Fayat BOMAG BW 120 AD-5, Operating Instruction

Page 1: ...BW 120 AD 5 Tandem vibratory roller Operating Instruction Maintenance Instruction Original Operating Instructions S N 961 880 42 2507 05 2020 008 202 53 EN ...

Page 2: ...uding toluene and benzene which are known to the State of California to cause cancer and birth defects or other reproductive harm WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the ou...

Page 3: ...ny 25 3 2 2 Expert qualified person 25 3 2 3 Driver operator 26 3 3 Fundamentals for safe operation 27 3 3 1 Remaining dangers remaining risks 27 3 3 2 Regular safety inspections 27 3 3 3 Modifications and alterations to the machine 27 3 3 4 Damage defects misuse of safety devices 28 3 3 5 Roll Over Protective Structure ROPS 28 3 4 Handling fuels and lubricants 29 3 4 1 Preliminary remarks 29 3 4 ...

Page 4: ...ation 46 3 7 5 Parking the machine 46 3 8 Refuelling 47 3 9 Emergency procedures 48 3 9 1 Actuating the emergency stop switch 48 3 9 2 Disconnecting the battery 48 3 9 3 Towing the machine 48 3 10 Maintenance work 50 3 10 1 Preliminary remarks 50 3 10 2 Working on hydraulic lines 50 3 10 3 Working on the engine 51 3 10 4 Maintenance work on electric components and battery 52 3 10 5 Cleaning work 5...

Page 5: ...le lever 78 4 3 Engine compartment 79 4 3 1 Main battery switch 79 5 Checks prior to start up 81 5 1 Notes on safety 82 5 2 Visual inspections and function tests 84 5 3 Checking the engine oil level 85 5 4 Checking the fuel level topping up fuel 86 5 4 1 Checking the fuel level 86 5 4 2 Refuelling 86 5 5 Checking the hydraulic oil level 88 5 6 Checking the coolant level 89 5 7 Checking the air fil...

Page 6: ...ures 116 6 9 1 Actuating the emergency stop switch 116 6 9 2 Disconnecting the battery 116 6 9 3 Towing the machine 116 6 9 4 After towing 119 7 Loading transporting the machine 123 7 1 Preparation for transport 124 7 2 Loading the machine 125 7 3 Lashing the machine to the transport vehicle 126 7 4 Loading by crane 127 7 5 After transportation 129 7 6 Folding down and erecting the foldable ROPS 1...

Page 7: ...g the radiator module 153 8 8 6 Battery service 155 8 8 7 Check the parking brake 156 8 9 Every 500 operating hours 157 8 9 1 Replacing the fuel filter 157 8 9 2 Replacing the V belt 158 8 9 3 Checking the anti freeze concentration and the condition of the coolant 159 8 9 4 Checking the hydraulic lines 160 8 10 Every 1000 operating hours 161 8 10 1 Checking adjusting the valve clearance 161 8 10 2...

Page 8: ...l tank sludge 186 8 13 6 Measures prior to extended shut down period 187 9 Setting up refitting 191 9 1 Manually adjusting the crabwalk 192 10 Troubleshooting 195 10 1 Preliminary remarks 196 10 2 Starting the engine with jump leads 197 10 3 Fuse assignment 198 10 3 1 Notes on safety 198 10 3 2 Fuses in engine compartment 198 10 3 3 Central electrics 199 10 4 Engine faults 201 10 5 Trouble shootin...

Page 9: ...1 Introduction Introduction BW 120 AD 5 9 ...

Page 10: ...enance instructions before taking your machine into operation Please observe the safety regulations strictly and follow all instructions to ensure safe opera tion If you are not yet acquainted with the controls and indicating elements on this machine you should thoroughly read the corresponding chapter Ä Chapter 4 Indicators and control elements on page 65 The description of the individual operati...

Page 11: ...ved fuels and lubri cants all warranty claims will become null and void For your own personal safety you should only use original parts from BOMAG For your machine we offer service kits to make maintenance easier In the course of technical development we reserve the right for technical modifications without prior notification These operating and maintenance instructions are also available in other...

Page 12: ...plate Please enter here Machine type 1 Serial number 2 Please enter here Engine type Fig 1 Engine number 2 Fig 1 Machine type plate example Fig 2 Engine type plate example Introduction Machine type plate and engine type plate BW 120 AD 5 12 ...

Page 13: ...2 Technical data Technical data BW 120 AD 5 13 ...

Page 14: ...568 101 Dimensions in millimetres Dimensions in inches K L O S W 254 10 0 2529 100 36 1 4 13 0 5 1200 47 Dimensions in millimetres Dimensions in inches Height with protective roof and flashing beacon optional equipment 2890 114 mm in Dimensions Technical data BW 120 AD 5 14 ...

Page 15: ... speed with vibration 0 10 0 6 2 km h mph Max gradeability without with vibration soil and weather dependent 40 30 Drive Engine manufacturer Kubota Type D 1703 M E3B Cooling system Water Number of cylinders 3 Rated power ISO 14396 24 3 kW Rated power SAE J 1995 32 6 hp Rated speed 2600 min 1 Fixed engine speed 1 2500 min 1 Fixed engine speed 2 2600 min 1 Driven drum front rear Technical data BW 12...

Page 16: ...eering operation hydrostatic Steering angle 32 Oscillation angle 10 Inner track radius 2450 97 mm in Crabwalk lateral offsetting of drum right left 50 2 0 mm in Exciter system Vibrating drum front rear Frequency 1 2 63 67 3780 4020 Hz vpm Amplitude 0 5 0 02 mm in Centrifugal force 1 2 36 41 8093 9217 kN lbf Technical data BW 120 AD 5 16 ...

Page 17: ...2000 14 EU Noise Protection Directive 2003 10 EU n Vibration Protection Directive 2002 44 EU During operation these values may vary because of the prevailing operating conditions 2 1 1 Noise data LpA 84 dB A determined acc to ISO 11201 and EN 500 WARNING Loss of hearing caused by too high noise burdens Wear your personal protective equipment ear protection LWA 106 dB A determined acc to ISO 3744 a...

Page 18: ...n value determined according to ISO 2631 is 0 5 m s2 The weighted effective acceleration value determined according to ISO 5349 is 2 5 m s2 Vibration of the entire body driver s seat Hand arm vibration Technical data Noise and vibration data BW 120 AD 5 18 ...

Page 19: ...3 Concerning your safety Concerning your safety BW 120 AD 5 19 ...

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

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

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

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

Page 24: ...sing the machine for towing Transporting persons except the machine driver is prohibited Starting and operating the machine in explo sive environments and in underground mining is prohibited 3 1 6 Estimated service life of the machine If the following general conditions are met the service life of the machine is usually in the range of several thousand operating hours n Regular safety inspections ...

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

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

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

Page 28: ...fective 3 3 5 Roll Over Protective Structure ROPS The frame of the machine must not be warped bent or cracked in the area of the ROPS fas tening The ROPS must not show any rust damage hairline cracks or open fractures The real machine weight must never exceed the testing weight for the ROPS No accessories may be welded or bolted on and no additional holes must be drilled without the consent of the...

Page 29: ...ame of substance n possible dangers n composition information on constituents n first aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitation and monitoring of exposure per sonal protective equipment n physical and chemical properties n stability and reactivity n toxicological data n environmental data n notes on waste disposal n informati...

