Bomag MPH 122 Soil Stabilizer Asphalt Recycler Operating & Maintenance Manual

Operating instructions Maintenance instructions Catalogue number 008 137 81 02/2004 MPH 122 S/N 101 590 03 .... > Soil Stabilizer Asphalt Recycler

Foreword BOMAG 3 MPH 122 F oreword BOMAG machines are products from the wide product range of BOMAG compaction equip- ment. The vast experience of BOMAG as well as modern production and testing methods such as lifetime tests of all important components and most stringent quality demands ensure highest reliability of the machine. These instructions comprise: l Safety regulations l Operating instructions l Maintenance instructions l Trouble shooting Using these instructions will l help to become acquainted with the machine. l avoid malfunctions caused by unprofessional operation. Compliance with the maintenance instructions will l increase the reliability of the machine on site, l prolong the lifetime of the machine, l reduce repair costs and downtimes. BOMAG shall not assume liability for correct func- tioning of the machine l if it is handled in a way which does not comply with the usual modes of use, l if it is used for purposes other than those mentioned in these instructions. No warranty claims can be lodged for damage re- sulting from l operating errors, l insufficient maintenance and l the use of wrong fuels and lubricants. Please note! This manual was written for operators and maintenance personnel on construction sites. Always keep this manual close at hand, e.g. in the tool compartment of the machine or in the container provided for this purpose. The operating and maintenance instruction manual is part of the machine. You should only operate this machine after you have been instructed and by observing these instructions. Please observe strictly the safety regulations. Please observe also the guidelines of the civil en- gineering liability association "safety regulations for the operation of road rollers and soil compac- tors" as well as the relevant accident prevention regulations. For your own safety you should only use gen- uine BOMAG spare parts. We reserve the right for technical modifica- tions without prior notification. These operating and maintenance instructions are also available in other languages. The spare parts catalogue and the repair instructions are available from your BOMAG dealer against the serial number of your machine. Your BOMAG dealer will also provide you with all relevant information on the correct use of our machines in soil and asphalt construction. The above mentioned or following notes do not constitute an extension or replacement of the general terms of business of BOMAG. We wish you successful work with your BOMAG machine. BOMAG GmbH Printed in Germany Copyright by BOMAG

Foreword BOMAG 4 MPH 122 Please fill in ............................ Machine type (Fig. 1) ............................ Serial-number (Fig. 1 and 2) ............................ Engine type (Fig. 3) ............................ Engine number (Fig. 3) i Note Supplement the above data together with the commissioning protocol. During commissioning our organisation will in- struct you in the operation and maintenance of the machine. Please observe strictly the safety regulations and all notes on risks and dangers! Fig. 1 Fig. 2 Fig. 3

Table of Contents BOMAG 5 MPH 122 Technical Data 9 Safety regulations 13 Indicators and Controls 19 3.1 General notes 23 3.2 Description of indicators and control elements 23 Operation 41 4.1 General notes 42 4.2 Tests before taking into operation 42 4.3 Starting the engine 44 4.4 Starting under low temperatures 45 4.5 Starting with jump wires 46 4.6 Driving the machine to work 47 4.7 Emergency exit 49 4.8 Operating the service brake 50 4.9 Operating the parking brake 50 4.10 Operating the hydraulic system emergency stop switch 51 4.11 Shutting the engine down 51 4.12 Parking on a slope 53 4.13 Preparing for work 53 4.14 Adjusting working depth, cutting depth 56 4.15 Switching on the load limit sensing control and adjusting the nominal speed 58 4.16 Adjusting the tailgate 59 4.17 Steering the rear axle 60 4.18 Adjusting the oscillation angle of the rotor (cross-slope) 60 4.19 Water dosing system, preparing for work 62 4.20 Finishing work 64 4.21 Changing the tires 65 4.22 Towing 65 4.23 Transport 67 Maintenance 69 5.1 General notes on maintenance 70 5.2 Fuels and lubricants 71 5.3 Table of fuels and lubricants 74 5.4 Running-in instructions 75 5.5 Maintenance chart 76 5.6 Checking the engine oil level 79 5.7 Checking the fuel level 79 5.8 Checking the hydraulic oil level 80 5.9 Check the condition of the cutting teeth 81 5.10 Checking front and rear tire pressures 83

