Fayat BOMAG BW 120 AD-5 Operating Instruction
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Fayat BOMAG BW 120 AD-5 Operating Instruction

Tandem vibratory roller
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Operating Instruction
Maintenance Instruction
Original Operating Instructions
BW 120 AD-5
S/N 961 880 42 2507>
Tandem vibratory roller
008 202 53 EN
© 05/2020

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Summary of Contents for Fayat BOMAG BW 120 AD-5

  • Page 1 Operating Instruction Maintenance Instruction Original Operating Instructions BW 120 AD-5 S/N 961 880 42 2507> Tandem vibratory roller 008 202 53 EN © 05/2020...
  • 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.............. 17 2.1.1 Noise data................... 17 2.1.2 Vibration data................18 Concerning your safety..............19 3.1 Basic prerequisites..............
  • Page 4 Table of contents 3.4.5 Safety regulations and environmental protection regulations for handling coolants................ 35 3.4.6 Safety regulations and environmental protection regulations for handling battery acid..............37 3.5 Loading/transporting the machine..........39 3.6 Starting up the machine.............. 41 3.6.1 Prior to commissioning..............41 3.6.2 Starting the engine..............
  • Page 5 Table of contents 4.1.3 Rotary switch for lighting............. 67 4.1.4 Rotary switch for hazard light system.......... 68 4.1.5 Rotary switch for flashing beacon..........68 4.1.6 Rotary switch for drum pre-selection........... 68 4.1.7 Rotary switch for vibration pre-selection........69 4.1.8 Emergency stop switch............... 69 4.1.9 Instrument cluster................
  • Page 6 Table of contents 6.4.1 Preliminary remarks and safety notes........103 6.4.2 Driving the machine..............104 6.4.3 Stopping the machine, applying the parking brake....104 6.5 Driving the machine in public traffic........105 6.6 Working with vibration............... 107 6.6.1 Preliminary remarks and safety notes........107 6.6.2 Preparing to work with vibration..........
  • Page 7 Table of contents 8.3.3 Coolant..................142 8.3.4 Hydraulic oil................143 8.4 List of fuels and lubricants............144 8.5 Running-in instructions............. 145 8.5.1 General..................145 8.5.2 After 50 operating hours............145 8.6 Maintenance Table..............146 8.7 Every 50 operating hours............148 8.7.1 Checking radiator hoses and hose clamps.......
  • Page 8 Table of contents 8.12 Every 3000 operating hours............ 175 8.12.1 Checking the fuel injection pump..........175 8.13 As required................176 8.13.1 Air filter maintenance............... 176 8.13.2 Checking the water spraying system........180 8.13.3 Cleaning the water spraying system........183 8.13.4 Measures if there is a risk of frost........... 185 8.13.5 Draining the fuel tank sludge...........

  • Page 9: Introduction

    Introduction Introduction BW 120 AD-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 chapter “Maintenance” Ä Chapter 8 ‘Mainte- nance’ on page 133. Do not service or repair your machine by your- self to avoid harming persons or damaging material or environment.

  • 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 120 AD-5...
  • Page 14 Technical data Dimensions B-880-0001 Fig. 3 1752 1272 1808 2568 (69) (50) (20.6) (27.6) (71) (101) Dimensions in millimetres (Dimensions in inches) 2529 1200 (10.0) (100) (1.4) (0.5) (47) Dimensions in millimetres (Dimensions in inches) Height with protective roof and flashing beacon 2890 (optional equipment) (114)
  • Page 15 Technical data Weights Max. operating weight 3650 (8047) (lbs) Operating weight with ROPS (CECE) 2700 (5953) (lbs) Average static linear load (CECE) 11.3 kg/cm (63) (pli) Travel characteristics Travel speed 0 - 10 km/h (0 - 6.2) (mph) Working speed with vibration 0 - 10 km/h (0 - 6.2)
  • Page 16 Technical data Electric system Voltage Brakes Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Oscill.-articul. Steering operation hydrostatic Steering angle +/- 32 ° Oscillation angle +/- 10 ° Inner track radius 2450 (97) (in) Crabwalk, lateral offsetting of drum right/left (2.0) (in) Exciter system...

  • Page 17: Noise And Vibration Data

    Technical data – Noise and vibration data Filling capacities Fuel (diesel) (9.2) (gal us) Water (54) (gal us) Noise and vibration data The following noise and vibration data were determined in accordance with the following guidelines under equipment specific conditions and by using harmonized standards: EU Machine Directive edition 2006/42/EU Noise Emission Directive 2000/14/EU, Noise...

  • Page 18: Vibration Data

    Technical data – Noise and vibration data 2.1.2 Vibration data Vibration of the entire The weighted effective acceleration value body (driver’s seat) determined according to ISO 2631 is ≤ 0.5 Hand-arm vibration The weighted effective acceleration value determined according to ISO 5349 is ≤ 2.5 BW 120 AD-5...

  • Page 19: Concerning Your Safety

    Concerning your safety Concerning your safety BW 120 AD-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: Estimated Service Life Of The Machine

    Concerning your safety – Basic prerequisites Examples of improper use are: Work with vibration on hard concrete, cured bitumen layers or extremely frozen ground cleaning the drums while driving or changing nozzles during travel Driving on non-load-bearing ground Driving on slippery surfaces (e.g. ice and snow) Driving on surfaces of insufficient size (danger of turning over)

  • 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: 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 30: 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 31 Concerning your safety – Handling fuels and lubricants – 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. BW 120 AD-5...

