BW 124 pdh5 Manual

Operating Instruction
Maintenance Instruction
Original Operating Instructions
BW 124 PDH-5
S/N 101 586 85 1001>
Single drum roller
008 202 90 EN © 01/2019

WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm.
Always start and operate the engine in a well-ventilated area.

If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING: Crude oil, gasoline, diesel fuel and other petroleum

products can expose you to chemicals including toluene and benzene,
which are known to the State of California to cause cancer and birth
defects or other reproductive harm.
These exposures can occur in and around oil fields, refineries, chemical
plants, transport and storage operations such as pipelines, marine
terminals, tank trucks and other facilities and equipment.
For more information go to www.P65Warnings.ca.gov/petroleum.
2
Table of contents
Table of contents
1 Introduction............................................................................................ 9
1.1 Foreword....................................................................................... 10
1.2 Machine type plate and engine type plate................................. 12
2 Technical data...................................................................................... 13
2.1 Noise and vibration data.............................................................. 16
2.1.1 Noise data................................................................................... 17
2.1.2 Vibration data.............................................................................. 17
3 Concerning your safety...................................................................... 19
3.1 Basic prerequisites...................................................................... 20
3.1.1 General........................................................................................ 20
3.1.2 Explanation of signal words used:............................................... 21
3.1.3 Personal protective equipment.................................................... 22
3.1.4 Intended use................................................................................ 23
3.1.5 Improper use............................................................................... 23
3.2 Definition of responsible persons.............................................. 25
3.2.1 Operating company..................................................................... 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..................................................... 30
3.4.1 Preliminary remarks.................................................................... 30
3.4.2 Safety regulations and environmental protection regulations for
handling diesel fuel...................................................................... 31
handling oil.................................................................................. 33
handling hydraulic oil................................................................... 35
handling coolants........................................................................ 37
BW 124 PDH-5 3
Table of contents

handling battery acid................................................................... 39
3.5 Load/transport the machine........................................................ 41
3.6 Starting up the machine.............................................................. 43
3.6.1 Prior to start-up............................................................................ 43
3.6.2 Starting the engine...................................................................... 44
3.6.3 Starting the engine with jump leads............................................ 44
3.7 Driving the machine; working operation.................................... 46
3.7.1 Driving the machine..................................................................... 46
3.7.2 Driving up and down slopes........................................................ 47
3.7.3 Cross slope................................................................................. 47
3.7.4 Working with vibration................................................................. 48
3.7.5 Parking the machine.................................................................... 48
3.8 Refuelling...................................................................................... 49
3.9 Regeneration of exhaust gas aftertreatment system................ 50
3.10 Emergency procedures............................................................. 51
3.10.1 Actuating the emergency stop switch........................................ 51
3.10.2 Disconnecting the battery.......................................................... 51
3.10.3 Towing the machine................................................................... 51
3.11 Maintenance work...................................................................... 53
3.11.1 Preliminary remarks................................................................... 53
3.11.2 Working on hydraulic lines......................................................... 53
3.11.3 Working on the engine............................................................... 54
3.11.4 Maintenance work on electric components and battery............ 55
3.11.5 Working on wheels and tyres..................................................... 55
3.11.6 Cleaning work............................................................................ 56
3.11.7 After maintenance work............................................................. 56
3.12 Repair.......................................................................................... 57
3.13 Signage....................................................................................... 58
3.14 Danger zones.............................................................................. 66
3.15 Safety Components.................................................................... 67
4 Indicators and control elements........................................................ 69
4.1 Driver’s stand............................................................................... 70
4.1.1 Instrument cluster........................................................................ 70
4.1.2 Operating console....................................................................... 73
4 BW 124 PDH-5
Table of contents
4.1.3 Travel lever.................................................................................. 77

4.1.4 Travel lever with dozer blade control........................................... 78
4.1.5 Main battery switch...................................................................... 79
4.1.6 12 V DIN socket.......................................................................... 80
4.1.7 ECONOMIZER display................................................................ 80
4.1.8 Rotary switch ECONOMIZER..................................................... 80
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.................................... 87
5.4.1 Checking the fuel level................................................................ 87
5.4.2 Refuelling.................................................................................... 87
5.5 Checking the hydraulic oil level.................................................. 89
5.6 Checking the coolant level.......................................................... 91
5.7 Checking wheels and tyres......................................................... 93
6 Operation.............................................................................................. 95
6.1 Setting up the work place............................................................ 96
6.1.1 Adjust the driver’s seat................................................................ 96
6.2 Starting the engine....................................................................... 97
6.3 Travel operation.......................................................................... 100
6.3.1 Preliminary remarks and safety notes....................................... 100
6.3.2 Driving the machine................................................................... 101
6.4 Working with vibration............................................................... 103
6.4.2 Switching the vibration on and off............................................. 104
6.5 ECONOMIZER............................................................................. 105
6.6 Parking the machine in secured condition.............................. 106
6.7 Regeneration of exhaust gas aftertreatment system.............. 107
6.7.2 Suppressing regeneration......................................................... 109
6.7.3 Running regeneration at standstill............................................. 110
6.8 Emergency procedures.............................................................. 112
6.8.1 Actuating the emergency stop switch........................................ 112
6.8.2 Disconnecting the battery.......................................................... 112
BW 124 PDH-5 5
Table of contents
6.8.3 Towing the machine................................................................... 112