Page 30: ...e clothing CAUTION Health hazard caused by contact with diesel fuel Wear your personal protective equipment protective gloves protective clothing Do not inhale any fuel fumes Avoid contact CAUTION Danger of slipping on spilled diesel fuel Immediately bind spilled diesel fuel with an oil binding agent ENVIRONMENT Diesel fuel is an environmentally hazardous substance Always keep diesel fuel in prope...

Page 31: ...ly bind spilled diesel fuel with an oil binding agent and dispose of properly Dispose of diesel fuel and fuel fil ters according to regulations Concerning your safety Handling fuels and lubricants BW 120 AD 5 31 ...

Page 32: ...used by contact with oil Wear your personal protective equipment protective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil Immediately bind spilled oil with an oil binding agent ENVIRONMENT Oil is an environmentally haz ardous substance Always keep oil in proper con tainers Immediately bind spilled oil with an oil binding agent Disp...

Page 33: ...id penetrate the skin immediate medical help is required WARNING Danger of burning by ignited hydraulic oil Do not allow hydraulic oil to come into contact with hot com ponents Smoking and open fire is pro hibited Wear your personal protective equipment protective gloves protective clothing CAUTION Health hazard caused by contact with hydraulic oil Wear your personal protective equipment protectiv...

Page 34: ...nding agent ENVIRONMENT Oil is an environmentally haz ardous substance Always keep oil in proper con tainers Immediately bind spilled oil with an oil binding agent Dispose of oil and oil filter according to regulations Concerning your safety Handling fuels and lubricants BW 120 AD 5 34 ...

Page 35: ...sed by contact with coolant and coolant addi tives Wear your personal protective equipment protective gloves protective clothing Do not inhale any fumes Avoid contact CAUTION Danger of slipping on spilled coolant Immediately bind spilled coolant with an oil binding agent ENVIRONMENT Coolant is an environmentally hazardous substance Always keep coolant and coolant additives in proper containers Con...

Page 36: ...ately bind spilled coolant with an oil binding agent and dis pose of it according to regula tions Dispose of coolant according to regulations Concerning your safety Handling fuels and lubricants BW 120 AD 5 36 ...

Page 37: ...n or eyes immediately with lots of clean water Immediately call for medical advice in case of cauterization WARNING Danger of injury caused by exploding gas mixture Remove the plugs before starting to recharge the battery Ensure adequate ventilation Smoking and open fire is pro hibited Do not lay any tools or other metal objects on the battery Do not wear jewellery watch bracelets etc when working...

Page 38: ...ENVIRONMENT Battery acid is an environmen tally hazardous substance Dispose of battery and battery acid according to regulations Concerning your safety Handling fuels and lubricants BW 120 AD 5 38 ...

Page 39: ... impaired in any way Always use appropriate lashing tackle at the lashing points Use lashing tackle only in the specified loading direction Lashing tackle must not be damaged by machine parts Secure the machine on the transport vehicle against rolling slipping and turning over Loads may only be attached and hoisted by an expert qualified person Only use lifting and lashing tackle with suffi cient ...

Page 40: ...ock 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 Concerning your safety Loading transporting the machine BW 120 AD 5 40 ...

Page 41: ...nting the machine check whether n persons or obstructions are beside or under the machine n the machine is free of oily and combustible materials n all access steps grips and platforms are free of obstacles grease oils fuel dirt snow and ice n all safety elements are in place n all maintenance flaps and doors are closed and locked Climb onto or off the machine only when the machine is standing Use...

Page 42: ...pilot or ether The machine must not be operated with dam aged missing or non functional safety installa tions After starting check all display instruments Do not inhale exhaust fumes because they contain toxic substances which could cause damage to health unconsciousness or even death For operation in closed or partly closed rooms ensure adequate ventilation 3 6 3 Starting the engine with jump lea...

Page 43: ...Do not start the engine by shorting the electric terminals on the starter motor because the machine may start to drive immediately Concerning your safety Starting up the machine BW 120 AD 5 43 ...

Page 44: ...ing Do not climb onto or off the machine while the machine is driving Do not use the machine to transport persons In the case of unusual noises and appearance of smoke perform troubleshooting to determine the cause and have the fault corrected Match the speed to the working conditions Do not make extreme steering movements when driving with high speed danger of tipping over Always give way to load...

Page 45: ...ons and slopes Increased danger of accident 3 7 3 Cross slope The tipping angle was measured statically on level hard ground with the machine stopped and without steering The max permissible inclination of the machine may be limited by the max permis sible slanted position of the engine The specified angle must not be exceeded With loose soil acceleration deceleration run ning vibration steering o...

Page 46: ... concrete ground Components may get dam aged 3 7 5 Parking the machine Park the machine on horizontal level firm ground Before leaving the machine n shift all control levers to Neutral position Off or 0 n apply the parking brake n shut down the engine pull off the ignition key n pull off the main battery switch n secure the machine against unauthorized use Do not jump off the machine but use hand ...

Page 47: ... charging than diesel fuel with a higher sulphur content You should therefore always make sure that the filling system is properly grounded and that there is equipotential bonding to the machine If necessary use a connecting cable between filling system and vehicle ground Monitor the entire refuelling process Do not spill any fuel Collect leaking fuel do not let it seep into the ground Wipe off sp...

Page 48: ... use the emergency stop switch as a service brake 3 9 2 Disconnecting the battery In events of emergency e g in case of a cable fire disconnect the battery from the vehicle network Pull out the main battery switch or lift off the battery pole to do so 3 9 3 Towing the machine Tow the machine only in case of emergency or to avoid an accident Before releasing the parking brake apply suit able measur...

Page 49: ...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 Concerning your safety Emergency procedures BW 120 AD 5 49 ...

Page 50: ...aulic lines Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury Immediately call for medical assistance if injured by hydraulic oil Do not step in front of or behind the machine when performing adjustment work in the hydraulic system Do not change the setting of pressure relief valves Drain the hydraulic oil at operating temperature danger of scalding Any hydraulic...

Page 51: ... operating temperature danger of scalding Wipe off spilled oil collect leaking oil and dis pose of it in an environmentally friendly way Store used filters and other oil contaminated materials in a separate specially marked con tainer and dispose of them in an environmen tally friendly way The settings for idle speed and highest speed must not be changed since this would affect the exhaust gas val...

Page 52: ...rking on the battery The connection cables of the battery must not touch or rub against machine parts 3 10 5 Cleaning work Do not perform cleaning work while the motor is running Allow the engine to cool down before starting cleaning work on engine and exhaust system Never use gasoline or other easily inflammable substances for cleaning When cleaning with a high pressure cleaner do not subject ele...

Page 53: ...t both before and after shut down Ä Chapter 8 13 6 Measures prior to extended shut down period on page 187 It is not necessary to define a maximum storage period if these measures have been performed 3 10 7 After maintenance work Reassemble all guards and protective devices Close all maintenance flaps and maintenance doors again Concerning your safety Maintenance work BW 120 AD 5 53 ...

Page 54: ...arning sign Only operate the machine after it has been repaired Repairs must only be performed by an expert qualified person When replacing safety relevant components only original spare parts must be used Concerning your safety Repair BW 120 AD 5 54 ...

Page 55: ...2 Signage Keep stickers and signage in good and legible condition and comply with their meaning Replace damaged and illegible stickers or sig nage immediately Concerning your safety Signage BW 120 AD 5 55 ...