  • Page 32: 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 33: 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 34 Concerning your safety – Handling fuels and lubricants CAUTION! Danger of slipping on spilled oil! – Immediately bind spilled oil with an oil-binding agent. ENVIRONMENT! Oil is an environmentally haz- ardous substance! – Always keep oil in proper con- tainers. –...

  • Page 35: 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 36 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 120 AD-5...

  • Page 37: 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 38 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 120 AD-5...

  • Page 39: Loading/Transporting The Machine

    Concerning your safety – Loading/transporting the machine Loading/transporting 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 40 Concerning your safety – Loading/transporting the machine After the transport loosen the articulation lock again, as otherwise the machine would not be steerable. Operate the machine only with the ROPS folded up and the fastening screws tightened with the correct tightening torque. BW 120 AD-5...

  • Page 41: Starting Up The Machine

    Concerning your safety – Starting up the machine Starting up the machine 3.6.1 Prior to commissioning 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 42: Starting The Engine

    Concerning your safety – Starting up the machine If the tests reveal damage or other defects, the machine must not be operated until these have been rectified. 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- ated from the driver’s seat.
  • Page 43 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 120 AD-5...

  • Page 44: 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 45: 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 46: Working With Vibration

    Concerning your safety – Driving the machine; working operation For rollers with a drum width of 1 meter or less there is a considerable risk of tipping over near edges (e.g. curbstones, embankments, trenches, potholes) when driving over these edges. 3.7.4 Working with vibration When compacting with vibration you must...

  • Page 47: 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 48: Emergency Procedures

    Concerning your safety – Emergency procedures Emergency procedures 3.9.1 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 49 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 50: Maintenance Work

    Concerning your safety – Maintenance work 3.10 Maintenance work 3.10.1 Preliminary remarks Always carry out the prescribed maintenance work and maintenance measures on time in order to maintain the safety, operational readi- ness and long service life of the machine. The machine must only be serviced by quali- fied personnel authorised by the operating company.

  • Page 51: Working On The Engine

    Concerning your safety – Maintenance work Hydraulic hoses must be visually inspected at regular intervals. Do not mix up hoses by mistake. Only genuine replacement hydraulic hoses ensure that the correct hose type (pressure range) is used at the right location. 3.10.3 Working on the engine Do not work on the fuel system while the engine is running - danger to life due to high...

  • Page 52: Maintenance Work On Electric Components And Battery

    Concerning your safety – Maintenance work 3.10.4 Maintenance work on electric components and battery Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material. Do not use fuses with higher ampere ratings and do not bridge fuses.

  • Page 53: Measures For Longer Shut-Down Periods

    Concerning your safety – Maintenance work 3.10.6 Measures for longer shut-down periods If the machine is taken out of operation for a longer period of time, various conditions must be met and maintenance work must be carried out both before and after shut-down Ä...

  • Page 54: Repair

    Concerning your safety – Repair 3.11 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 120 AD-5...

  • Page 55: Signage

    Concerning your safety – Signage 3.12 Signage Keep stickers and signage in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or sig- nage immediately. BW 120 AD-5...
  • Page 56 Concerning your safety – Signage Nm 75-200 Nm 75-200 ft.lb. 55-147 ft.lb. 55-147 20 kg 20 kg ~ 200 Nm ~ 200 Nm 25 kg 25 kg ~ 75 Nm ~ 75 Nm Hydraulic Oil B-880-0276 Fig. 10 BW 120 AD-5...
  • Page 57 Concerning your safety – Signage WARNING California Proposition 65 Warning This product contains chemicals that cause cancer + chemicals that are reproductive toxicants 180° Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) B-880-0257 Fig.
  • Page 58 Concerning your safety – Signage Warning sticker - Danger of crushing Fig. 13 Warning sticker - Foldable ROPS B-DEC-0207 Fig. 14 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 59 Concerning your safety – Signage Instruction sticker - Always wear your seat belt Fig. 17 Information sticker - Lifting point Fig. 18 Information sticker - Lashing point Fig. 19 Information sticker - Filler opening for hydraulic Hydraulic Oil B-DEC-0214 Fig. 20 BW 120 AD-5...
  • Page 60 Concerning your safety – Signage Information sticker - Engine oil drain B-DEC-0211 Fig. 21 Information sticker - Hydraulic oil drain B-DEC-0210 Fig. 22 Information sticker - Coolant drain B-DEC-0212 Fig. 23 Information sticker - Disconnecting the battery B-DEC-0219 Fig. 24 BW 120 AD-5...
  • Page 61 Concerning your safety – Signage Operation sticker - Throttle lever B-DEC-0236 Fig. 25 Information sticker - Guaranteed sound capacity level Fig. 26 Information sticker - Foldable ROPS operation Nm 75-200 ft.lb. 55-147 20 kg ~ 200 Nm 25 kg ~ 75 Nm B-DEC-0208 Fig.
  • Page 62 Concerning your safety – Signage Machine type plate (example) Fig. 29 BW 120 AD-5...

  • Page 63: Danger Zones

    Concerning your safety – Danger zones 3.13 Danger zones B-880-0243 Fig. 30 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 64 Concerning your safety – Danger zones BW 120 AD-5...

  • Page 65: Indicators And Control Elements

    Indicators and control elements Indicators and control elements BW 120 AD-5...

