central electrics are to the right of the driv- er’s stand underneath the cover.
  • Page 199: Main Fuse

    Troubleshooting – Fuse assignment Fuse Amperage Designation F158 BOMAG TELEMATIC (potential 30) F241 15 A Optional headlights F243 BOMAG TELEMATIC (potential 30) F275 ECONOMIZER 9.3.3 Main fuse The main fuse is located underneath the driv- er's seat. B-586-0398 Fig. 177 Fuse Amperage Designation...
  • Page 200: Engine Faults

    Troubleshooting – Engine faults Engine faults Fault Possible cause Remedy Engine does Fuel tank empty Refuel, bleed the fuel system not start Fuel filter clogged, in winter Change the fuel filter, use due to paraffin separation winter fuel Fuel lines leaking Check all line connections for leaks and tighten the fittings, bleed the fuel system...
  • Page 201 Troubleshooting – Engine faults Fault Possible cause Remedy Engine over- Cooling fins on radiator are Clean the cooling fins heating, extremely dirty (the warning engine must lamp for engine oil tempera- be shut down ture lights) immediately! Engine oil level too low Check, fill up if necessary Lack of coolant Check all pipes and hoses for...
  • Page 202 Troubleshooting – Engine faults Fault Possible cause Remedy The charge Generator speed too low Check the generator belt for control light tension, replace the belt if lights during necessary operation, the Generator or regulator defec- Have examined by a spe- warning tive cialist...
  • Page 203: Trouble Shooting Economizer

    Troubleshooting – Trouble shooting ECONOMIZER Trouble shooting ECONOMIZER In case of a malfunction the LEDs will show a fault code. At first, the 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.
  • Page 204 Troubleshooting – Trouble shooting ECONOMIZER BW 124 PDH-5...
  • Page 205: Disposal

    Disposal Disposal BW 124 PDH-5...
  • Page 206: Final Shut-Down Of Machine

    Disposal – Final shut-down of machine 10.1 Final shut-down of machine If the machine can no longer be used and needs to be finally shut down you must carry out the following work and have the machine disassembled by an officially recognized spe- cialist workshop.
  • Page 207: List Of Special Tools

    List of special tools List of special tools BW 124 PDH-5...
  • Page 208 List of special tools BW 124 PDH-5...
  • Page 210 BOMA Equipment Hong Kong LTD BOMAG Italia Srl. FAYAT BOMAG Polska Sp. z.o.o. Room 1003, 10/F Charm Centre Via Roma 50 Ul. Szyszkowa 52 700, Castle Peak Road 48011 Alfonsine 02-285 Warzawa Kowloon, ITALY...

Table of Contents

Save PDF