Page 56: ...20 kg 200 Nm 25 kg 75 Nm 1 m Nm 75 200 ft lb 55 147 30 cm 20 kg 200 Nm 25 kg 75 Nm 1 m Nm 75 200 ft lb 55 147 30 cm Hydraulic Oil B 880 0276 Fig 10 Concerning your safety Signage BW 120 AD 5 56 ...

Page 57: ...z DQC CC 14 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that are reproductive toxicants B 880 0257 Fig 11 Warning sticker Follow operating instructions Fig 12 Concerning your safety Signage BW 120 AD 5 57 ...

Page 58: ...ia Proposition 65 Prohibition sticker High pressure cleaning Fig 13 B DEC 0207 Fig 14 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that are reproductive toxicants B DEC 0316 Fig 15 Fig 16 Concerning your safety Signage BW 120 AD 5 58 ...

Page 59: ...your seat belt Information sticker Lifting point Information sticker Lashing point Information sticker Filler opening for hydraulic oil Fig 17 Fig 18 Fig 19 B DEC 0214 Hydraulic Oil Fig 20 Concerning your safety Signage BW 120 AD 5 59 ...

Page 60: ... Information sticker Hydraulic oil drain Information sticker Coolant drain Information sticker Disconnecting the battery B DEC 0211 Fig 21 B DEC 0210 Fig 22 B DEC 0212 Fig 23 B DEC 0219 Fig 24 Concerning your safety Signage BW 120 AD 5 60 ...

Page 61: ...on sticker Foldable ROPS operation Information sticker Coolant B DEC 0236 Fig 25 Fig 26 B DEC 0208 20 kg 200 Nm 25 kg 75 Nm 1 m Nm 75 200 ft lb 55 147 30 cm Fig 27 B DEC 0221 Part No 009 940 03 20 l Engine Coolant Spec MB 325 5 Deutz DQC CC 14 Fig 28 Concerning your safety Signage BW 120 AD 5 61 ...

Page 62: ...Machine type plate example Fig 29 Concerning your safety Signage BW 120 AD 5 62 ...

Page 63: ...is a danger zone Before starting the machine and during opera tion the driver operator must ensure that nobody is in the danger zone Give warning signals if necessary Stop work immediately if persons are in the danger zone Concerning your safety Danger zones BW 120 AD 5 63 ...

Page 64: ...Concerning your safety Danger zones BW 120 AD 5 64 ...

Page 65: ...4 Indicators and control elements Indicators and control elements BW 120 AD 5 65 ...

Page 66: ... 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 8 Emergency stop switch 9 Instrument cluster 10 ECONOMIZER display optional equipment 11 Rotary switch for water spraying system Indicators and control elements Operating console BW 1...

Page 67: ...ng side are flashing Optional equipment 4 1 2 Rotary switch for working lights Position Left Working lights off Position Right Working light on 4 1 3 Rotary switch for lighting Position Left Light off Position Middle Side light on Position Right Travel light on Optional equipment Fig 32 Fig 33 Fig 34 Indicators and control elements Operating console BW 120 AD 5 67 ...

Page 68: ...off Position Right Flashing beacon on Optional equipment 4 1 6 Rotary switch for drum pre selection Position left Vibration of front drum Position middle Vibration of front and rear drums Position right Vibration of rear drum Drum pre selection is only acti vated if the vibration has been switched off beforehand Fig 35 Fig 36 B SWI 1488 Fig 37 Indicators and control elements Operating console BW 1...

Page 69: ...ertain value 4 1 8 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 The engine is shut down switch off unlock Turn the Emergency Stop switch clockwise and let it go NOTICE In case of frequent use the wear on the multi discs br...

Page 70: ...ight Lights up when the driver s seat is not occu pied If the machine is travelling the warning buzzer will sound and the engine will be shut down after 2 seconds If the travel lever is shifted to any travel direc tion the engine will be shut down If the engine stops occupy the driver s seat and restart the engine Pre heating control light Lights up during pre heating Control and warning lights In...

Page 71: ...r the engine Charge control light Lights up if the battery is not being charged Check the V belt if necessary repair the gen erator Indicator control light Parking brake warning light Lights up when the parking brake is applied Central warning light Flashes in case of a fault of the rotation angle sensor or rotary switch for the water spraying system Each actuation of the F2 button switches betwee...

Page 72: ...scription of display possibilities Ä Chapter 6 6 6 ECONOMIZER on page 110 Optional equipment 4 1 11 Rotary switch for water spraying system Position 0 Spraying off Position 1 to 4 Interval spraying Position MAX Permanent spraying Fig 42 B SWI 1763 Fig 43 Indicators and control elements Operating console BW 120 AD 5 72 ...

Page 73: ... 3 5 4 6 1 2 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 Indicators and control elements Driver s stand BW 120 AD 5 73 ...

Page 74: ... key up to 10 seconds in position II Position III Turn further against spring pressure the engine starts Turn the ignition key back to position I when the engine starts The starter switch is designed with a re start lock The ignition key must first be turned back to position 0 before a new starting attempt can be made 4 2 2 12 V DIN socket Permanent current loadable up to 10 A Fig 45 Fig 46 Indica...

Page 75: ...vel n Position I up to approx 5 km h 3 mph n Position II up to approx 10 km h 6 2 mph Pull back Backward travel n Position I up to approx 5 km h 3 mph n Position II up to approx 10 km h 6 2 mph Position Middle Service brake position Position middle right travel lever right Parking brake position Position middle left travel lever left Indicators and control elements Driver s stand BW 120 AD 5 75 ...

Page 76: ...vel lever On machines with double travel lever optional equipment the push button assignment is identical on both travel levers 1 2 B ELE 0271 1 Vibration on off 2 Warning horn Indicators and control elements Driver s stand BW 120 AD 5 76 ...

Page 77: ...he end stop the weight adjustment automatically switches back to the top position 2 Length adjust ment Pull the lever up and push the seat forward or back 3 Backrest inclina tion Relieve the backrest and pull the lever up 4 Sliding the seat sideways optional equip ment Pull the lever up slide the seat to the desired position and lock it securely in place Indicators and control elements Driver s st...

Page 78: ...tle lever Position MIN Idle speed position Position MAX I Full load position I Position MAX II Full load position II MIN MAX II MAX I B 880 0159 Fig 49 Indicators and control elements Driver s stand BW 120 AD 5 78 ...

Page 79: ...olates the batteries from the on board electrics in case of cable fire and fire in the engine compartment as well as protection against unauthorized use Individual control units may still be connected to the board electrics despite the main battery switch being pulled out Optional equipment B 880 0033 Fig 50 Indicators and control elements Engine compartment BW 120 AD 5 79 ...

Page 80: ...Indicators and control elements Engine compartment BW 120 AD 5 80 ...

Page 81: ...5 Checks prior to start up Checks prior to start up BW 120 AD 5 81 ...

Page 82: ...and lubricants Safety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Ä Chapter 3 4 Handling fuels and lubri cants on page 29 WARNING Danger of injury caused by rotating parts Before starting work on the machine make sure that the engine can not be started CAUTION Danger of being injured by the engine hood dropping down Always secure an ope...

Page 83: ...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 Checks prior to start up Notes on safety BW 120 AD 5 83 ...