6.8.4 After towing................................................................................ 114
7 Loading / transporting the machine................................................. 119
7.1 Preparation for transport........................................................... 120
7.2 Loading the machine................................................................. 121
7.3 Lashing the machine to the transport vehicle......................... 123
7.4 Loading by crane........................................................................ 124
7.5 After transport............................................................................ 126
8 Maintenance....................................................................................... 127
8.1 Preliminary remarks and safety notes..................................... 128
8.2 Preparations/concluding work.................................................. 130
8.2.1 Opening/closing the engine hood.............................................. 130
8.2.2 Articulation lock......................................................................... 130
8.2.3 Side engine covers.................................................................... 132
8.3 Fuels and lubricants.................................................................. 133
8.3.1 Engine oil................................................................................... 133
8.3.2 Fuel........................................................................................... 134
8.3.3 Coolant...................................................................................... 135
8.3.4 Hydraulic oil............................................................................... 137
8.3.5 Gear oil SAE 80W-140.............................................................. 138
8.4 List of fuels and lubricants........................................................ 139
8.5 Running-in instructions............................................................. 141
8.5.1 General...................................................................................... 141
8.5.2 After 50 operating hours............................................................ 141
8.5.3 After 250 operating hours.......................................................... 141
8.5.4 After 500 operating hours.......................................................... 142
8.5.5 After 1000 operating hours........................................................ 142
8.6 Maintenance Table..................................................................... 143
8.7 Every 50 operating hours.......................................................... 145
8.7.1 Checking radiator hoses and hose clamps............................... 145
8.8 Every 250 operating hours........................................................ 146
8.8.1 Check the air intake lines.......................................................... 146
8.8.2 Checking radiator hoses and hose clamps............................... 146
8.8.3 Checking, tensioning the V-belt................................................. 147
8.8.4 Cleaning the radiator module.................................................... 148
6 BW 124 PDH-5
Table of contents
8.8.5 Checking the oil level in the drive axle...................................... 149

8.8.6 Check the oil level in the bevel gear housing............................ 150
8.8.7 Checking the oil level in the wheel hubs................................... 151
8.8.8 Checking the oil level in the drum drive reduction gear............. 151
8.8.9 Check the parking brake........................................................... 152
8.9 Every 500 operating hours........................................................ 153
8.9.1 Change engine oil and oil filter cartridge................................... 153
8.9.2 Replacing the fuel filter, bleeding the fuel system..................... 155
8.9.3 Replacing the V-belt.................................................................. 158
8.9.4 Checking the anti-freeze concentration and the condition of the
coolant....................................................................................... 159
8.9.5 Checking the hydraulic lines...................................................... 159
8.9.6 Servicing the battery, checking the main battery shutoff........... 161
8.10 Every 1000 operating hours.................................................... 163
8.10.1 Adjusting the valve clearance.................................................. 163
8.10.2 Checking the lines on the diesel engine.................................. 165
8.10.3 Checking the exhaust manifold............................................... 166
8.10.4 Checking the engine mounts................................................... 166
8.10.5 Replacing the hydraulic oil filter............................................... 166
8.10.6 Change the oil in the drive axle............................................... 169
8.10.7 Changing the oil in the bevel gear housing............................. 171
8.10.8 Changing the oil in the wheel hubs......................................... 172
8.10.9 Change the oil in the drum drive reduction gear..................... 173
8.10.10 Retightening the fastening of the axle on the frame.............. 175
8.10.11 Retightening the wheel nuts.................................................. 175
8.10.12 Checking the ROPS.............................................................. 175
8.10.13 Checking the travel lever control........................................... 176
8.11.1 Changing the hydraulic oil....................................................... 177
8.11.2 Changing the coolant............................................................... 180
8.11.3 Replacing the oil separator element........................................ 183
8.11.4 Checking the exhaust gas recirculation cooler........................ 183
8.11.5 Replacing hoses...................................................................... 183
8.12.1 Checking the turbo charger..................................................... 184
BW 124 PDH-5 7
Table of contents
8.12.2 Cleaning the DPF.................................................................... 184

8.12.3 Checking the exhaust gas recirculation system...................... 184
8.13 As required............................................................................... 185
8.13.1 Air filter maintenance............................................................... 185
8.13.2 Checking and cleaning the water separator............................ 188
8.13.3 Adjusting the scrapers............................................................. 189
8.13.4 Cleaning the machine.............................................................. 190
8.13.5 Draining the fuel tank sludge................................................... 191
8.13.6 Measures prior to extended shutdown period......................... 191
9 Troubleshooting................................................................................ 195
9.1 Preliminary remarks................................................................... 196
9.2 Starting the engine with jump leads......................................... 197
9.3 Fuse assignment........................................................................ 198
9.3.1 Notes on safety......................................................................... 198
9.3.2 Central electrics......................................................................... 198
9.3.3 Main fuse................................................................................... 199
9.4 Engine faults............................................................................... 200
9.5 Trouble shooting ECONOMIZER............................................... 203
10 Disposal.............................................................................................. 205
10.1 Final shut-down of machine.................................................... 206
11 List of special tools........................................................................... 207
8 BW 124 PDH-5
Introduction
1 Introduction
BW 124 PDH-5 9
Introduction – Foreword
1.1 Foreword
BOMAG manufactures machines for earth,
asphalt and refuse compaction, stabilizers/
recyclers as well as planers and pavers.
BOMAG’s vast experience in connection
with state-of-the-art production and testing
methods, such as lifetime tests of all impor-
tant components and highest quality
demands guarantee maximum reliability of
your machine.
These operating and maintenance instructions
are part of your machine.
They provide necessary information to operate
your machine safely and properly.
They also contain information on required oper-
ating, maintenance and repair measures.
Carefully read the operating and maintenance
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 69.
The description of the individual operating
steps including the notes on safety to be fol-
lowed can be found in chapter “Operation”
Ä Chapter 6 „Operation“ on page 95.
Before every start up, carry out all required
visual inspections and function tests Ä Chapter
5 „Checks prior to start up“ on page 81.
Ensure the compliance with the specified oper-
ating, maintenance and repair measures to
maintain the functional safety of your machine.
10 BW 124 PDH-5
Introduction – Foreword
A description of all necessary maintenance

work, maintenance intervals as well as informa-
tion on fuels and lubricants can be found in the
chapter “Maintenance” Ä Chapter 8 „Mainte-
nance“ on page 127.
Do not service or repair your machine by your-
self to avoid harming persons or damaging
material or environment.
The machine must only be serviced and
repaired by qualified and authorized personnel.
Contact our Customer Service to carry out the
required maintenance work or necessary
repairs.
In case of operating errors, inadequate mainte-
nance or the use of unapproved 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 languages.
Apart from that, you can also order the spare
parts catalogue against the serial number of
your machine.
The above notes do not constitute an extension
of the warranty and liability conditions specified
in the general sales and delivery conditions of
BOMAG GmbH.
We wish you successful work with your
BOMAG machine.
BW 124 PDH-5 11
Introduction – Machine type plate and engine type plate
1.2 Machine type plate and engine type plate