  • Page 66: Operating Console

    Indicators and control elements – Operating console Operating console B-880-0266 Fig. 31 1 Rotary switch for direction indicators (optional equipment) 2 Rotary switch for working lights 3 Rotary switch for lighting (optional equipment) 4 Rotary switch for hazard light system (optional equipment) 5 Rotary switch for flashing beacon (optional equipment) 6 Rotary switch for drum pre-selection 7 Rotary switch for vibration pre-selection...

  • Page 67: Rotary Switch For Direction Indicators

    Indicators and control elements – Operating console 4.1.1 Rotary switch for direction indicators Position Direction indicators off “Middle” Position “left or Front and rear direction indi- right” cators on the corresponding side are flashing Optional equipment Fig. 32 4.1.2 Rotary switch for working lights Position "Left"...

  • Page 68: Rotary Switch For Hazard Light System

    Indicators and control elements – Operating console 4.1.4 Rotary switch for hazard light system Position "Left" Hazard light system off Position "Right" Hazard light system on Optional equipment Fig. 35 4.1.5 Rotary switch for flashing beacon Position “Left” Flashing beacon off Position “Right”...

  • Page 69: Rotary Switch For Vibration Pre-Selection

    Indicators and control elements – Operating console 4.1.7 Rotary switch for vibration pre-selection Position “left” Pre-selection vibration in manual mode Vibration is switched on or off via the vibration push button in the travel lever. Position Vibration off “middle” B-SWI-1485 Position “right”...

  • Page 70: Instrument Cluster

    Indicators and control elements – Operating console 4.1.9 Instrument cluster 1/ 2 3/ 4 1/ 4 100 120 140 160 °C 140 176 212 248 284 320 °F B-DIS-0516 Fig. 40 1 Control and warning lights 2 Fuel level gauge 3 Display field 4 [F1] button (not assigned) 5 [F2] button...
  • Page 71 Indicators and control elements – Operating console Designation Note Engine oil pressure Lights up if the engine oil pressure is too low. warning light Warning buzzer sounds. The engine will be shut down after a short while. Check the engine oil level; if necessary, repair the engine.

  • Page 72: Economizer Display

    Indicators and control elements – Operating console 4.1.10 ECONOMIZER display The ECONOMIZER shows the compaction status of the road substructure or the asphalt layer. Description of display possibilities Ä Chapter 6.6.6 ‘ECONOMIZER’ on page 110. Optional equipment Fig. 42 4.1.11 Rotary switch for water spraying system Position “0”...

  • Page 73: Driver's Stand

    Indicators and control elements – Driver’s stand Driver’s stand B-650-0050 Fig. 44 1 Starter switch 2 12 V DIN socket 3 Travel lever, right 4 Driver’s seat 5 Travel lever, left (optional equipment) 6 Throttle lever BW 120 AD-5...

  • Page 74: Starter Switch

    Indicators and control elements – Driver’s stand 4.2.1 Starter switch Position "P"/"0" Ignition off Ignition key can be removed Position "I" Ignition on All control and warning lamps light up for a moment (test function). Position "II" Under low temperatures the Fig.

  • Page 75: Travel Lever

    Indicators and control elements – Driver’s stand 4.2.3 Travel lever B-ELE-0261 Fig. 47 On machines with double travel lever (optional equipment), the two travel levers are mechanically con- nected to each other. Function Note Shift forward Forward travel Position I: up to approx. 5 km/h (3 mph) Position II: up to approx.
  • Page 76 Indicators and control elements – Driver’s stand 4.2.3.1 Push button assignment on travel lever On machines with double travel lever (optional equipment), the push button assignment is identical on both travel levers. B-ELE-0271 Vibration on/off Warning horn BW 120 AD-5...

  • Page 77: Driver's Seat

    Indicators and control elements – Driver’s stand 4.2.4 Driver’s seat B-SEA-0012 Fig. 48 Pos. Control element Setting Description Driver’s weight Press down the handle 50 kg until the correct driver’s weight has been set. 130 kg Press down the handle against the end stop, the weight adjustment automatically switches...

  • Page 78: Throttle Lever

    Indicators and control elements – Driver’s stand 4.2.5 Throttle lever Position “MIN” Idle speed position Position “MAX Full load position I I” Position “MAX Full load position II II” B-880-0159 Fig. 49 BW 120 AD-5...

  • Page 79: Engine Compartment

    Indicators and control elements – Engine compartment Engine compartment 4.3.1 Main battery switch Position “on” Main battery switch locked Normal position, operation Turn anticlock- Main battery switch can be wise pulled out Isolates the batteries from the on-board electrics in case of cable fire and fire in B-880-0033 the engine compartment as...
  • Page 80 Indicators and control elements – Engine compartment BW 120 AD-5...

  • Page 81: Checks Prior To Start Up

    Checks prior to start up Checks prior to start up BW 120 AD-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 Ä Chapter 8.2.1.1 ‘Open and secure the engine hood’ on page 136. Close the engine hood again after work is com- pleted. BW 120 AD-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 the hydraulic oil tank and lines for condition and leaks. 2. Check the fuel tank and lines for condition and leaks. 3. Check the cooling system for contamina- tion, 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: 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 the engine.
  • Page 87 Checks prior to start up – Checking the fuel level; topping up fuel Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Clean the area around the filling port. Diesel 2. Unscrew the cap and fill with fuel. 3. Close the cap. B-880-0187 Fig.