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

Page 85: ...g clothes n Safety shoes n Protective gloves 1 Pull the dipstick out wipe it off with a lint free clean cloth and reinsert it to the end stop 2 Pull the dipstick out again ð The oil level must be between the MIN and MAX marks 3 For topping up clean the area around the filling port 4 Unscrew the cap and fill with engine oil up to the MAX mark 5 Push the dipstick in 6 Close the cap MIN MAX 2 1 B 880...

Page 86: ...Never run the fuel tank empty as otherwise the fuel system needs to be bled Monitor the entire refuelling process Contaminated fuel can cause malfunction or even damage of the engine If necessary fill in fuel through a screen filter Use only fuel of the permitted specification Ä Chapter 8 3 2 Fuel on page 140 0 1 4 3 4 1 h 1 2 B DIS 0005 Fig 52 Checks prior to start up Checking the fuel level topp...

Page 87: ...hes n Safety shoes n Protective gloves 1 Clean the area around the filling port 2 Unscrew the cap and fill with fuel 3 Close the cap B 880 0187 Diesel Fig 53 Checks prior to start up Checking the fuel level topping up fuel BW 120 AD 5 87 ...

Page 88: ...l of the permitted specification Ä Chapter 8 3 4 Hydraulic oil on page 143 Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 For checking and topping up clean the area around the filling port 2 Remove the cap and check the hydraulic oil level on the dipstick 3 The hydraulic oil level must always be between the MIN and MAX marks ð Top up hydraulic oil 4 Close the cap B 88...

Page 89: ... page 142 Protective equip ment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 WARNING Danger of scalding by hot fluid Open the compensation tank only when the engine is cold Wear your personal protec tive equipment protective gloves protective clothing goggles Check the coolant level in the compensa tion tank 2 To refill remove the cover and fill up to the MAX mark with c...

Page 90: ...otective 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 Chapter 8 13 1 Air filter maintenance on page 176 1 B 880 0084 Fig 56 Checks prior to start up Checking the air filter BW 120 AD 5 90 ...

Page 91: ... maintenance instructions in case of frost Ä Chapter 8 13 4 Measures if there is a risk of frost on page 185 NOTICE Dirty or contaminated water can block the water spraying system Fill only with clean water 1 Check the filling level on the water level gauge fill up if necessary B 880 0188 Water Fig 57 Checks prior to start up Checking the water level topping up BW 120 AD 5 91 ...

Page 92: ...fill in clean water through the strainer 2 3 Make sure that the ventilation bore in the filler cap is free 4 Close the cap 1 2 B 880 0189 Water Fig 58 Checks prior to start up Checking the water level topping up BW 120 AD 5 92 ...

Page 93: ...p ment n Working clothes n Safety shoes n Protective gloves 1 Check the condition of the scrapers 1 on both drums clean if necessary 2 Replace worn scrapers 1 1 1 B 880 0056 Fig 59 Checks prior to start up Checking and cleaning the scrapers BW 120 AD 5 93 ...

Page 94: ...al indicator which must be checked at operating temperature 1 Make sure that no persons are in the danger zone during maintenance work 2 Drive the machine onto level firm ground 3 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 2 seconds The parking brake warning ...

Page 95: ...ressed in the hydraulic oil filter is in good condition 10 If the pin pops out replace the hydraulic oil filter Ä Chapter 8 10 5 Replacing the hydraulic oil filter on page 164 11 Close the engine hood Ä Chapter 8 2 1 2 Closing the engine hood on page 136 12 Shift the throttle lever to position MIN idle speed 13 NOTICE Danger of engine damage Do not shut down the engine all of a sudden from full lo...

Page 96: ...Checks prior to start up Checking the hydraulic oil filter BW 120 AD 5 96 ...

Page 97: ...6 Operation Operation BW 120 AD 5 97 ...

Page 98: ...6 1 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 Operation Setting up the workplace BW 120 AD 5 98 ...

Page 99: ...obilizer armed the light emitting diode a flashes slowly 1 Slowly enter the six digit user code ð When entering the code the light emit ting diode 6 lights up with every digit 2 Press the diamond button ð The electronic immobilizer is now dis armed and the engine can be started within the next 15 minutes Fig 64 Operation Electronic immobilizer BW 120 AD 5 99 ...

Page 100: ...rerequisites n Main battery switch if present switched on n Emergency stop switch is unlocked n Travel lever in parking brake position When closing the dashboard cover the emergency stop switch will lock automatically and must be unlocked before starting again 1 Set the throttle lever to position MIN MIN MAX II MAX I B 880 0159 Fig 65 Operation Starting the engine BW 120 AD 5 100 ...

Page 101: ...ignition key must first be turned back to position 0 before a new starting attempt can be made NOTICE Components may get dam aged Run the starting process for maximum 20 seconds without interruption and pause for a minute between starting attempts If the engine has not started after two attempts determine the cause Turn the ignition key through position II to position III ð The starter cranks the ...

Page 102: ...NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under full load Operation Starting the engine BW 120 AD 5 102 ...

Page 103: ...the machine Wet and loose soil considerably reduces trac tion of the machine on inclinations and slopes Greater danger of accident When driving up and down slopes move the travel lever slowly back towards neutral to brake the machine If the operator leaves his seat while travelling the driver s seat warning light lights up The warning buzzer sounds After approx 3 seconds the machine brakes to a st...

Page 104: ...3 Stopping the machine applying the parking brake 1 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 2 seconds The parking brake warning light lights up MIN MAX II MAX I B 880 0160 Fig 70 B ELE 0262 Fig 71 B ELE 0263 Fig 72 B SYM 0018 Fig 73 Operation Travel mode B...

Page 105: ...ur seat belt 5 Set the throttle lever to position MAX I 6 Before starting to drive make sure that the driving area is absolutely safe 7 Disengage the travel lever to the left out of parking brake position and move it slowly to the required travel direction ð The further the travel lever is moved for wards or backwards the faster the machine will travel Stick to the maximum speed of 8 km h 5 mph 8 ...

Page 106: ...9 Always apply the parking brake when stop ping on inclinations or slopes Operation Driving the machine in public traffic BW 120 AD 5 106 ...

Page 107: ...tion on hard frozen concrete ground Vibration at standstill causes transverse marks n Switch the vibration on only after the machine has reached its nominal speed n Switch the vibration off approx one machine length before stopping the machine In automatic operation vibration is automati cally activated when a certain low travel speed is reached The vibration is automatically switched off when fal...

Page 108: ...on is only acti vated if the vibration has been switched off beforehand 2 Set the throttle lever to position MAX I or MAX II 6 6 3 Manual vibration 1 Turn the rotary switch for vibration pre selection to position Left B SWI 1488 Fig 76 MIN MAX II MAX I B 880 0160 Fig 77 B SWI 1486 Fig 78 Operation Working with vibration BW 120 AD 5 108 ...

Page 109: ...e again to switch off vibration 6 6 4 Vibration in automatic mode 1 Turn the rotary switch for vibration pre selection to position Right 2 Shift the travel lever slowly in the desired travel direction ð The vibration comes on at a low travel speed 3 To switch off vibration return the travel lever towards Middle position ð The vibration switches off when falling below a low travel speed B ELE 0264 ...

Page 110: ...he detection and selected re compaction of weak spots The acceleration transducer on the front drum measures the reaction of the road subbase on the vibrating drum The ECONOMIZER is automatically started by switching the ignition on The ECONOMIZER first of all runs an LED test The LEDs light up one after the other starting with LED 1 Once all LEDs are on the display goes out again in single steps ...