Table of Contents BOMAG 6 MPH 122 5.11 Inspect the machine visually for damage and leaks 84 5.12 Checking the coolant level (compensation tank) 84 5.13 Checking the condition of the coolant 85 5.14 Check/empty the fuel pre-cleaner (water separator) 86 5.15 Cleaning the lateral hood boxes 87 5.16 Cleaning the air conditioning condenser 88 5.17 Cleaning the cabin ventilation filter 89 5.18 Cleaning the dirt scrapers on the hydraulic cylinders for the rotor hood 90 5.19 Cleaning the charge air filter 91 5.20 Grease oscillating articulated joint and steering cylinder bearings 92 5.21 Greasing the lift cylinder bearings on the rotor hood 92 5.22 Grease the bearings of the lift cylinders on the rotor hood gates 93 5.23 Greasing oscillating joint and rear axle steering 93 5.24 Grease the hinges of the battery compartment door 94 5.25 Cleaning front radiator (water/hydraulics) 95 5.26 Change the engine oil 97 5.27 Changing the engine oil filter 98 5.28 Checking condition and tension of generator V-belt, replacing the V-belt 98 5.29 Check condition and tension of refrigerant compressor V-belt, replace the V- belt 100 5.30 Servicing the air conditioning 101 5.31 Checking the oil level in the rear axle reduction gear 105 5.32 Clean the breather valve for the reduction gear on the rear axle 105 5.33 Checking the oil level in the rear axle 106 5.34 Cleaning the rear axle ventilation valve 106 5.35 Check the oil level in the left and right hand planetary gears on the rear axle 107 5.36 Battery service, check the main battery switch 108 5.37 Check the engine mounts 109 5.38 Draining the fuel tank sludge 110 5.39 Checking the oil level in the front right/left hand travel gears 110 5.40 Changing the oil in the rear axle reduction gear 111 5.41 Change the oil in the left and right hand planetary gears on the rear axle 112 5.42 Changing the oil in the rear axle 113 5.43 Checking/changing the coolant 114 5.44 Checking, adjusting the valve clearance 115 5.45 Changing the fuel filter 116 5.46 Changing the fuel prefilter element 117 5.47 Check fastening of engine / turbocharger / combustion air hoses 118 5.48 Oil change in the front travel gears 119 5.49 Changing the hydraulic oil 120 5.50 Changing the hydraulic oil fine filter 122

Table of Contents BOMAG 7 MPH 122 5.51 Tightening the screws on the articulated joint 123 5.52 Clean, change the dry air filter cartridge 125 5.53 Replacing the cutting tooth holders/cutting teeth 127 5.54 Grease the bearings of the lift cylinder for the cabin 130 5.55 Water sprinkler system, maintenance in the event of frost 130 5.56 Fill the container for the windscreen washer system, maintenance in the event of frost 131 5.57 Tightening torques for screws with metric unified thread 131 5.58 Conservation 132 Trouble shooting 133 6.1 General notes 134 6.2 Engine problems 135 6.3 Air conditioning system faulty 138

Table of Contents BOMAG 8 MPH 122

BOMAG 9 MPH 122 1 Technical Data

Technical Data BOMAG 10 MPH 122 Fig. 4 Dimensions in mm A B B1 H H1 K L MPH 122 5815 2330 2850 3250 3420 510 9125 * MPH 122 Weights Operating weight (CECE) kg 20090 Front axle load (axle load, wheels) kg 14020 Rear axle load kg 6070 Dimensions Oscillation angle ° 15 Inner track radius mm 3500 Travel characteristics Working speed km/h 0 - 25 Travel speed (1) km/h 0-5 Travel speed (2) km/h 0 - 10 Max. gradability/ with rotor operation % 57/37

Bomag MPH 122 Soil Stabilizer Asphalt Recycler Operating & Maintenance Manual

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