BOMAG MPH 454 RECYCLER & STABILIZER Operation & Maintenance Manual

Recycler and Stabilizer MPH 454 Operating Instructions Maintenance Instructions 0852714 Catalog Number S/N 109A2231530 And Above 9/04 Printed in U.S.A. 2000 Kentville Road • Kewanee, IL 61443 MPH454 0852714 CVR 9/9/04 11:30 AM Page 1

09/04 i ® If the machine was received with the Roll Over Protective Structure (ROPS) or Roll Over/Falling Object Protection System (ROPS/FOPS) and Operator Restraint (Seat Belt) NOT installed, both MUST be installed BEFORE the machine is operated. Use the installation instructions drawing included with the installation kit and/or the illustration below. In the event of a machine roll over, serious injury, or death, can occur due to the failure to correctly install the Roll Over Protective Structure (ROPS) or Roll Over/ Falling Object Protection System (ROPS/FOPS) and the Operator Restraint (Seat Belt). MPH 454 RECYCLER - STABILIZER DANGER: DO NOT operate machine with Roll Over Protective Structure (ROPS) or Roll Over/Falling Object Protec- tion System (ROPS/FOPS) and/or Operator Restraint (Seat Belt) NOT properly installed. DANGER:

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09/04 iii ® SYMBOLS USED IN THIS MANUAL Serious personal injury, death and/ or extensive property damage can result if the DANGER instructions are not followed. Serious personal injury and/or extensive property damage can result if the WARNING instructions are not followed. Minor personal injury can result, or a part, an assembly, or the engine can be damaged if the CAUTION instructions are not followed. NOTE: Gives additional information, and/or clarification details, which are used in conjunction with previously presented information. The following symbols have been used in this manual to help communicate the intent of the instructions. When one of these symbols appears, it conveys the meaning as defined in the following descriptions: DANGER: WARNING: CAUTION:

iv 09/04 Safety Regulations SAFETY SAFETY REGULATIONS INTRODUCTION The following safety regulations apply to all personnel engaged in the operation, maintenance or repair of this machine. Intended Use The machine is available in both Recycler and Stabilizer configurations. As a Recycler, the machine is intended for use in recycling bituminous surfaced roadways and paved surfaces using recycling teeth mounted on the rotor. When configured as a Stabi- lizer the machine is intended to stabilize soil, using paddles mounted on the rotor. Only authorized and trained personnel can operate this machine. The potential for damage to the machine or injury to personnel exists if this machine is used for purposes other than those for which it was designed, or if it is used by personnel not familiar with information contained in this manual. General ● Make certain you are familiar with all controls and accessories on the machine. ● Do not operate the machine unless you are trained on all operating and control features and know how the machine functions. ● Familiarize yourself with the work area including surface and subsurface conditions, vegetation, water tables and other indications of conditions that may be encountered during operation. ● Use the machine only for the purpose for which it is intended. ● Wear protective clothing such as safety helmet, protective shoes, noise protection and eye protection. ● Original parts and accessories have been specifi- cally designed for this machine. Unauthorized conversions and alterations to the machine or its component parts or assemblies are prohibited as they may endanger safe operation. ● The factory has not tested or authorized any component parts or special equipment not supplied by the factory. The installation or use of unauthorized products can have an adverse effect on design characteristics and influence active or passive operating safety. The manufacturer expressly excludes any liability for damages, actual or consequential, resulting from the use of non-factory approved parts or accessories on this machine. ● Should the machine contact high voltage power lines: – Move the machine out of the danger zone, if at all possible. – Do not leave the operator’s platform. – Alert and warn others to move away from the machine. – Request electric utility shut down electrical power. Use EXTREME caution whenever anyone is working inside the wheels on the steering (front) axle. Serious or fatal injuries can result from the wheels being turned while a worker is inside this area. NEVER turn the steering wheel, release the brakes, or engage the hydrostatic drive(s) while someone is working in this area. Exhaust fumes are dangerous. Ensure an adequate supply of fresh air when starting up in enclosed spaces or vent the vehicle exhaust outside through an approved exhaust system. DANGER: DANGER:

09/04 v Safety Regulations SAFETY Safety Regulations SAFETY Prior to Starting ● Review operating instructions before starting the engine. ● Check the machine and controls for obvious faults. ● Do not drive or operate the machine with damaged instruments, control lights or control ele- ments or systems. ● All protective devices must be properly secured in their locations. ● Do not leave any loose objects such as tools or personal items such as lunch boxes lying about. Secure or store such objects in a safe manner. ● Keep the machine free from all oily or combus- tible materials. ● Before climbing onto the machine, make sure there are no persons or obstacles near or under the machine. ● Use care when climbing onto the machine. Always use the steps and handrails provided. ● Adjust the seat before starting the engine. ● Always use the seat belt provided on machines with ROPS/FOPS or ROPS structures. Starting ● Ensure all controls are in the “neutral” position when starting the engine. ● Only start and operate the machine from the operator’s seat. ● Check all indicators after start-up to ensure all systems are operating correctly. ● Never leave a machine unattended while the engine is running. ● For emergency starting using jumper cables from an external power source, connect positive to positive and negative to negative. Always connect the ground wire (negative) last and disconnect the ground wire first. This is a 24 volt system. Operation ● Press the Emergency Stop push button immediately in emergencies and potentially dangerous situations. ● The machine may only be operated from the operator’s seat. ● Before starting work, check that controls, lighting and horn are operating properly. ● Before starting or resuming work, you must make sure no one is in the danger area surrounding the machine. – You must give a warning signal. – Stop work immediately if persons remain in the danger area despite the warning. ● When driving in reverse, make sure that no one or any obstacles are in the way. ● Control the speed of the machine to working conditions. ● Keep the machine away from edges and em- bankments. ● When driving under a flyover, bridge, power lines, through a tunnel, etc. make sure there is suffi- cient clearance. ● Use lighting whenever visibility is poor. ● If a slope must be traversed, drive very carefully and always drive directly up or down the slope (never on an angle). Select the lower travel speed range whenever approaching a slope. ● Soil conditions and weather influences reduce the ability of the machine to climb or descend grades. ● Wet and loose soils considerably reduce machine ground traction on grades. It also increases the danger of accidents. ● Never climb on the machine while it is in motion. ● The machine may never be used as a transport for personnel or equipment.