Page 111: ...the vibration motor has reached its nominal frequency n flashes if the drum is in jump operation n lights in case of faults Ä Chapter 10 5 Trouble shooting ECONOMIZER on page 204 In order to achieve the desired compaction condition of the road substructure or asphalt layer one must always perform a suitable ref erence measurement before compaction is started The reference measurement is used to de...

Page 112: ...The measuring values achieved with different tandem vibratory rollers can be made compa rable by calibration to a reference value Operation Working with vibration BW 120 AD 5 112 ...

Page 113: ...r the travel lever is actuated in travel direction or after the rotary switch for the water spraying system has been set to permanent spraying position MAX With the travel lever in neu tral spraying will continue for a short while 3 After the end of work turn the rotary switch for the water spraying system back to posi tion 0 B SWI 1765 Fig 84 B SWI 1763 Fig 85 Operation Water spraying system BW 1...

Page 114: ...after approx 2 seconds The parking brake warning light lights up 3 Shift the throttle lever to position MIN idle speed 4 NOTICE Danger of engine damage Do not shut down the engine all of a sudden from full load speed but let it idle for about two minutes Turn the ignition key to position 0 and pull it out B ELE 0263 Fig 86 B SYM 0018 Fig 87 MIN MAX II MAX I B 880 0159 Fig 88 B ELE 0069 Fig 89 Oper...

Page 115: ...5 Turn the main battery switch if present anticlockwise and pull it out B SWI 0079 Fig 90 Operation Parking the machine in secured condition BW 120 AD 5 115 ...

Page 116: ... of danger e g cable fire the minus terminal has been designed as a quick release pole clamp 1 Pull up the cap from the minus pole ð The pole clamp comes off the minus pole 2 Disconnect the pole clamp from the minus pole of the battery and lay it to the side 6 9 3 Towing the machine Tow the machine only in case of emergency or to prevent an accident Always use a tow bar Towing distance only out of...

Page 117: ...ing clothes n Safety shoes n Protective gloves 1 Shut down the engine 2 Fold the front or rear cover up 3 Fasten the tow bar to the towing eye 4 Open the engine hood Ä Chapter 8 2 1 1 Open and secure the engine hood on page 136 WARNING Danger of burning on hot compo nents Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components 5 Remove the cover ...

Page 118: ...ten the counter nuts tightening torque 22 Nm 16 ft lbf WARNING Danger of injury caused by uncontrolled machine movement Always secure the machine against unintended rolling 10 Remove two plugs 11 Press both screws in against the springs 12 Tighten both screws alternately and step by step against the end stop tightening torque 35 Nm 25 ft lbf B HYD 0003 1 2 1 2 1 2 Fig 95 B 880 0014 Fig 96 Fig 97 O...

Page 119: ...owed 6 9 4 After towing Protective equip ment n Working clothes n Safety shoes n Protective gloves WARNING Danger of injury caused by uncontrolled machine movement Always secure the machine against unintended rolling 1 After towing park the machine in a safe place and secure it against accidentally rolling away 2 Remove two plugs B 880 0014 Fig 98 B 880 0014 Fig 99 Operation Emergency procedures B...

Page 120: ...e limiting valves of the travel pump 7 Unscrew the socket head cap screws 1 against the end stop 8 Tighten the counter nuts tightening torque 22 Nm 16 ft lbf 9 Open the engine hood Ä Chapter 8 2 1 1 Open and secure the engine hood on page 136 10 Mount the cover on the travel pump Fig 100 B 880 0014 Fig 101 B HYD 0003 1 2 1 2 1 2 Fig 102 B 880 0050 Fig 103 Operation Emergency procedures BW 120 AD 5...

Page 121: ...ng the engine hood on page 136 3 Set the throttle lever to position MIN 4 Start the engine and shut it down again after approx 2 3 seconds 5 Repeat this process after a short break 6 Pull off the ignition key 7 Open the engine hood and reconnect the plug Y04 to the solenoid valve for the parking brake 8 Close the engine hood B 880 0049 1 Fig 104 1 Plug Y04 MIN MAX II MAX I B 880 0159 Fig 105 B 880...

Page 122: ...Operation Emergency procedures BW 120 AD 5 122 ...

Page 123: ...7 Loading transporting the machine Loading transporting the machine BW 120 AD 5 123 ...

Page 124: ...7 1 Preparation for transport 1 Close all flaps 2 Remove all loose objects from the machine or fasten them properly Loading transporting the machine Preparation for transport BW 120 AD 5 124 ...

Page 125: ...ine 1 Fasten your seat belt 2 Set the throttle lever to position MAX I DANGER Danger to life caused by the machine slipping or turning over Make sure that no persons are in the danger zone 3 Drive the machine carefully onto the trans port vehicle 4 Observe the centre of gravity 5 Switch off the engine and remove the igni tion key 6 Attach and secure the articulation lock Ä Chapter 8 2 2 1 Engaging...

Page 126: ...ecified loading direction Lashing tackle must not be damaged by machine parts Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Fasten the lifting and lashing tackle on the marked lashing points on front or rear frame 2 Lash the machine securely to the transport vehicle B 880 0190 Fig 108 Loading transporting the machine Lashing the machine to the transport vehicle BW 12...

Page 127: ...shing points Use lifting and lashing gear only in the pre scribed direction of load application Lifting tackle must not be damaged by machine components When lifting the machine avoid uncontrolled movements of the load If necessary hold the load with guide ropes Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Shut down the engine 2 Attach and secure the articulation lo...

Page 128: ...ng tackle 5 DANGER Danger to life caused by sus pended loads Do not step or stand under suspended loads Lift the machine carefully and set down again at the intended location B 880 0261 Fig 109 Loading transporting the machine Loading by crane BW 120 AD 5 128 ...

Page 129: ...n 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 Make sure that no persons are in the danger zone 5 Drive the machine carefully off the trans port vehicle MIN MAX II MAX I B 880 0160 Fig 110 Loading transporting the machine After transportation BW 120 AD 5 129 ...

Page 130: ... adjust the clamping plates vertically 2 CAUTION Head injuries caused by folding the foldable ROPS Do not step into the slewing area of the foldable ROPS Fold the foldable ROPS back 7 6 2 Erecting the foldable ROPS Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Erect the clamping plates on both sides vertically B 650 0018 Fig 111 B 650 0019 Fig 112 Loading transportin...

Page 131: ...lewing area of the foldable ROPS Fold up the foldable ROPS 3 Turn the clamping plates horizontally and tighten the eye bolts tightening torque 75 200 Nm 55 148 ft lbf B 650 0039 75 200 Nm 55 148 ft lbf Fig 113 Loading transporting the machine Folding down and erecting the foldable ROPS BW 120 AD 5 131 ...

Page 132: ...Loading transporting the machine Folding down and erecting the foldable ROPS BW 120 AD 5 132 ...

Page 133: ...8 Maintenance Maintenance BW 120 AD 5 133 ...

Page 134: ...Safety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Ä Chapter 3 4 Handling fuels and lubri cants on page 29 CAUTION Danger of being injured by the engine hood dropping down Always secure an opened engine hood Wear your personal protective equipment Park the machine on horizontal level firm ground Keep unauthorised persons away from the m...

Page 135: ...k use the access steps and working platforms provided or other secure means Do not step on machine parts which are not intended for this purpose Always attach the articulation lock when working in the area of the articulated joint Do not leave any tools or other objects that could cause damage in or on the machine After all maintenance work is completed rein stall all guards and safety installatio...