Please enter here:
Machine type (1):
Serial number (2):
Fig. 1: Machine type plate

(example)
Please enter here:

Engine type (Fig. 1)
Engine number (2):
Fig. 2: Engine type plate

(example)
12 BW 124 PDH-5
Technical data
2 Technical data
BW 124 PDH-5 13
Technical data
Dimensions
Fig. 3
A B D H H2 K L O1/2 S W
1815 1310 960 1850 2520 320 3520 55 15 1200
(71) (52) (37.8) (73) (99) (12.6) (139) (2.2) (0.59) (47)
Dimensions in millimetres
(Dimensions in inch)
Weights
Max. operating weight 4000 kg
(8818) (lbs)
Operating weight (CECE) 3390 kg
(7474) (lbs)
Axle load, drum (CECE) 1660 kg
(3660) (lbs)
Axle load, wheels (CECE) 1730 kg
(3814) (lbs)
14 BW 124 PDH-5
Technical data
Travel characteristics
Travel speed 0-9 km/h
(0 - 5.5) (mph)
Max. gradeability without/with vibration (soil 55/55 %
dependent)
Drive
Engine manufacturer Kubota
Type V2403-CR-E4
Cooling system Water
Number of cylinders 4
Rated power ISO 3046 34 kW
Rated power SAE J 1995 46 hp
Nominal speed 2400 min-1
Electric system
Voltage 12 V
Tyres
Tyre size 9.5-24/4PR
Air pressure, nominal value 1.8 bar
(26) (psi)
Air pressure, range 0.8 - 1.8 bar
(12 - 26) (psi)
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
BW 124 PDH-5 15
Technical data – Noise and vibration data
Steering
Type of steering Oscill.-articul.
Steering angle +/- 35 °
Oscillation angle +/- 12 °
Inner track radius 2260 mm
(89) (in)
Exciter system
Drive system hydrostatic
Frequency 41 Hz
(2460) (vpm)
Amplitude (1/2) 1.60/0.80 mm
(0.063/0.031) (in)
Centrifugal force (1/2) 85/43 kN
(16861/9217) (lbf)
Filling capacities
Fuel (diesel) 60 l
(16) (gal us)
2.1 Noise and vibration data

The following noise and vibration data were
determined in accordance with the following
guidelines under equipment specific conditions
and by using harmonized standards:
n EU Machine Directive edition 2006/42/EU
n Noise Emission Directive 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.
16 BW 124 PDH-5
2.1.1 Noise data

Sound pressure level at LpA = 87 dB(A), determined acc. to ISO 11201
the operator's stand and EN 500.
WARNING!
Loss of hearing caused by too
high noise burdens!
– Wear your personal protective
equipment (ear protection).
Guaranteed sound LWA = 106 dB(A), determined acc. to ISO 3744

power level and EN 500
2.1.2 Vibration data

Vibration of the entire The weighted effective acceleration value
body (driver’s seat) determined according to ISO 7096 is ≤ 0.5
m/s2.
Hand-arm vibration The weighted effective acceleration value

determined according to EN 500/ISO 5349 is ≤
2.5 m/s2.
BW 124 PDH-5 17
18 BW 124 PDH-5
Concerning your safety
3 Concerning your safety
BW 124 PDH-5 19
Concerning your safety – Basic prerequisites
3.1 Basic prerequisites

3.1.1 General
This machine has been built in compliance with
the latest technical standard and complies with
the applicable regulations and technical rules.
However, dangers for persons and property
may arise from this machine, if:
n it is used for purposes other than the ones it
is intended for,
n it is operated by untrained personnel,
n it is changed or converted in an unprofes-
sional way,
n the safety instructions are not observed.
Each person involved in the operation, mainte-
nance and repair of the machine must there-
fore read and comply 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 to apply these
accordingly. This also applies for local regula-
tions and regulations concerning different types
of handling activities. Should the recommenda-
tions in these instructions be different from the
regulations valid in your country, you must
comply with the safety regulations valid in your
country.
20 BW 124 PDH-5
3.1.2 Explanation of signal words used:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indi-
cate an extremely dangerous situa-
tion that could lead to fatal or
severe injuries, if this warning is dis-
regarded.
WARNING!
Danger to life or danger of severe
injuries if failing to comply!
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!
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!
cate possible dangers for machines
or components.
BW 124 PDH-5 21

cate technical information or notes
on using the machine or its compo-
nents.
ENVIRONMENT!
Environmental damage if failing
to comply!
Paragraphs marked accordingly
indicate practices for safe and envi-
ronment-friendly disposal of fuels
and lubricants as well as replace-
ment parts.
3.1.3 Personal protective equipment