  • Page 88: 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 89: 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 90: Checking The Air Filter

    Checks prior to start up – Checking the air filter Checking the air filter Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Check the air filter on the maintenance indicator. 2. If the yellow pin has reached the red area (1) conduct maintenance of the air filter Ä...

  • Page 91: Checking The Water Level, Topping Up

    Checks prior to start up – Checking the water level, topping up Checking the water level, topping up Protective equip- Working clothes ment: Safety shoes Protective gloves NOTICE! Components may get damaged by frost! – Follow the special maintenance instructions in case of frost Ä...
  • Page 92 Checks prior to start up – Checking the water level, topping up 2. Unscrew the cap (1) and fill in clean water Water through the strainer (2). 3. Make sure that the ventilation bore in the filler cap is free. 4.

  • Page 93: Checking And Cleaning The Scrapers

    Checks prior to start up – Checking and cleaning the scrapers Checking and cleaning the scrapers Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Check the condition of the scrapers (1) on both drums, clean if necessary. 2. Replace worn scrapers. B-880-0056 Fig.

  • Page 94: Checking The Hydraulic Oil Filter

    Checks prior to start up – Checking the hydraulic oil filter 5.10 Checking the hydraulic oil filter WARNING! Danger of burning on hot compo- nents! – Wear your personal protective equipment (protective gloves, protective clothing). – Avoid touching hot components. Protective equip- Working clothes ment:...
  • Page 95 Checks prior to start up – Checking the hydraulic oil filter 4. Set the throttle lever to position “MAX II”. 5. Before leaving the machine, make sure that nobody enters the driver’s stand. 6. Open the engine hood Ä Chapter 8.2.1.1 ‘Open and secure the engine hood’...
  • Page 96 Checks prior to start up – Checking the hydraulic oil filter BW 120 AD-5...

  • Page 97: Operation

    Operation Operation BW 120 AD-5...

  • Page 98: Setting Up The Workplace

    Operation – Setting up the workplace Setting up the workplace 1. Park the machine safely Ä Chapter 6.8 ‘Parking the machine in secured condition’ on page 114. 2. Adjust the driver’s seat. BW 120 AD-5...

  • Page 99: Electronic Immobilizer

    Operation – Electronic immobilizer Electronic immobilizer Optional equipment Before starting the engine the anti-theft protec- tion* must be disarmed by entering a code. With the electronic immobilizer armed, the light emitting diode (a) flashes slowly. 1. Slowly enter the six-digit user code. ð...

  • Page 100: 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 (if present) switched on Emergency stop switch is unlocked Travel lever in parking brake position When closing the dashboard cover, the emergency stop switch will lock...
  • Page 101 Operation – Starting the engine 2. Turn the ignition key to position “I”. ð All control and warning lights in the instrument cluster light up for a moment. B-ELE-0070 Fig. 66 3. With cold ambient temperatures hold the ignition key up to 10 seconds in position “II”.
  • Page 102 Operation – Starting the engine NOTICE! Danger of engine damage! – Warm up engine for a short while before starting work. Do not operate the engine immediately under full load. BW 120 AD-5...

  • Page 103: Travel Mode

    Operation – Travel mode Travel mode 6.4.1 Preliminary remarks and safety notes Before starting to drive make sure that the driving area is absolutely safe. DANGER! Danger to life caused by the machine turning over! – Never drive across a slope. –...

  • Page 104: Driving The Machine

    Operation – Travel mode 6.4.2 Driving the machine 1. Fasten your seat belt. 2. Set the throttle lever to position “MAX I” or “MAX II”. B-880-0160 Fig. 70 3. Disengage the travel lever out of braking position and move it slowly to the required travel direction.

  • Page 105: Driving The Machine In Public Traffic

    Operation – Driving the machine in public traffic Driving the machine in public traffic The machine must be equipped for driving in public traffic. Driving in public traffic is not permitted without additional equipment (e.g. lighting, first aid kit, warning triangle). Observe national regulations! 1.
  • Page 106 Operation – Driving the machine in public traffic 9. Always apply the parking brake when stop- ping on inclinations or slopes. BW 120 AD-5...

  • Page 107: Working With Vibration

    Operation – Working with vibration Working with vibration 6.6.1 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 108: Preparing To Work With Vibration

    Operation – Working with vibration 6.6.2 Preparing to work with vibration 1. Use the rotary switch for drum pre-selec- tion to pre-select the desired drum(s). Drum pre-selection is only acti- vated, if the vibration has been switched off beforehand. B-SWI-1488 Fig.

  • Page 109: Vibration In Automatic Mode

    Operation – Working with vibration NOTICE! Vibration at standstill causes transverse marks! – Do not switch on vibration with the machine at stand- still. B-ELE-0264 Shift the travel lever slowly in the desired Fig. 79 travel direction. 3. Press the travel lever push button on the left or right.

  • Page 110: Stop Working With Vibration

    Operation – Working with vibration 6.6.5 Stop working with vibration 1. Switch the vibration off. 2. Turn the rotary switch for vibration pre- selection to position “Middle”. B-SWI-1485 Fig. 82 6.6.6 ECONOMIZER The ECONOMIZER continuously informs the driver about the compaction status of the road subbase or the asphalt layer and enables the detection and selected re-compaction of weak spots.
  • Page 111 Operation – Working with vibration Measuring operation With the vibration switched on, the measuring value is displayed by the LED display (1-10). If the display value does not increase any fur- ther, no further compaction can be achieved with this machine. The maximum display value (10) is not always reached.
  • Page 112 Operation – Working with vibration The measuring values achieved with different tandem vibratory rollers can be made compa- rable by calibration to a reference value. BW 120 AD-5...