Page 136: ... all maintenance flaps and doors again and return all components to their operating condition 8 2 1 Engine hood 8 2 1 1 Open and secure the engine hood 1 Open the locking 2 Push the hood to top position ð The hood is raised supported by the gas springs 8 2 1 2 Closing the engine hood 1 Push the hood at the handle into initial position 2 Lock the hood B 880 0192 Fig 114 B 880 0193 Fig 115 Maintenan...

Page 137: ...middle position and stop the machine 2 Switch off the engine and remove the igni tion key 3 WARNING Danger of crushing by the articulating machine Do not step into the articula tion area of the machine while the engine is running Swing the articulation lock up and secure it with screws B 880 0262 Fig 116 Maintenance Preparations concluding work BW 120 AD 5 137 ...

Page 138: ...s 1 Switch off the engine and remove the igni tion key 2 WARNING Danger of crushing by the articulating machine Do not step into the articula tion area of the machine while the engine is running Loosen the articulation lock and fold it down B 880 0263 Fig 117 Maintenance Preparations concluding work BW 120 AD 5 138 ...

Page 139: ...iscosity 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 SAE class The temperature data of the SAE class always refer to fresh oils In travel operation engine oil ages because of soot and fuel residues This adversely affects the properties of the engine oil especial...

Page 140: ...urs reached If the sulphur content in the fuel is higher than 0 5 the oil change intervals must be halved 8 3 2 Fuel 8 3 2 1 Fuel quality We recommend using a diesel fuel with a sul phur content of less than 0 1 When using a diesel fuel with a high sulphur content of 0 5 to 1 0 the oil change inter vals must be halved Fuels with a sulphur content of more than 1 0 are not permitted In order to fulf...

Page 141: ...para tion At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel 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 8 3 2 3 Storage Even traces of zinc lead and copper can c...

Page 142: ...For this engine you should use eth ylene glycol 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 Do not mix different coolants and additives of any other kind Mixing the coolant n Prepare a mixture of 50 anti fr...

Page 143: ...g agent it may cause the development of sludge which could damage the cooling system Anti freeze concen tration Freezing point 50 37 C 35 F 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 mm2 s at 40 C 104 F and 8 mm2 s at 100 C 212 F When refilling or changing oil use only hydraulic oil type...

Page 144: ...9 2 gal us Specification Ä Chapter 8 3 2 Fuel on page 140 Coolant Mixture of water and anti freeze agent Specification Ä Chapter 8 3 3 Coolant on page 142 009 940 03 20 l 6 l 1 6 gal us Hydraulic system Hydraulic oil ISO HVLP 46 Specification Ä Chapter 8 3 4 1 Mineral oil based hydraulic oil on page 143 009 930 09 20 l 35 l 9 2 gal us or ester based biodegradable hydraulic oil Specification Water ...

Page 145: ...e engine oil level twice every day Depending on the load the engine is subjected to the oil consumption will drop to the normal level after approx 100 to 250 operating hours 8 5 2 After 50 operating hours 1 Check the engine for leaks 2 Tighten all bolted connections on air intake exhaust oil sump and engine mounts 3 Retighten the bolted connections on the machine Maintenance Running in instruction...

Page 146: ...ng brake 156 Every 500 operating hours 8 9 1 Replacing the fuel filter 157 8 9 2 Replacing the V belt 158 8 9 3 Checking the anti freeze concentration and the con dition of the coolant 159 8 9 4 Checking the hydraulic lines 160 Every 1000 operating hours 8 10 1 Checking adjusting the valve clearance 161 8 10 2 Checking the engine mounts 163 8 10 3 Checking the ROPS 163 8 10 4 Checking the travel l...

Page 147: ...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 186 8 13 6 Measures prior to extended shut down period 187 Maintenance Maintenance Table BW 120 AD 5 147 ...

Page 148: ...are found to be damaged the corresponding parts must be immediately repaired or replaced by authorized service personnel NOTICE Danger of engine damage After work on the fuel system bleed the system perform a test run and check for leaks 8 7 2 Checking and cleaning the water separator The service intervals for the water separator depend on the water con tent in the fuel and can therefore not be de...

Page 149: ...ransparent container under the drain plug 3 Loosen the drain plug and drain the fluid until pure diesel fuel starts to run out 4 Collect running out fluid 5 Screw the drain plug tightly back in Check for leaks if necessary use a new seal ring 6 Dispose of collected fluid in line with envi ronmental regulations B GEN 0050 Fig 118 Maintenance Every 50 operating hours BW 120 AD 5 149 ...

Page 150: ...er 8 4 List of fuels and lubricants on page 144 Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 8 Parking the machine in secured condition on page 114 2 WARNING Danger of burning on hot components Wear your personal protec tive equipment protective gloves protective clothing Avoid touching hot compo nents Unscrew the drain plug and c...

Page 151: ...ort test run check the oil level on the oil dipstick 1 if necessary top up to the MAX mark 11 Check oil filter cartridge and drain plug for leaks 12 Dispose of the oil and filters in line with environmental regulations 8 8 2 Checking tensioning the V belt 8 8 2 1 Checking the V belt Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 8 Pa...

Page 152: ...on the generator 2 Press the generator towards the outside using a lever until the correct V belt ten sion is reached 3 Retighten clamping screw 1 and screw 2 8 8 3 Check the air intake lines Protective equip ment n Working clothes n 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 Check t...

Page 153: ... fit of all radi ator hoses and hose clamps 4 If a radiator hose is swollen hardened or cracked both hose and hose clamp must be replaced immediately 8 8 5 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 8 Parking the machine in secured condition on page 114 2 Allow...

Page 154: ...g around Wear your personal protective equipment safety gloves protec tive working clothes goggles 1 Blow the cooler out with compressed air from inside the engine compartment 2 Blow the cooler out with compressed air from the outside Cleaning with com pressed air Fig 124 Fig 125 Maintenance Every 250 operating hours BW 120 AD 5 154 ...

Page 155: ...strong water jet 2 Run the engine warm for a while to avoid corrosion 8 8 6 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 charge Exhausted batteries batteries with formation...

Page 156: ...nt 3 Clean the outside of the battery 4 Clean battery poles and pole clamps and grease them with pole grease Vaseline 5 Install the battery and check the battery fastening 6 On serviceable batteries check the acid level if necessary top up to the filling mark with distilled water 8 8 7 Check the parking brake This work must only be performed by authorized service personnel Fig 126 Maintenance Ever...

Page 157: ...ne power stalls the engine and makes starting impossible Protective equip ment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 8 Parking the machine in secured condition on page 114 2 Loosen the hose clamps 1 on the fuel pre filter 3 Pull the hoses off the fuel pre filter 4 Install the new fuel pre filter and observe the flow direction arrow Fig 127 Mainte...

Page 158: ...rt into the clean side Slightly oil the rubber seal on the new fuel filter 9 Attach the fuel filter 1 with the quick lock and ensure correct coding 10 Close the quick lock 2 so that is engages noticeably 11 Screw in drain plug 3 12 Dispose of fuel and fuel filter in an environ mentally friendly manner 8 9 2 Replacing the V belt Perform this maintenance work at the latest after two years Fig 128 Fi...

Page 159: ...3 Checking the anti freeze concentration and the condition of the coolant Protective equip ment n Protective gloves n Safety goggles 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 Remove the cover 1 from the compensa tion tank and check the anti freeze concen tration with a conventional tester 4 Check the...