Depending on the work to be carried out, personal protective equip-
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, against
irritating and caustic substances as well
as against burns.
Safety goggles To protect the eyes against airborne
particles and squirting fluids.
22 BW 124 PDH-5
Face protection To protect the face against airborne par-

ticles and squirting fluids.
Hard hat To protect the head against falling parts

and to protect against injuries.
Hearing protection To protect hearing against excessive

noise.
Respiratory protection To protect respiratory tracts against sub-

stances or particles.
3.1.4 Intended use

This machine must only be used for:
n Compaction work in earth construction and
road bases.
n Compaction of bituminous material, e.g.
road surface layers,
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 danger caused by improper use is the sole
responsibility of the operating company or
driver/operator; the manufacturer cannot be
held liable.
BW 124 PDH-5 23
Examples of improper use are:

n Work with vibration on hard concrete, cured
bitumen layers or extremely frozen ground
n Driving on non-load-bearing subsoil or inad-
equate contact areas (danger of tilting)
n Using the machine for towing
n Using to pull down walls or demolish build-
ings
Transporting persons, except the machine
driver, is prohibited.
Starting and operating the machine in explo-
sive environments and in underground mining
is prohibited.
24 BW 124 PDH-5
Concerning your safety – Definition of responsible persons
3.2 Definition of responsible persons

3.2.1 Operating company
The operating company is the natural or jurid-
ical person who uses the machine or in who's
name the machine is used.
The operating company must make sure that
the machine is only used for the purpose it is
intended for and in strict compliance with the
safety regulations mentioned in these operating
and maintenance instructions.
The operating company must determine and
assess the danger in its company. It must then
take appropriate action to ensure health and
safety at work for its employees and point out
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
planning and professional execution of regular
safety inspections.
3.2.2 Expert / qualified person

An expert / qualified person is a person who,
based on his/her professional education and
experience, has profound knowledge in the
field of construction equipment and the
machine in question in particular.
BW 124 PDH-5 25
Concerning your safety – Definition of responsible persons
This person is acquainted with the applicable

governmental industrial safety regulations,
accident prevention instructions, guidelines and
generally acknowledged technical rules and
regulations (standards, directives, technical
rules of other member states of the European
Union or other contractual states concerning
the agreement about the European Economic
Area) in as far as is necessary to be able to
judge the safe condition of this machine.
3.2.3 Driver / operator

This machine must only be operated by
trained, instructed persons entrusted by the
operating company 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 and psychologically able to
drive and operate the machine.
Persons under the influence of alcohol, medi-
cation or drugs are not allowed to operate,
service or repair the machine.
Maintenance and repair work requires specific
knowledge and must therefore only be per-
formed by trained specialists.
26 BW 124 PDH-5
Concerning your safety – Fundamentals for safe operation
3.3 Fundamentals for safe operation

3.3.1 Remaining dangers, remaining risks
Despite careful work and compliance with
standards and regulations it cannot be ruled
out that further dangers may arise when
working with and handling the machine.
Both the machine as well as all other system
components comply with the currently valid
safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even
when using the machine for the purpose it is
intended for and following all information given
in the operating instructions.
A remaining risk can also not be excluded
beyond the 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 by an expert /
qualified person as required for the conditions
the machine is working under, but at least once
every year.
3.3.3 Modifications and alterations to the machine

Unauthorized changes to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been spe-
cially designed for this machine.
BW 124 PDH-5 27
We wish to make explicitly clear that we have

not tested or approved any parts or accesso-
ries not supplied by us.
The installation and/or use of such products
may have an adverse effect on the active
and/or passive safety.
3.3.4 Damage, defects, misuse of safety devices

Machines which are not safe to operate or in
traffic must be immediately taken out of service
and shall not be used, until these deficiencies
have been properly rectified.
Safety installations and switches must neither
be removed nor must they be made ineffective.
3.3.5 Roll Over Protective Structure (ROPS)
On machines with cab the ROPS is

an integral part of the cab.
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 manufacturer, since this will
impair the strength of the unit.
The ROPS must therefore also not be straight-
ened or repaired if it is damaged.
28 BW 124 PDH-5
A defect ROPS must generally be replaced

with an original spare part in close coordination
with the manufacturer.
BW 124 PDH-5 29
Concerning your safety – Handling fuels and lubricants
3.4 Handling fuels and lubricants

3.4.1 Preliminary remarks
The operating company must ensure that all
professional users have read and follow the
corresponding safety data sheets for the indi-
vidual fuels and lubricants.
Safety data sheets provide valuable informa-
tion about the following characteristics:
n name 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 information on transport
n legislation
n other data
30 BW 124 PDH-5
3.4.2 Safety regulations and environmental protection regula-

tions for handling diesel fuel
WARNING!
Danger of burning by ignited
diesel fuel!
– Do not allow diesel fuel to come
into contact with hot compo-
nents.
– Smoking and open fire is pro-
Fig. 4 hibited!
equipment (protective gloves,
protective clothing).
CAUTION!
Health hazard caused by contact
with diesel fuel!
– 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.
BW 124 PDH-5 31
ENVIRONMENT!
Diesel fuel is an environmentally
hazardous substance!
– Always keep diesel fuel in proper
containers.
– Immediately bind spilled diesel
fuel with an oil-binding agent and
dispose of properly.
– Dispose of diesel fuel and fuel fil-
ters according to regulations.
32 BW 124 PDH-5

tions for handling oil
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come into con-
tact with hot components.
hibited!
Fig. 5 equipment (protective gloves,
CAUTION!
with oil!
– 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.
» Continued on the next page
BW 124 PDH-5 33