  • Page 113: Water Spraying System

    Operation – Water spraying system Water spraying system 1. Set the rotary switch for the water spraying system to the desired spraying interval. 2. Disengage the travel lever from parking brake position. ð Spraying will only become active after the travel lever is actuated in travel direction, or after the rotary switch for B-SWI-1765 the water spraying system has been set...

  • Page 114: 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, firm ground. 2. Shift the travel lever to “Middle” position and engage it in parking brake position. ð The machine will decelerate down to a standstill and the parking brake will be applied after approx.
  • Page 115 Operation – Parking the machine in secured condition 5. Turn the main battery switch (if present) anticlockwise and pull it out. B-SWI-0079 Fig. 90 BW 120 AD-5...

  • Page 116: Emergency Procedures

    Operation – Emergency procedures Emergency procedures 6.9.1 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 117 Operation – Emergency procedures Before towing make sure that: the tractor vehicle has sufficient traction and braking power for the non-braking towed load; tow bar and fastening means are able to withstand the load and are fastened at the points provided for this purpose. The machine cannot be steered.
  • Page 118 Operation – Emergency procedures 6. Loosen the counter nuts (2) on the high pressure limiting valves of the travel pump. 7. Tighten the socket head cap screws (1) until the screw touches the spring cup (increased resistance). 8. Tighten the socket head cap screws another half turn.

  • Page 119: After Towing

    Operation – Emergency procedures 13. Screw both plugs back in, tightening torque: 50 Nm (37 ft·lbf). 14. Also release the brake on the second drum. 15. Close the engine hood Ä Chapter 8.2.1.2 ‘Closing the engine hood’ on page 136. ð...
  • Page 120 Operation – Emergency procedures 3. Completely release both screws to close the brake. Fig. 100 4. Screw both plugs back in, tightening torque: 50 Nm (37 ft·lbf). 5. Close also the brake on the second drum. B-880-0014 Fig. 101 6. Loosen the counter nuts (2) on the high pressure limiting valves of the travel pump.
  • Page 121 Operation – Emergency procedures The hydraulic circuit needs to be filled and bled before the machine can be put back into opera- tion (e.g. following repair). 1. Pull plug (Y04) off the solenoid valve for the parking brake, to prevent the parking brake from opening.
  • Page 122 Operation – Emergency procedures BW 120 AD-5...

  • Page 123: Loading / Transporting The Machine

    Loading / transporting the machine Loading / transporting the machine BW 120 AD-5...

  • Page 124: 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 fasten them properly. BW 120 AD-5...

  • Page 125: 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 126: 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 lashing points that are damaged or impaired in any way. Always use appropriate lashing tackle at the lashing points.

  • Page 127: Loading By Crane

    Loading / transporting the machine – Loading by crane Loading by crane Loads must only be attached and hoisted by an expert / capable person. Do not use damaged or in any other way impaired lashing points. Use only lifting gear and lifting tackle with suffi- cient load bearing capacity for the weight to be loaded.
  • Page 128 Loading / transporting the machine – Loading by crane 4. Swing the central lifting point up and fasten the lashing tackle. DANGER! Danger to life caused by sus- pended loads! – Do not step or stand under B-880-0261 suspended loads. Fig.

  • Page 129: After Transportation

    Loading / transporting the machine – After transportation After transportation 1. If necessary, erect the foldable ROPS back 2. Loosen the articulation lock Ä Chapter 8.2.2.2 ‘Disengaging the articulation lock’ on page 138. 3. Fasten your seat belt. 4. Set the throttle lever to position “MAX I”. DANGER! Danger to life caused by the machine slipping or turning over!

  • Page 130: Folding Down And Erecting The Foldable Rops

    Loading / transporting the machine – Folding down and erecting the foldable ROPS Folding down and erecting the foldable ROPS The transport height of the machine can be reduced by folding down the foldable ROPS. 7.6.1 Folding down the foldable ROPS Protective equip- Working clothes ment:...
  • Page 131 Loading / transporting the machine – Folding down and erecting the foldable ROPS CAUTION! 75-200 Nm Danger of crushing when 55-148 ft·lbf erecting the foldable ROPS! – Do not reach with your hands into the slewing area of the foldable ROPS. B-650-0039 Fold up the foldable ROPS.
  • Page 132 Loading / transporting the machine – Folding down and erecting the foldable ROPS BW 120 AD-5...

  • Page 133: Maintenance

    Maintenance Maintenance BW 120 AD-5...

  • Page 134: 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 maintenance work Ä...
  • Page 135 Maintenance – Preliminary remarks and safety notes Make sure that the engine cannot be acciden- tally started during maintenance work. Do not touch hot components. Thoroughly clean the 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 136: 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 137: Articulation Lock

    Maintenance – Preparations/concluding work 8.2.2 Articulation lock 8.2.2.1 Engaging the articulation lock Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Move the steering to middle position and stop the machine. 2. Switch off the engine and remove the igni- tion key.
  • Page 138 Maintenance – Preparations/concluding work 8.2.2.2 Disengaging the articulation lock Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Switch off the engine and remove the igni- tion key. WARNING! Danger of crushing by the articulating machine! – Do not step into the articula- tion area of the machine while the engine is running.