vi 09/04 ● All handrails, steps and platforms are to be kept free of grease, oil, fuel, dirt, snow and ice. ● Should the machine develop an unusual noise or generate smoke while operating the machine, stop the engine, trace the cause, and have any faults corrected. ● Never adjust the operator’s seat while the machine is in motion. ● Do not use the emergency stop push button as an operating brake. Parking ● Before leaving the machine, set the Travel Direction Control Lever (FNR) to “neutral”, apply the parking brake and stop the engine. ● Park the machine on level and firm ground. ● Never jump off the machine. Use the access steps and hand rails. ● If you must park on an incline, set wedges in front of, or behind, the tires. Loading and Transport ● Use only strong and stable loading ramps when loading the machine. Make sure no one is endangered in the event the unit accidentally turns over or slips during the loading process. ● Ramp incline must be lower than the machine’s ability to climb or gradability. ● Secure the machine on the transport vehicle using the attachment points provided. (See Transportation Data – Section 3.) This action will guard against the machine rolling, slipping or turning over. ● Do not step or stand under lifted loads. This constitutes a danger to life. ● Do not stand in danger areas of the machine during operation, demonstrations or loading. This constitutes a danger to life. Maintenance ● For repairs and maintenance work, place the machine on firm and level ground. ● Do not perform any adjustments while the engine is running or machine is being driven. ● Keep unauthorized persons away from the machine whenever performing maintenance work. ● Identify a machine with problems by attaching a warning sign to the steering wheel. ● Before starting engine, check that the battery disconnect switch is in the ON position. ● Whenever refueling or working with the fuel system: – Only refuel while the engine is stopped. – Observe cleanliness. – Do not spill any fuel. ● Petrol-diesel mixtures (winter fuel) are as flammable as standard diesel fuel mixtures. ● Do not refuel in enclosed spaces. ● Place used filters in a specially marked container and dispose of them in an approved manner to prevent pollution. ● During maintenance work, collect oils and fuels and dispose of them carefully to prevent pollution. Be aware there is a danger of scalding when working with hot oil. ● Do not heat oil to a temperature over 320°F (160°C) otherwise oil, or oil vapor, may ignite. ● Wipe away any fuel, or oil, which has been spilled. ● Never smoke when filling the fuel tank or check- ing acid level of the batteries. ● Never check acid level of the batteries or fuel level with an open flame. Safety Regulations SAFETY

09/04 vii ● Dispose of used batteries carefully to prevent pollution. ● Never perform cleaning work with the engine running. ● Use caution when working with cleansing agents. Gasoline, or other easily flammable substances, must never be used for cleaning purposes. ● Cover electric parts with watertight insulating material when using a steam cleaner. Never subject these parts to a direct water jet. ● Visually inspect hydraulic hoses at regular intervals. ● Check to ensure hydraulic lines are depressurized before disconnecting them. Hydraulic oil, escaping under pressure, can penetrate your skin and cause serious injury. ● When performing adjustments to the hydraulic system, never step behind or in front of the machine. ● Never attempt to adjust pressure relief valves. These are factory set. ● While the system is depressurized, check all connections and fittings for leaks when all maintenance work has been completed. ● Refit all protective devices when all maintenance work has been completed. NOTE: Following the lubrication and maintenance schedules, and the operating instructions will help to ensure that your machine has a long service life and is always fully operational. Repair ● Repairs to this machine may only be performed by skilled and trained personnel. ● Use only Bomag/Compaction America approved repair procedures. ● Observe any special welding instructions when performing welding work. ROPS/FOPS or ROPS Structure Inspection ● The machine frame must not be bent, deformed or cracked in the area of the ROPS/FOPS or ROPS installation. ● The ROPS/FOPS or ROPS structure must not show rust, damage, hairline cracks or open fractures. ● The ROPS/FOPS or ROPS structure must not rattle when the machine is being driven. ● All screw connections must be in accordance with manual specifications and must be secure (observe tightening torques). ● Screws and nuts must not be damaged, bent or deformed. ● No additional parts may be welded or screwed, and no additional holes may be drilled without the approval of the manufacturer. Unauthorized alterations may influence stability and safe operation. Safety Regulations SAFETY

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Section 1 INTRODUCTION 09/04 1-1 ® TABLE OF CONTENTS PAGE GENERAL INFORMATION ........................................................................................................................... 1-2 TECHNICAL DATA ........................................................................................................................................ 1-2 SPECIFICATIONS ......................................................................................................................................... 1-3 OPERATING INSTRUCTIONS ...................................................................................................................... 1-3 MAINTENANCE PROCEDURES .................................................................................................................. 1-3 NAMEPLATE ................................................................................................................................................. 1-3 SERIAL NUMBER ......................................................................................................................................... 1-4

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BOMAG MPH 454 RECYCLER & STABILIZER Operation & Maintenance Manual

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