– Dispose of oil and oil filter
according to regulations.
34 BW 124 PDH-5

tions for handling hydraulic oil
WARNING!
Danger of injury caused by
escaping pressure fluid!
– Always depressurize the
hydraulic system before starting
work in the hydraulic system.
Fig. 6 equipment (protective gloves,
protective clothing, goggles).
Should pressure fluid penetrate the

skin, immediate medical help is
required.
WARNING!
hydraulic oil!
– Do not allow hydraulic oil to
come into contact with hot com-
ponents.
hibited!
BW 124 PDH-5 35
CAUTION!
with hydraulic oil!
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
ENVIRONMENT!
Oil is an environmentally haz-
ardous substance!
– Always keep oil in proper con-
tainers.
– Dispose of oil and oil filter
according to regulations.
36 BW 124 PDH-5

tions for handling coolants
WARNING!
Danger of scalding by hot fluid!
– Open the compensation tank
only when the engine is cold.
Fig. 7
CAUTION!
with coolant and coolant addi-
tives!
– 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.
» Continued on the next page
BW 124 PDH-5 37
– Immediately bind spilled coolant

with an oil-binding agent and dis-
pose of it according to regula-
tions.
– Dispose of coolant according to
regulations.
38 BW 124 PDH-5

tions for handling battery acid
WARNING!
Danger of cauterization with acid!
– Do not allow clothes, skin or
eyes to come into contact with
Fig. 8: acid.
– Rinse off spilled battery acid
immediately with lots of water.
Rinse acid off clothes, skin or eyes

immediately with lots of clean water.
Immediately call for medical advice
in case of cauterization.
WARNING!
exploding gas mixture!
– Remove the plugs before starting
to recharge the battery.
– Ensure adequate ventilation.
hibited!
– Do not lay any tools or other
metal objects on the battery.
– Do not wear jewellery (watch,
bracelets, etc.) when working on
the battery.
BW 124 PDH-5 39
ENVIRONMENT!
Battery acid is an environmen-
tally hazardous substance!
– Dispose of battery and battery
acid according to regulations.
40 BW 124 PDH-5
Concerning your safety – Load/transport the machine
3.5 Load/transport the machine

Use only stable loading ramps of sufficient load
bearing capacity.
Loading ramps and transport vehicle must be
free of grease, oil, snow and ice.
The ramp inclination must be less than the
gradability of the machine.
Make sure that persons are not endangered by
the machine tipping or sliding off. The
instructing person must stand within the view of
the operator, but outside the danger area.
Secure the machine with the articulation lock
after driving it on the transport vehicle or before
loading it with a crane.
Do not use damaged or in any other way
impaired lashing points.
Always use appropriate lifting and lashing
means on the lifting and lashing points.
Use lifting and lashing gear only in the pre-
scribed direction of load application.
Lifting tackle must not be damaged by machine
components.
Secure the machine on the transport vehicle
against rolling, slipping and turning over.
Loads must only be attached and hoisted by an
expert / capable person.
Use only lifting gear and lifting tackle with suffi-
cient load bearing capacity for the weight to be
loaded.
Fasten the lifting gear only at the specified
lifting points.
Danger to the life of persons if they step or
stand under a suspended load.
When lifting the machine avoid uncontrolled
movements of the load. If necessary hold the
load with guide ropes.
BW 124 PDH-5 41
Concerning your safety – Load/transport the machine
After the transport loosen the articulation lock

again, as otherwise the machine wouild not be
steerable.
42 BW 124 PDH-5
Concerning your safety – Starting up the machine
3.6 Starting up the machine

3.6.1 Prior to start-up
Only use machines which have been serviced
at regular intervals.
Become acquainted with the equipment, the
indicators and control elements, the working
principle of the machine and the working area.
Use your personal protective equipment (hard
hat, safety boots, if necessary also goggles
and ear protection).
Make sure that the machine is equipped with
the required lighting according to the require-
ments of the application.
Do not take any loose objects with you or
fasten them to the machine.
Before mounting 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 the existing access
steps and grips.
When climbing on and off the machine use the
three-point support method: Always keep two
feet and one hand or one foot and two hands
on the machine.
Never jump off the machine.
Before start-up, carry out all required visual
inspections and function tests.
BW 124 PDH-5 43
If the tests reveal damages or other defects,

the machine must not be operated, until these
deficiencies have been corrected.
Do not operate the machine with defective indi-
cators and control elements.
3.6.2 Starting the engine

The machine must only be started and oper-
ated from the driver’s seat.
Before starting and moving the machine, make
sure that there is nobody in the danger zone.
To start, set all control levers to “neutral posi-
tion”.
Do not use any starting aids like start 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 leads

Connect positive with positive and negative
with negative (ground cable) – always connect
the ground strap last and disconnect it first! A
wrong connection will cause severe damage in
the electric system.
44 BW 124 PDH-5
Do not start the engine by shorting the electric

terminals on the starter motor, because the
machine may start to drive immediately.
BW 124 PDH-5 45
Concerning your safety – Driving the machine; working operation
3.7 Driving the machine; working operation

3.7.1 Driving the machine
Always wear the seat belt when driving.
Only drive on load-bearing surfaces.
Do not drive on ice and snow.
If the machine has touched high-voltage power
lines:
n do not leave the driver’s stand,
n warn others from coming close to or
touching the machine,
n if possible, drive the machine out of the
danger zone,
n have the power switched off.
Operate the machine only from the driver’s
stand.
Do not adjust the driver’s seat while driving.
Do not climb onto or off the machine while the
machine is driving.
Do not use the machine to transport persons.
In case of unusual noises and development of
smoke perform trouble shooting 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 loaded transport vehicles.
Switch the lights on if visibility is poor.
Always keep a safe distance to excavation pit
borders, embankments and edges.
Refrain from any work that could adversely
affect the stability of the machine.
46 BW 124 PDH-5
Always keep a sufficient distance when

passing through subways, under bridges, tun-
nels, electric power lines etc.
3.7.2 Driving up and down slopes

Do not drive on gradients or slopes exceeding
the maximum gradeability of the machine
Ä Chapter 2 „Technical data“ on page 13.
Drive extremely carefully on gradients and
always directly up or down the slope.
Soil conditions and weather influences impair
the gradeability of the machine.
Wet and loose soil considerably reduces trac-
tion of the machine on inclinations and slopes.
Increased danger of accident!
3.7.3 Cross slope