  • Page 139: Fuels And Lubricants

    Maintenance – Fuels and lubricants Fuels and lubricants 8.3.1 Engine oil 8.3.1.1 Oil quality The following engine oil specifications are per- mitted: Engine oils as per API-classification CF, CF-4, CG-4, CH-4 and CI-4 For operation of an engine with high sulphur fuels we recommended to use an engine oil of API-classification CF or higher with a total base number of at least 10.

  • Page 140: Fuel

    Maintenance – Fuels and lubricants Ambient temperature Oil viscosity higher than 25 °C SAE 30 (77 °F) SAE 10W-30 SAE 15W-40 -10 °C to 25 °C (14 °F SAE 10W-30 to 77 °F) SAE 15W-40 below - 10 °C (14 °F) SAE 10W-30 8.3.1.3 Oil change intervals...
  • Page 141 Maintenance – Fuels and lubricants The recommended Cetan index number is 45. A Cetan index number higher than 50 should preferably be used, especially at ambient tem- peratures below -20 °C (-4 °F) and when working at altitudes of more than 1500 m (4921 ft).

  • Page 142: Coolant

    Maintenance – Fuels and lubricants Copper containing materials (copper lines, brass items) should be avoided, because they can cause catalytic reactions in the fuel with subsequent depositing in the injection system. 8.3.3 Coolant Always use a mixture of anti-freeze agent and clean, dehardened water with a mixing ratio of 1:1.

  • Page 143: Hydraulic Oil

    Maintenance – Fuels and lubricants Add anti-freeze agent: If the coolant level drops because of evapo- ration,only clean water is to be used for top- ping up. In case of leakages you must always fill in anti-freeze agents of the same brand and the same mixing ratio.

  • Page 144: 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 10W-40 009 920 06 6.5 l Specification: 20 l (1.7 gal us) Ä...

  • Page 145: 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 146: Maintenance Table

    Maintenance – Maintenance Table Maintenance Table Maintenance works Page Every 50 operating hours 8.7.1 Checking radiator hoses and hose clamps 8.7.2 Checking and cleaning the water separator Every 250 operating hours 8.8.1 Change engine oil and oil filter cartridge 8.8.2 Checking, tensioning the V-belt 8.8.3 Check the air intake lines...
  • Page 147 Maintenance – Maintenance Table Maintenance works Page Every 3000 operating hours 8.12.1 Checking the fuel injection pump As required 8.13.1 Air filter maintenance 8.13.2 Checking the water spraying system 8.13.3 Cleaning the water spraying system 8.13.4 Measures if there is a risk of frost 8.13.5 Draining the fuel tank sludge 8.13.6...

  • Page 148: 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 6.8 ‘Parking the machine in secured condition’ on page 114. 2.
  • Page 149 Maintenance – Every 50 operating hours Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine safely Ä Chapter 6.8 ‘Parking the machine in secured condition’ on page 114. 2. Place the transparent container under the drain plug. 3.

  • Page 150: Every 250 Operating Hours

    Maintenance – Every 250 operating hours Every 250 operating hours 8.8.1 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 151: Checking, Tensioning The V-Belt

    Maintenance – Every 250 operating hours 4. Thoroughly clean the outside of the oil filter cartridge. 5. Unscrew the oil filter cartridge using an appropriate strap wrench. 6. Remove any dirt from the sealing face of the filter carrier. 7. Thinly apply oil to the rubber seal of the B-880-0108 new oil filter cartridge.

  • Page 152: Check The Air Intake Lines

    Maintenance – Every 250 operating hours 3. Check the entire circumference of the V- belt for damage and cracks. 4. Replace a damaged or cracked V-belt Ä Chapter 8.9.2 ‘Replacing the V-belt’ on page 158. 5. Check with thumb pressure whether the V- belt can be depressed more than 7 to 9 mm (0.28 –...

  • Page 153: Checking Radiator Hoses And Hose Clamps

    Maintenance – Every 250 operating hours 8.8.4 Checking radiator hoses and hose clamps Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.8 ‘Parking the machine in secured condition’ on page 114. 2. Allow the engine to cool down. 3.
  • Page 154 Maintenance – Every 250 operating hours Cleaning with com- Protective equip- Working clothes pressed air ment: Protective gloves Safety goggles CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protec- tive working clothes, goggles). 1.

  • Page 155: Battery Service

    Maintenance – Every 250 operating hours 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! – Protect electrical equipment such as generator, regulator and starter against the direct water jet.

  • Page 156: Check The Parking Brake

    Maintenance – Every 250 operating hours Protective equip- Working clothes ment: Protective gloves Safety goggles 1. Park the machine in secured condition Ä Chapter 6.8 ‘Parking the machine in secured condition’ on page 114. 2. Remove the battery and clean the battery compartment.

  • Page 157: Every 500 Operating Hours

    Maintenance – Every 500 operating hours Every 500 operating hours 8.9.1 Replacing the fuel filter NOTICE! Danger of engine damage! – Ensure strict cleanliness! Thor- oughly clean the area around the fuel filters. – Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting...

  • Page 158: Replacing The V-Belt

    Maintenance – Every 500 operating hours 5. Unscrew the drain plug (1) and catch run- ning out fuel. 6. Open the quick lock (2) and take off the fuel filter (3). 7. Clean the sealing face on the filter carrier from any dirt.

