Fayat Group Bomag MPH 122-2 Installations- und Betriebshandbuch

Operating instructions

Maintenance instructions

Original operating instructions

Catalogue No.

008 061 61 05/2011

MPH 122-2

S/N 101 590 06 .... S/N 101 590 07 ....

Soil Stabilizer

Asphalt Recycler

Foreword

BOMAG 3MPH 122-2

F oreword

These BOMAG machines are products from

the wide range of BOMAG machines for earth

work, asphalt and refuse compaction as well

as stabilizers/recyclers.

BOMAG’s vast experience in connection with

state-of-the-art production and testing meth-

ods, such as lifetime tests of all important

components and highest quality demands

guarantee maximum reliability of your ma-

chine.

This manual comprises:

lSafety regulations

lOperating instructions

lMaintenance instructions

lTrouble shooting

Using these instructions will

lhelp you to become familiar with the machine.

lavoid malfunctions caused by unprofessional

operation.

Compliance with the maintenance instructions will

lenhance the reliability of the machine on con-

struction sites,

lprolong the lifetime of the machine,

lreduce repair costs and downtimes.

BOMAG will not assume liability for the function of

the machine

lif it is handled in a way not complying with the

usual modes of use,

lif it is used for purposes other than those men-

tioned in these instructions.

No warranty claims can be lodged in case of dam-

age resulting from

loperating errors,

linsufficient maintenance and

lwrong fuels and lubricants.

Please note!

This manual was written for operators and mainte-

nance personnel on construction sites.

Always keep this manual close at hand, e.g. in the

tool compartment of the machine or in a specially

provided container. These operating and mainte-

nance instructions are part of the machine.

You should only operate the machine after you

have been instructed and in compliance with these

instructions.

Strictly observe the safety regulations.

Please observe the applicable accident prevention

instructions.

For your own personal safety you should only

use original spare parts from BOMAG.

In the course of technical development we re-

serve the right for technical modifications

without prior notification.

These operating and maintenance instructions are

also available in other languages.

Furthermore, the spare parts catalogue is availa-

ble from your BOMAG dealer against the serial

number of your machine.

Your BOMAG dealer will also supply you with in-

formation about the correct use of our machines.

The above notes do not constitute an extension of

the warranty and liability conditions specified in the

general terms of business of BOMAG.

We wish you successful work with your BOMAG

machine.

BOMAG GmbH

Printed in Germany

Foreword

BOMAG4MPH 122-2

Please fill in

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine type (Fig. 1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial-number (Fig. 1 and 2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor type (Fig. 3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor number (Fig. 3)