The tipping angle was measured on level, hard
ground with the machine stopped and without
steering.
Max. 18° The max. permissible cross slope of the
32% machine may be limited by the max. permis-
sible slanted position of the engine.
B-586-0334 The specified angle must not be exceeded.
Fig. 9: Maximum cross With loose soil, acceleration/deceleration, run-
slope ning vibration, steering or attached accessories
the tipping angle may be considerably lower.
Driving across slopes should therefore be
strictly avoided, because of the high risk of tip-
ping over and the related risk of severe or even
fatal accidents.
BW 124 PDH-5 47
3.7.4 Working with vibration

When compacting with vibration you must
always check the effect of the vibration on
nearby buildings and underground supply lines
(gas, water, sewage, electric power). If neces-
sary stop compacting with vibration.
Do not activate the vibration on hard (frozen,
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
grips and access steps.
Mark machines, which could be in the way, with
a clearly visible sign.
When parking on ascents or descents use
appropriate means to secure the machine
against rolling.
48 BW 124 PDH-5
Concerning your safety – Refuelling
3.8 Refuelling
Do not inhale any fuel fumes.
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Static charges may be generated in the fuel as
it passes through the filling system. The dis-
charge of these charges in the presence of
combustible vapours can cause fire or an
explosion.
Ultra-low sulphur diesel fuel poses a higher risk
of combustion caused by the static 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 spilled fuel. Keep dirt and water away
from the fuel.
A leaking fuel tank can cause an explosion.
Ensure tight fit of the fuel tank cover, if neces-
sary replace immediately.
BW 124 PDH-5 49
Concerning your safety – Regeneration of exhaust gas aftertreatment system
3.9 Regeneration of exhaust gas aftertreatment system

During regeneration, the exhaust gas reaches
very high temperatures and the exhaust gas
quantity increases - fire hazard!
Components of the exhaust gas aftertreatment
system get very hot.
Do not touch hot components or exhaust
gases.
Ensure an adequate supply of fresh air.
Keep a safe distance to combustible or explo-
sive materials.
When performing regeneration at standstill,
park the machine outdoors at a safe distance
from any combustible or explosive materials.
50 BW 124 PDH-5
Concerning your safety – Emergency procedures
3.10 Emergency procedures

3.10.1 Actuating the emergency stop switch
In events of emergency and in case of danger
actuate the emergency stop switch immedi-
ately.
The machine is braked immediately, the engine
is shut down.
Restart the machine only after the danger that
caused the actuation of the emergency stop
switch has been eliminated.
In case of frequent use the wear on the multi-
discs brakes will be very high, you should
therefore never use the emergency stop switch
as a service brake.
3.10.2 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.
3.10.3 Towing the machine

Tow the machine only in a case of emergency
or to avoid an accident.
Before releasing the parking brake apply suit-
able measures to secure the machine against
unintended rolling.
Use a tractor vehicle with sufficient traction and
braking power for the unbraked towed load.
If no tow bar is used, towing is only permitted
uphill.
BW 124 PDH-5 51
Concerning your safety – Emergency procedures
Before starting towing operations make sure

that the fastening means are able to withstand
the load and are fastened at the points pro-
vided for this purpose.
Before removing the towing facility apply
appropriate measures to secure the machine
against unintended rolling.
52 BW 124 PDH-5
Concerning your safety – Maintenance work
3.11 Maintenance work

3.11.1 Preliminary remarks
Adhere to the specified operating, maintenance
and repair measures.
The machine must only be serviced by quali-
fied personnel authorised by the operating
company.
Keep unauthorised persons away from the
machine.
Perform maintenance work only with the
engine shut down.
Make sure that the engine cannot be acciden-
tally started during maintenance work.
3.11.2 Working on hydraulic lines

Relieve hydraulic pressures before working on
hydraulic 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 oil must be collected and dis-
posed of in an environmentally friendly way.
Always collect and dispose of hydraulic oils
separately.
BW 124 PDH-5 53
Do not start the engine after draining off the

hydraulic oil. Once all work is completed (with
the system still depressurized!) check all con-
nections and fittings for leaks.
Hydraulic hoses must be visually inspected at
regular intervals.
Do not mix up hoses by mistake.
Only genuine replacement hydraulic hoses
ensure that the correct hose type (pressure
range) is used at the right location.
3.11.3 Working on the engine

Do not work on the fuel system while the
engine is running - danger to life due to high
pressures!
Wait until the engine has stopped, then wait
approx. another 15 minutes.
Keep out of the danger zone during the initial
test run.
In case of leaks return to the workshop immedi-
ately.
Drain the engine oil at 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 values and cause damage to
engine and power train.
54 BW 124 PDH-5
Engine and exhaust system work at high tem-

peratures. Keep combustible materials away
and do not touch any hot surfaces.
Check and change coolant only when the
engine is cold. Collect coolant and dispose of it
in an environmentally friendly way.
3.11.4 Maintenance work on electric components and battery

Before starting to work on electric parts of the
machine disconnect the battery and cover it
with insulating material.
Do not use fuses with higher ampere ratings
and do not bridge fuses.
When working on the battery, smoking or open
fire is prohibited!
Do not lay any tools or other metal objects on
the battery.
Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.
The connection cables of the battery must not
touch or rub against machine parts.
3.11.5 Working on wheels and tyres

Explosion-like bursting of tyres or parts of tyres
and rims can cause most severe or even fatal
injuries.
Do not drive with damaged wheels or tyres.
Install the tyres only if you are sufficiently expe-
rienced and with the right tools at hand. If nec-
essary have the tyres assembled in a qualified
workshop.
Always ensure the correct tyre pressure and do
not exceed the specified maximum pressure.
BW 124 PDH-5 55
When checking the tyre pressure stand in the

extended path of the tyre track. Use an at least
6 meter air hose, so that you can keep a safe
distance to the tyre.
Always consider the heavy weight of a wheel
during disassembly and assembly. Use a crane
or forklift truck equipped with suitable claws or
a belt-type hoisting device.
3.11.6 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 electrical parts and insulation mate-
rial to the direct jet of water, or cover them
beforehand.
Do not guide the water jet into the exhaust pipe
and into the air filter.
3.11.7 After maintenance work