  • Page 159: Checking The Anti-Freeze Concentration And The Condition Of The Coolant

    Maintenance – Every 500 operating hours Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.8 ‘Parking the machine in secured condition’ on page 114. 2. Allow the engine to cool down. 3. Loosen the tensioning screw (1) and the screw (2) on the generator.

  • Page 160: Checking The Hydraulic Lines

    Maintenance – Every 500 operating hours 8.9.4 Checking the hydraulic lines This work must only be performed by an expert / qualified person! 1. Park the machine in secured condition Ä Chapter 6.8 ‘Parking the machine in secured condition’ on page 114. 2.

  • Page 161: Every 1000 Operating Hours

    Maintenance – Every 1000 operating hours 8.10 Every 1000 operating hours 8.10.1 Checking, 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 162 Maintenance – Every 1000 operating hours 4. Set cylinder 1 to overlapping and check the valve clearance on the valves marked black, adjust if necessary. Cylinder 1 is on the cooling fan side. Fig. 133 I Intake valve E Exhaust valve 5.

  • Page 163: Checking The Engine Mounts

    Maintenance – Every 1000 operating hours 1. Check valve clearance (A) between rocker arm and valve with a feeler gauge. The feeler gauge must fit through the gap with little resistance. 2. If the gap is too narrow or too wide for the feeler gauge, adjust the valve clearance.

  • Page 164: Checking The Travel Lever Control

    Maintenance – Every 1000 operating hours Unusual movements and noises (vibrations) during operation are signs for damage or loos- ened fastening elements. 1. Inspect the ROPS structure for cracks, cor- rosion, damage and missing fastening parts. 2. Check the fastening screws for the ROPS to the operator’s stand for tight fit.
  • Page 165 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 166 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 167 Maintenance – Every 1000 operating hours 3. Dispose of the hydraulic oil and filter in line with environmental regulations. BW 120 AD-5...

  • Page 168: 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 169 Maintenance – Every 2000 operating hours Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine safely Ä Chapter 6.8 ‘Parking the machine in secured condition’ on page 114. 2. Clean the area around hydraulic oil tank, filler opening and filler cap.
  • Page 170 Maintenance – Every 2000 operating hours NOTICE! This will contaminate the hydraulic oil! – Never use detergents. Wipe the inside of the hydraulic oil tank clean with a lint-free cloth. 8. Remove the suction filter from the hydraulic tank. 9. Screw in the new suction filter in the hydraulic tank.

  • Page 171: Changing The Coolant

    Maintenance – Every 2000 operating hours 15. Dispose of the hydraulic oil and suction filter in line with environmental regulations. 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.
  • Page 172 Maintenance – Every 2000 operating hours Protective equip- Working clothes ment: Protective gloves Safety goggles 1. Park the machine safely Ä Chapter 6.8 ‘Parking the machine in secured condition’ on page 114. 2. Allow the engine to cool down. 3. Unscrew the cover. B-880-0090 Fig.

  • Page 173: Replacing Hoses

    Maintenance – Every 2000 operating hours 16. Fill in coolant until the level reaches the bottom edge of the filler socket. 17. Screw the lid back on again. 18. Remove the cap from the compensation tank. B-880-0112 Fig. 147 19. Fill in coolant up to the “MAX” mark on the compensation tank.

  • Page 174: Check The Injection Valves

    Maintenance – Every 2000 operating hours 8.11.4 Check the injection valves This work must only be performed by authorized service personnel. BW 120 AD-5...

  • Page 175: Every 3000 Operating Hours

    Maintenance – Every 3000 operating hours 8.12 Every 3000 operating hours 8.12.1 Checking the fuel injection pump This work must only be performed by authorized service personnel. BW 120 AD-5...

  • Page 176: 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 177 Maintenance – As required Protective equip- Working clothes ment: Protective gloves Safety goggles Air filter maintenance is due when the yellow piston in the maintenance indicator has reached the red sector (1), but at the latest after one year. 1. Park the machine in secured condition Ä...
  • Page 178 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). 6. 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 if free of dust.
  • Page 179 Maintenance – As required 11. Press the reset button (1) for the yellow piston on the maintenance indicator. Fig. 155 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.

  • Page 180: Checking The Water Spraying System

    Maintenance – As required 8.13.2 Checking the water spraying system Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine on level and firm ground. 2. Shut down the engine. Water NOTICE! The spraying pump may get damaged if the tank is empty! –...
  • Page 181 Maintenance – As required NOTICE! The battery is being dis- charged! – Do not remain too long in testing position. Turn the rotary switch for the water B-SWI-1764 spraying system to permanent spraying Fig. 159 (position “MAX”). In positions “1” to “4” the corre- sponding spraying interval is activated only once.
  • Page 182 Maintenance – As required 8. Turn the ignition key to position “0” and pull it out. B-ELE-0069 Fig. 162 BW 120 AD-5...

  • Page 183: Cleaning The Water Spraying System

    Maintenance – As required 8.13.3 Cleaning the water spraying system Perform this maintenance work at the latest after one year. Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine safely Ä Chapter 6.8 ‘Parking the machine in secured condition’ on page 114.
  • Page 184 Maintenance – As required 9. Clean the water filter (1) and check for damage, replace if necessary. 10. Screw the drain cover back on with the water filter and a new seal (2). B-880-0126 Fig. 165 11. Unscrew the caps (1) and all nozzles (2) from the spray tube and let the water run out.