Page 160: ...uine shape of the hydraulic hose e g layer separa tion formation of blisters crushed spots buckling n leaks on hose socket or fitting n the hydraulic hose has separated from the fitting n fittings are damaged or deformed whereby the function and strength of the hose fitting connection is impaired n the fitting shows corrosion that impairs both function and strength n incorrect installation squeezi...

Page 161: ...e cool down for at least 30 minutes The engine oil temperature must be below 80 C 176 F Valve clearance Intake exhaust valve 0 18 mm to 0 22 mm 0 007 in to 0 009 in Protective equip ment n Working clothes n Safety shoes n Protective gloves 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 Remove the valve cover Fig 132 Ma...

Page 162: ...he crankshaft one full turn 360 fur ther 6 Check the valve clearance on the valves marked black adjust if necessary 7 Install the cylinder head cover with a new seal 8 After a short test run check the engine for leaks Fig 133 I Intake valve E Exhaust valve Fig 134 Fig 135 Checking the valve clear ance Maintenance Every 1000 operating hours BW 120 AD 5 162 ...

Page 163: ...low the engine to cool down 3 Check air intake and exhaust manifold fas tenings for tight fit 4 Check sockets and clamps between air filter exhaust turbocharger and charge air line as well as the engine oil lines for tight fit and leaks 5 Check fastening screws on the engine oil sump and engine mounts for tight fit 6 Check condition and tight fit of engine pillow blocks 8 10 3 Checking the ROPS Al...

Page 164: ...ening of the seat belts 8 10 4 Checking the travel lever control 1 Park the machine safely Ä Chapter 6 8 Parking the machine in secured condition on page 114 2 Move the travel lever forwards backwards and to braking position Check the function for ease of movement clearance and damage 3 In case of malfunction perform trouble shooting and replace the corresponding parts 4 Only operate the machine a...

Page 165: ...e intervals the filter element must also be changed after major repairs in the hydraulic system 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 Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Unscrew the filter bowl 3 Preparations Hydraulic oil filter 3 2 1 B HYD 0013 Fig 138 Mai...

Page 166: ...a new O ring 2 Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Clean the area around the high pressure filter 2 Disconnect the hydraulic oil lines 1 from the high pressure filter 2 3 Remove the high pressure filter and install the new high pressure filter while paying attention to the flow direction arrow 4 Connect and tighten the hydraulic lines 1 After the test run c...

Page 167: ...3 Dispose of the hydraulic oil and filter in line with environmental regulations Maintenance Every 1000 operating hours BW 120 AD 5 167 ...

Page 168: ...ydraulic oil Do not use any detergents to clean the system Use only lint free cleaning cloths for cleaning When changing from mineral oil based hydraulic oil to an ester based biologically degradable hydraulic oil you should consult the lubrication oil service of the oil manufac turer or our customer service for details NOTICE Risk of damage Perform the oil change when the hydraulic oil is warm Us...

Page 169: ...aulic oil tank 4 WARNING Danger of burning on hot components Wear your personal protec tive equipment protective gloves protective clothing Avoid touching hot compo nents Unscrew the drain plug and collect any hydraulic oil running out 5 Screw the drain plug back in tightly 6 Loosen tightening strap and take off the cover to clean the hydraulic oil tank from inside B 880 0066 Fig 140 B 880 0182 Fi...

Page 170: ...er to fill the system This ensures finest filtration of the hydraulic oil prolongs the life time of the hydraulic oil filter and protects the hydraulic system Fill in new hydraulic oil 12 Check the hydraulic oil level on the dip stick 13 The hydraulic oil level must always be between the MIN and MAX marks 14 The breather filter for the hydraulic oil tank is integrated in the cap you must therefore...

Page 171: ... the sealing materials used in the cooling system If oil has entered you must add a cleansing agent in order to remove any residues from the system Follow the instructions of the manufac turer If in doubt consult your Customer Service or the engine manufacturer When changing the coolant without any signs of contamination cleaning of the cooling system is not necessary NOTICE Danger of engine damag...

Page 172: ... the condition of the coolant 8 Thoroughly flush the cooling system if the coolant is contaminated by corrosion resi dues or other suspended matter 9 Remove the thermostat 10 Fill with clean water 11 Start the engine and flush the cooling system out for a short while 12 Allow the engine to cool down to approx 50 C 122 F 13 Drain off all water 14 If using a cleaning agent repeat the flushing proces...

Page 173: ...ure 22 Let the engine cool down and check the coolant level again if necessary top up in the compensation tank 23 Dispose of coolant in line with environ mental regulations 8 11 3 Replacing hoses This work must only be performed by authorized service personnel Perform this maintenance work at the latest after two years The following hoses need to be renewed n fuel hoses n air intake hoses B 880 01...

Page 174: ...8 11 4 Check the injection valves This work must only be performed by authorized service personnel Maintenance Every 2000 operating hours BW 120 AD 5 174 ...

Page 175: ...8 12 Every 3000 operating hours 8 12 1 Checking the fuel injection pump This work must only be performed by authorized service personnel Maintenance Every 3000 operating hours BW 120 AD 5 175 ...

Page 176: ...ement is covered with a sooty deposit Do not use gasoline or hot fluids to clean the filter element After cleaning the air filter must be inspected for damage using a torch Do not continue to use a dam aged air filter element If in doubt use a new air filter If the air filter is damaged the safety element must be replaced as well The safety element must not be cleaned We generally recommend to ren...

Page 177: ...est after one year 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 both locking hooks on the housing cover and take the cover off 4 Clean housing cover and dust discharge valve 5 Pull out the main filter element with light turning movements Fig 149 Fig 150 Fig 151 Maintenance As required BW 120 AD 5...

Page 178: ...inside the element until it if free of dust 7 Examine the air filter element with a torch for cracks and holes in the paper bellows 8 In case of damage replace the air filter and the safety element 9 Slide the air filter carefully into the housing NOTICE Danger of engine damage The dust discharge valve must point vertically downwards Make sure that the cover locks engage correctly 10 Reassemble th...

Page 179: ...ed The safety element must be replaced if the air filter is damaged at the latest after one year if the air filter warning light comes on again after the air filter has been cleaned 1 Remove the housing cover and pull the air filter element off 2 Pull the safety element out by turning it lightly 3 Push in a new safety element 4 Insert the air filter and reassemble the housing cover Fig 155 Fig 156...

Page 180: ... ground 2 Shut down the engine 3 NOTICE The spraying pump may get damaged if the tank is empty Always keep the water tank filled with a sufficient amount of water Check the filling level on the water level gauge fill up if necessary 4 Turn the ignition key to position I B 880 0188 Water Fig 157 B ELE 0070 Fig 158 Maintenance As required BW 120 AD 5 180 ...

Page 181: ...rre sponding spraying interval is activated only once Then the water pump is switched off again ð The water spraying system is switched on 6 Check water output and spray pattern on all nozzles 1 for both drums 7 Turn the rotary switch for pressure spraying to 0 to switch the water spraying system off B SWI 1764 Fig 159 B 880 0070 1 Fig 160 B SWI 1763 Fig 161 Maintenance As required BW 120 AD 5 181...

Page 182: ...8 Turn the ignition key to position 0 and pull it out B ELE 0069 Fig 162 Maintenance As required BW 120 AD 5 182 ...