Reassemble all guards and protective devices.
Close all maintenance flaps and maintenance
doors again.
56 BW 124 PDH-5
Concerning your safety – Repair
3.12 Repair
Identify a defective machine with a warning
sign.
Only operate the machine after it has been
repaired.
Repairs must only be performed by an expert/
qualified person.
When replacing safety relevant components,
only original spare parts must be used.
BW 124 PDH-5 57
Concerning your safety – Signage
3.13 Signage
Keep stickers and signage in good and legible
condition and comply with their meaning.
Replace damaged and illegible stickers or sig-
nage immediately.
Hydraulic Oil
WARNING
California Proposition 65 Warning
This product contains chemicals

that cause cancer + chemicals
that are reproductive toxicants
12 Volt
B-586-0477
Fig. 10
58 BW 124 PDH-5
Engine Coolant
Spec.: • MB 325.5
• Deutz DQC CC-14
Part No.: 009 940 03 (20 l)
Part No.:
009 920 09 (20 l) / 009 920 10 (5 l)
Diesel
ULTRA LOW SULFUR

FUEL ONLY
B-586-0328
Fig. 11
BW 124 PDH-5 59
Warning sticker - Danger of crushing
Fig. 12
Warning sticker - Follow operating instructions
Fig. 13
Warning sticker – California Proposition 65
WARNING
California Proposition 65 Warning
This product contains chemicals

that cause cancer + chemicals
that are reproductive toxicants
B-DEC-0316
Fig. 14
Prohibition sticker - High pressure cleaning
Fig. 15
60 BW 124 PDH-5
Instruction sticker - Always wear your seat belt
Fig. 16
Instruction sticker - Wear ear defenders
Fig. 17
Information sticker - Lashing point
Fig. 18
Information sticker - Lifting point
Fig. 19
BW 124 PDH-5 61
Information sticker - Guaranteed sound

capacity level
Fig. 20
Information sticker - travel lever control
B-DEC-0228
Fig. 21
Information sticker - Filler opening for hydraulic
Hydraulic Oil oil
B-DEC-0214
Fig. 22
Information sticker - Disconnecting the battery
B-DEC-0219
Fig. 23
62 BW 124 PDH-5
Information sticker - Main battery switch plus

side
Fig. 24
Information sticker - Vehicle voltage 12 V
Fig. 25
Information sticker - Hydraulic oil drain
B-DEC-0210
Fig. 26
Information sticker - Engine oil drain
B-DEC-0211
Fig. 27
BW 124 PDH-5 63
Information sticker - Coolant

Engine Coolant
Spec.: • MB 325.5
• Deutz DQC CC-14
Part No.: 009 940 03 (20 l)
B-DEC-0221
Fig. 28
Information sticker - Low ash engine oil
Fig. 29
Information sticker - Filler opening for diesel
Diesel
B-DEC-0215
Fig. 30
Information sticker - Ultra-low sulphur fuel
Fig. 31
64 BW 124 PDH-5
Information sticker - travel lever control and

dozer blade push button assignment
B-DEC-0229
Fig. 32
Information sticker - travel lever control and tilt
blade push button assignment
B-DEC-0230
Fig. 33
Machine type plate (example)
Fig. 34
BW 124 PDH-5 65
Concerning your safety – Danger zones
3.14 Danger zones
3m 3m
B-586-0460
Fig. 35
The area around the machine is a danger

zone.
Before starting the machine and during opera-
tion, the driver / operator must ensure that
nobody is in the danger zone.
Give warning signals, if necessary. Stop work
immediately if persons are in the danger zone.
66 BW 124 PDH-5
Concerning your safety – Safety Components
3.15 Safety Components
3
11
10
5
6
9
B-586-0459
Fig. 36
1 ROPS/FOPS
2 Exhaust gas aftertreatment system
3 Engine hood
4 Fan protection
5 Backup protection
BW 124 PDH-5 67
Concerning your safety – Safety Components
6 Safety belt
7 Main battery switch
8 Articulation lock
9 Operator detection system
10 Emergency stop switch
11 Control system
68 BW 124 PDH-5
Indicators and control elements
4 Indicators and control elements
BW 124 PDH-5 69
Indicators and control elements – Driver’s stand
4.1 Driver’s stand

4.1.1 Instrument cluster
1/ 2
1/ 4 3/ 4
2 0 1
4
60
140 176
80 100
212
120 140 160 °C
5
248 284 320 °F
B-DIS-0516
Fig. 37
1 Control and warning lights
2 Fuel level gauge
3 Display field
4 Function key [F1]
5 Function key [F2]
Control and warning

lights
Designation Note
Driver’s seat Lights up when the driver’s seat is not occu-
warning light pied.
If the machine is travelling, the warning buzzer
will sound and the engine is shut down after 2
seconds.
If the travel lever is shifted out of parking brake
position, the engine is immediately shut down.
Regeneration con- Lights up, if regeneration at high exhaust gas
trol light temperatures is necessary.
Also lights up during regeneration.
70 BW 124 PDH-5
Designation Note
Flashes when regeneration at standstill is
required.
Carry out regeneration at standstill.
Exhaust gas tem- Lights up when the exhaust gas temperature is
perature control light too high during regeneration.
Water in fuel Lights up when there is excessive water con-