Note

Supplement the above data together with the com-

missioning 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 5MPH 122-2

Technical Data 9

Safety regulations 13

Indicators and Controls 25

3.1 General notes 29

3.2 Description of indicators and control elements 29

Operation 49

4.1 General 50

4.2 Tests before taking into operation 50

4.3 Starting the engine 51

4.4 Starting with jump wires 53

4.5 Driving the machine to work 54

4.6 Operating the service brake 57

4.7 Operating the parking brake 57

4.8 Actuating the emergency stop switch 58

4.9 Emergency exit 58

4.10 Shutting down engine and machine 59

4.11 Parking on a slope 61

4.12 Preparing for work 62

4.13 Work operation, setting the cutting depth 65

4.14 Adjusting the tailgate 68

4.15 Steering the rear axle 69

4.16 Adjusting the oscillation angle of the rotor (cross-slope) 69

4.17 Mixing water connection, preparing for operation 70

4.18 Water dosing system nozzle change 72

4.19 Taking the attachment plates into service 73

4.20 Finishing work 74

4.21 Raising/lowering the cabin 75

4.22 Towing 77

4.23 Transport 79

4.24 Final shut-down of machine 81

Operation of binder dosing system 83

5.1 Inspection before starting the binder dosing system 84

5.2 Preparing for work 84

5.3 Starting work with emulsion 87

5.4 Starting work with foam bitumen 89

5.5 Changing the bitumen tank 91

5.6 Finishing work 92

5.7 Blowing out bitumen system and spray bar 93

5.8 Flushing the binder pump 94

Maintenance 95

6.1 General notes on maintenance 96

Table of Contents

BOMAG6MPH 122-2

6.2 Fuels and lubricants 97

6.3 Table of fuels and lubricants 102

6.4 Running-in instructions 104

6.5 Maintenance table 105

6.6 Checking the engine oil level 111

6.7 Checking the fuel level 111

6.8 Checking the hydraulic oil level 112

6.9 Check the coolant level 113

6.10 Checking the condition of the cutters 114

6.11 Check the tire pressure 116

6.12 Visual inspection for leakages and damage, clean the machine 117

6.13 Clean the lateral hood boxes 118

6.14 Cleaning the dirt scrapers on the hydraulic cylinders for the rotor hood 118

6.15 Cleaning the intercooler 119

6.16 Checking the reaction water level 120

6.17 Checking the oil level for the reaction water pump 120

6.18 Checking the oil level in compressor and service unit 121

6.19 Checking the thermal oil level 121

6.20 Checking the contamination of the hydraulic oil filters 122

6.21 Checking the binder pump for leaks 122

6.22 Checking the spraying sections for leaks 123

6.23 Lubricating the machine 125

6.24 Cleaning front radiator (water/hydraulics) 127

6.25 Checking, cleaning the additional fuel filter water separator 129

6.26 Service the air conditioning 131

6.27 Checking the oil level in the front right/left hand travel gear 134

6.28 Checking the oil level in the rear axle reduction gear 134

6.29 Clean the breather valve for the reduction gear on the rear axle 135

6.30 Check the oil level in the rear axle 135

6.31 Cleaning the rear axle ventilation valve 136

6.32 Check the oil level in the rear planetary gear 136

6.33 Changing engine oil and oil filter cartridge 137

6.34 Check, clean the water separator 138

6.35 Servicing the generator V-belt 139

6.36 Servicing the air conditioning compressor V-belt 140

6.37 Battery service, checking the main battery switch 141

6.38 Checking the engine mounts 143

6.39 Draining the fuel tank sludge 144

6.40 Oil change in rotor gearbox, check rotor water level 144

6.41 Check, adjust the valve clearance 151

6.42 Changing the fuel filter 152

6.43 Replacing the fuel pre-filter cartridge, bleed the fuel system 153

Table of Contents

BOMAG 7MPH 122-2

6.44 Check the anti-freeze concentration and the condition of the coolant 155

6.45 Intercooler, draining off oil/condensation water 156

6.46 Check the fastening of engine / turbocharger / combustion air hoses 156

6.47 Checking the crankcase pressure 157

6.48 Oil change in front travel gear 158

6.49 Oil change in rear planetary gear 159

6.50 Change the oil in the rear axle reduction gear 160

6.51 Oil change in rear axle 161

6.52 Oil change in attachment plate exciter housing 162

6.53 Change the additional fuel filter 163

6.54 Changing the thermal oil 163

6.55 Compressor oil change 164

6.56 Changing hydraulic oil and breather filter 165

6.57 Change the hydraulic oil fine filter 167

6.58 Changing the coolant 168

6.59 Tightening the screws on the articulated joint 169

6.60 Checking the fire extinguisher . 170

6.61 Changing the injection valve 171

6.62 Replacing the crankcase ventilation valve 173

6.63 Changing the coolant pump 173

6.64 Changing the pressure retaining valve on te injection pump 174

6.65 Cleaning, changing the dry air filter cartridge 175

6.66 Replacing the cutting teeth/cutting tooth holders 177

6.67 Grease the bearings of the lift cylinder for the cabin 181

6.68 Water sprinkler system, maintenance in the event of frost 182

6.69 Change the fresh air filter in the cabin 183

6.70 Fill the provision tank for the windscreen washer system 183

6.71 Change the tires 184

6.72 Lubricate the attachment plate adjustment spindles 185

6.73 Cleaning the bitumen filter 186

6.74 Reaction water tank, maintenance in the event of frost 187

6.75 Tightening torques for screws with metric unified thread 187

6.76 Conservation 188

Trouble shooting 189

7.1 General notes 190

7.2 Engine problems 191

7.3 General notes on diagnostic push button and control light 194

7.4 Air conditioning system faulty 195

7.5 Faults in binder dosing system 196

Table of Contents

BOMAG8MPH 122-2

BOMAG 9MPH 122-2

1 Technical Data

Technical Data

BOMAG10 MPH 122-2

Fig. 4

Dimensions in mm A B B1 H1 KL

MPH 122-2 5815 2810 2790 3420 510 9050

*MPH 122-2

Weights

Operating weight (CECE) kg 20950

Front axle load (CECE) kg 14164

Rear axle load (CECE) kg 6786

Max. operating weight kg 28000

Dimensions

Track radius, inner/outer mm 3500/6300

Travel characteristics

Travel speed (1) km/h 0 – 2.7

Travel speed (2) km/h 0 – 12

Max. gradability (depending on soil) % 40

Drive

Engine manufacturer Deutz

Type TCD 2015 V06

Cooling Water

Number of cylinders 6

Rated power ISO 9249 kW 360

Rated power SAE J 1995 hp 482

Rated speed rpm 2100

Electrical equipment V 24

Drive system hydrostatic

Wheels driven All wheel drive

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