Page 183: ...ng the machine in secured condition on page 114 2 Remove the cap 1 3 Take the filling screen 2 out and clean it 4 Check the filling screen for damage replace if necessary 5 Close the cap 6 Open the drain cover on the water tank and let all water run out 7 Flush the water tank out with a strong water jet 8 Drain off all water and dirt 1 2 B 880 0189 Water Fig 163 B 880 0067 Fig 164 Maintenance As r...

Page 184: ...from the spray tube and let the water run out 12 Switch the water spraying system on for a short while to flush contaminants out of the lines 13 Switch off the water spraying system 14 Turn the ignition key back to position 0 and pull it out 15 Reassemble the caps and nozzles on the spray tube B 880 0126 1 2 Fig 165 1 1 2 B 880 0127 Fig 166 Maintenance As required BW 120 AD 5 184 ...

Page 185: ...k on 4 Open the line connection in the articulation area and let all water run out 5 Close the line connection again 6 Route the water line on the spraying pump to the outside 7 Open the drain valve and drain off all water 8 Switch on the water spraying system for a short while to drain the water from the pump 9 Switch off the water spraying system 10 Turn the ignition key back to position 0 and p...

Page 186: ...rotective gloves 1 Park the machine safely Ä Chapter 6 8 Parking the machine in secured condition on page 114 2 When performing this work the fuel tank should only hold a small amount of fuel pump some out if necessary 3 Unscrew the drain plug and collect leaking fuel 4 Screw the drain plug firmly back in with a new seal ring 5 Fill the fuel tank with clean fuel 6 Dispose of fuel in line with envi...

Page 187: ...a thin oil film onto to all lever joints and bearing points without lubrication 5 Repair damaged paint preserve bare areas thoroughly with anti corrosive agent 6 Clean the water separator 7 Fill the fuel tank with diesel fuel to prevent the formation of condensation water in the tank 8 Change engine oil and oil filter if the oil has been changed more than 300 hours ago or if the oil is older than ...

Page 188: ...loves protective clothing goggles Protective equip ment n Working clothes n Protective gloves n Safety goggles 1 Switch off all consuming devices e g igni tion light 2 Measure the open circuit voltage of the battery at regular intervals at least 1 x per month ð Reference values 12 6 V fully charged 12 3 V discharged to 50 3 Recharge the battery immediately after an open circuit voltage of 12 25 V ...

Page 189: ...level 5 Check the charge condition of the bat teries recharge if necessary Check the battery fluid level before and after charging 6 Connect the ground straps to the batteries 7 Check the function of the electric system 8 Check cables hoses and lines for cracks and leaks 9 Check the service life of hydraulic hoses and replace if necessary 10 Start the engine and run it for 15 to 30 minutes with id...

Page 190: ...Maintenance As required BW 120 AD 5 190 ...

Page 191: ...9 Setting up refitting Setting up refitting BW 120 AD 5 191 ...

Page 192: ...lashing tackle only in the specified loading direction Lashing tackle must not be damaged by machine parts Protective equip ment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 8 Parking the machine in secured condition on page 114 2 If necessary loosen the articulation lock 2 Ä Chapter 8 2 2 2 Disengaging the articu lation lock on page 138 3 Slightly loo...

Page 193: ...t up the machine just above the ground 6 Shift the rear frame to the desired position on the left or right 7 Lower the machine to the ground 8 Retighten the screws 1 B 880 0261 Fig 173 B 880 0072 1 Fig 174 Setting up refitting Manually adjusting the crabwalk BW 120 AD 5 193 ...

Page 194: ...Setting up refitting Manually adjusting the crabwalk BW 120 AD 5 194 ...

Page 195: ...10 Troubleshooting Troubleshooting BW 120 AD 5 195 ...

Page 196: ...e Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance If you cannot locate the cause of a fault or rec tify it yourself by following the trouble shooting chart you should contact our customer service department Troubleshooting Preliminary remarks BW 120 AD 5 196 ...

Page 197: ...ngine or chassis ground as far away from the bat tery as possible 3 Start the engine Ä Chapter 6 3 Starting the engine on page 100 NOTICE Danger of damage to the elec tronic system If no powerful consuming device is switched on voltage peaks may occur when separating the con necting cables between the bat teries which could damage elec trical components 4 Once the engine is running switch on a pow...

Page 198: ...nger 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 Pos Fuse Amperage Designation 1 F00 80 A Main battery fuse Fig 176 Troubleshooting Fuse assignment BW 120 AD 5 198 ...

Page 199: ...ion F04 7 5 A Instruments F05 10 A 12 V socket F06 5 A Rotary switch for water spraying system F07 15 A Hazard light system F08 15 A Direction indicators and working head lights F09 10 A Parking and tail light left F10 10 A Parking and tail light right F11 15 A Head lights left F12 15 A Head lights right F23 10 A Warning horn F30 10 A Potential 15 F37 10 A Water pump F45 10 A Edge cutter F48 40 A ...

Page 200: ...tial 15 F156 15 A Lighting F157 30 A Starter F241 15 A Optional headlights F274 10 A Chip spreader hydraulic cutting tool F275 5 A Economizer F276 10 A Emulsion pump JP1 5 A Vibration also with travel lever in position II Troubleshooting Fuse assignment BW 120 AD 5 200 ...

Page 201: ...a tion Check the engine oil level correct if necessary Check the engine oil filter replace if necessary Have the lubrication system examined by a specialist Poor starting of engine or engine works irregularly with poor power Battery power too low ter minal clamps loose or oxi dized causing the starter to turn too slowly Check the battery charge condition clean the terminal clamps tighten and cover...

Page 202: ...ng lamp for engine oil tempera ture lights Clean the cooling fins Engine oil level too low Check fill up if necessary Lack of coolant Check all pipes and hoses for good condition and leak tight ness Check the coolant level top up if necessary Do not use radiator sealant to seal leaks Anti freeze concentration too high Use coolant with the speci fied mixing ratio Air filter dirty Clean replace if n...

Page 203: ...sary Lubrication system leaking Have the lubrication system examined by a specialist The charge control light lights during operation the warning buzzer sounds Generator speed too low Check the generator belt for tension replace the belt if necessary Generator or regulator defec tive Have examined by a spe cialist Troubleshooting Engine faults BW 120 AD 5 203 ...

Page 204: ...ion sensor Cable breakage Inform our Customer Service Department LED a lights up The Economizer is unable to read a calibration value when starting Since this value is required for calculation the measuring values measuring operation is blocked Restart the Economizer Turn the ignition key back to posi tion 0 and then again to position I If the LED a remains on inform our Customer Service Departmen...

Page 205: ...rews of the acceleration sensor Weak spots in the road sub base are also measured when paving asphalt In unfavourable cases an excessively varying material composition or moisture in the road subbase can influ ence the measuring results On material which is too dry or moist lower measuring values will be displayed Troubleshooting Trouble shooting ECONOMIZER BW 120 AD 5 205 ...

Page 206: ...Troubleshooting Trouble shooting ECONOMIZER BW 120 AD 5 206 ...

Page 207: ...11 Disposal Disposal BW 120 AD 5 207 ...

Page 208: ... hazard caused by fuels and lubricants Safety regulations and environ mental protection regulations must be followed when handling fuels and lubricants Ä Chapter 3 4 Handling fuels and lubri cants on page 29 Protective equip ment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Remove the batteries 2 Empty the fuel tank 3 Drain the hydraulic oil tank 4 Drain the coolant from...

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