  • Page 185: Measures If There Is A Risk Of Frost

    Maintenance – As required 8.13.4 Measures if there is a risk of frost Protective equip- Working clothes ment: Safety shoes Protective gloves 1. Park the machine safely Ä Chapter 6.8 ‘Parking the machine in secured condition’ on page 114. 2. Open the drain cover on the water tank and let all water run out.

  • Page 186: Draining The Fuel Tank Sludge

    Maintenance – As required 11. Close the drain valve on the water pump and route the water line back into the machine. 12. Unscrew the caps (1) and all nozzles (2) from the spray tube and let the water run out.

  • Page 187: Measures Prior To Extended Shut-Down Period

    Maintenance – As required 8.13.6 Measures prior to extended shut-down period 8.13.6.1 Measures before shutting down If the machine is shut down for a longer period of time, e.g. winter season, the following work must be carried out: 1. Clean the machine thoroughly. 2.
  • Page 188 Maintenance – As required 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. – Ensure adequate ventilation. – Smoking and open fire is pro- hibited! –...
  • Page 189 Maintenance – As required 4. Switch off the charging current before removing the charging clamps. 5. After each charging process allow the bat- tery to rest for one hour before taking it into service. 6. For standstill periods of more than one month you should always disconnect the battery.
  • Page 190 Maintenance – As required BW 120 AD-5...

  • Page 191: Setting Up / Refitting

    Setting up / refitting Setting up / refitting BW 120 AD-5...

  • Page 192: Manually Adjusting The Crabwalk

    Setting up / refitting – Manually adjusting the crabwalk Manually adjusting the crabwalk Loads may only be attached and hoisted by an expert/qualified person. Do not use lashing points that are damaged or impaired in any way. Use only lifting gear and lifting tackle with suffi- cient load bearing capacity for the loads to be lifted.
  • Page 193 Setting up / refitting – Manually adjusting the crabwalk 4. Swing the central lifting point up and fasten the lashing tackle. 5. Lift up the machine just above the ground. 6. Shift the rear frame to the desired position on the left or right. 7.
  • Page 194 Setting up / refitting – Manually adjusting the crabwalk BW 120 AD-5...

  • Page 195: Troubleshooting

    Troubleshooting Troubleshooting BW 120 AD-5...

  • Page 196: Preliminary Remarks

    Troubleshooting – Preliminary remarks 10.1 Preliminary remarks Malfunctions are frequently caused by incorrect operation of the machine or insufficient mainte- nance. Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance. If you cannot locate the cause of a fault or rec- tify it yourself by following the trouble shooting chart, you should contact our customer service department.

  • Page 197: Starting The Engine With Jump Leads

    Troubleshooting – Starting the engine with jump leads 10.2 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 10.3 Fuse assignment 10.3.1 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. 10.3.2 Fuses in engine compartment Fig. 176 Pos.

  • Page 199: Central Electrics

    Troubleshooting – Fuse assignment 10.3.3 Central electrics The central electrics are located in the oper- ating console. 1. Unscrew the fastening screws and fold out the central electrics against the end stop. The printed circuit board is equipped with a fuse test socket ‘Fuse Test’.
  • Page 200 Troubleshooting – Fuse assignment Fuse Amperage Designation F139 30 A Engine solenoid F153 10 A Potential 15 F156 15 A Lighting F157 30 A Starter F241 15 A Optional headlights F274 10 A Chip spreader / hydraulic cutting tool F275 Economizer F276 10 A...

  • Page 201: Engine Faults

    Troubleshooting – Engine faults 10.4 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 202 Troubleshooting – Engine faults Fault Possible cause Remedy Moving parts overheating Check the engine oil level, because of a lack of lubrica- correct if necessary tion Check the engine oil filter, replace if necessary Check the lubrication system Excessive Engine oil level too high Check, drain off if necessary exhaust Insufficient fuel quality...
  • Page 203 Troubleshooting – Engine faults Fault Possible cause Remedy Engine has Engine oil level too low Check, fill up if necessary insufficient Lubrication system leaking Have the lubrication system engine oil examined by a specialist pressure (engine oil pressure warning lamp lights) The charge Generator speed too low...

  • Page 204: Trouble Shooting Economizer

    Troubleshooting – Trouble shooting ECONOMIZER 10.5 Trouble shooting ECONOMIZER Fig. 178: Economizer dis- play Fault Possible cause Remedy LED (a) Switching on: The LED (a) flashes flashes for approx 1 - 2 sec- onds after the vibration has been switched on. Jump operation of the drum on hard ground Acceleration sensor is not...
  • Page 205 Troubleshooting – Trouble shooting ECONOMIZER Fault Possible cause Remedy The displayed The acceleration sensor is Shut down the engine and measuring not fastened correctly. check the fastening screws of values are not the acceleration sensor. plausible. Weak spots in the road sub- In unfavourable cases, an base are also measured excessively varying material...
  • Page 206 Troubleshooting – Trouble shooting ECONOMIZER BW 120 AD-5...

  • Page 207: Disposal

    Disposal Disposal BW 120 AD-5...

  • Page 208: Final Shut-Down Of Machine

    Disposal – Final shut-down of machine 11.1 Final shut-down of machine After the machine has reached the end of its service life, the individual components of the machine must be disposed of properly. Observe national regulations! Carry out the following work and have the machine dismantled by a state-approved recy- cling company.

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