warning light tent in the fuel pre-filter. Warning buzzer
sounds. The engine is shut down after approx.
2 minutes.
Clean the water separator.
Pre-heating control Lights up during pre-heating.
light
Engine oil pressure Lights up if the engine oil pressure is too low.
warning light Warning buzzer sounds. The engine is shut
down after a short while.
Check the engine oil level; if necessary, repair
the engine.
Coolant temperature Lights up when the engine overheats. Warning
warning light buzzer sounds. The engine power is reduced
after a short while.
Run the engine with idle speed or, if necessary,
shut it down and clean the radiator; if neces-
sary, repair the engine.
Charge control light Lights up if the battery is not being charged.
Check V-belt, if necessary repair the generator.
Air filter warning Lights up if the air filter is blocked.
light Clean or replace the air filter.
Hydraulic oil filter Lights up if the hydraulic oil filter is blocked.
warning light Warning buzzer sounds. The engine is shut
down after a short while.
Check the hydraulic system and replace the
hydraulic oil filter.
BW 124 PDH-5 71
Designation Note
Parking brake Lights up when the parking brake is applied.
warning light
Warning light for Lights up or flashes in case of a fault in the

engine control unit engine control unit or in the exhaust gas after-
treatment.
Have the engine control unit inspected by our
Customer Service.
Coolant level Lights up if the coolant level is too low. Warning
warning light buzzer sounds. The engine is shut down after
a short while.
Check coolant level, check cooling system for
leaks; repair if necessary.
Display field
Function key [F1] is used to toggle between the
0 1
operating hour meter and the fault code dis-
play.
60 80 100 120 140 160 °C
140 176 212 248 284 320 °F
F1 F2 Function key [F2] is not assigned.
B-DIS-0517
Fig. 38
72 BW 124 PDH-5
4.1.2 Operating console
1 2 3
4 8
MIN EC
O MAX
7 6 5
B-586-0278
Fig. 39
1 Emergency stop switch
2 Rotary switch for working lights
3 Rotary button for regeneration
4 Rotary switch for engine speed
5 Push button for warning horn
6 Rotary switch for flashing beacon (optional equipment)
7 Rotary switch for amplitude pre-selection
8 Starter switch
BW 124 PDH-5 73
4.1.2.1 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
Fig. 40 shut down.
switch off/ Turn the Emergency Stop
unlock switch clockwise and let it
go.
NOTICE!
In case of frequent use the wear
on the multi-discs brakes will be
very high.
– Do not use the emergency stop
switch as service brake!
4.1.2.2 Rotary switch for working lights

Position "Left" Working lights off
Position "Right" Working light on
Fig. 41
74 BW 124 PDH-5
4.1.2.3 Rotary button for regeneration

actuate to the Suppress regeneration
left
Position Regeneration active
“Middle” Regeneration is automati-
cally executed, if required.
Turn clockwise To activate regeneration at
for 3 seconds standstill
Fig. 42
Description of the operating
sequences and operating possibili-
ties Ä Chapter 6.7 „Regeneration of
exhaust gas aftertreatment
system“ on page 107.
4.1.2.4 Rotary switch for engine speed

Position “Left” Idle speed position (MIN)
Position ECO -mode
“Middle” The engine speed automati-
cally adapts to the power
requirements. This enables
economical operation.
Position “Right” Full load position (MAX)
Fig. 43
BW 124 PDH-5 75
4.1.2.5 Push button for warning horn

Press. Warning horn sounds
Fig. 44
4.1.2.6 Rotary switch for flashing beacon

Position “Left” Flashing beacon off
Position “Right” Flashing beacon on
Optional equipment
Fig. 45
4.1.2.7 Rotary switch for amplitude pre-selection

Position “Left” low amplitude, high fre-
quency
Position Vibration off
“Middle”
Position “Right” high amplitude, low fre-
quency
Fig. 46
76 BW 124 PDH-5
4.1.2.8 Starter switch

Position “P”/“0” Switch the ignition off
Ignition key can be removed
Position “I”/“II” Ignition on
All control and warning lights
light up for a moment (test
function).
At low temperatures the pre-
Fig. 47 heating control light lights
up.
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.
4.1.3 Travel lever

Shift forward Forward travel
Pull back Backward travel
Position Service brake position
“Middle”
Position “Middle Parking brake position
B-ELE-0138
right”
Fig. 48
BW 124 PDH-5 77
Push button for vibration

Press Vibration on
Press again Vibration off
B-ELE-0139
Fig. 49
4.1.4 Travel lever with dozer blade control
Machines with dozer blade are

equipped with a different travel
lever.
Shift forward Forward travel

Pull back Backward travel
Position Service brake position
“Middle”
Position “Middle Parking brake position
B-ELE-0140
right”
Fig. 50
78 BW 124 PDH-5
3 Designation Note
2 4 1 Tilt the tilt blade to Optional equipment
the left
2 Vibration Vibration on/off
5 3 Raise the dozer
1
blade
6 4 Dozer blade floating
position
5 Tilt the tilt blade to Optional equipment
the right
6 Lower the dozer
blade
B-ELE-0141
Fig. 51
4.1.5 Main battery switch

Position “on” Main battery switch locked
Normal position, operation
Turn anticlock- Main battery switch can be
wise pulled out
Isolates the batteries from
the on-board electrics e.g. to
B-596-0279
protect against unauthorized
Fig. 52 use
Individual control units may
still be connected to the
board electrics despite the
main battery switch being
pulled out
BW 124 PDH-5 79
4.1.6 12 V DIN socket

Permanent current, loadable up to 20 A.
Fig. 53
4.1.7 ECONOMIZER display

The ECONOMIZER displays the compaction
status of the layer to be compacted.
Description of display possibilities

Ä Chapter 6.5 „ECONO-
MIZER“ on page 105.
Optional equipment
Fig. 54
4.1.8 Rotary switch ECONOMIZER

Position “Left” ECONOMIZER display for
smooth drum
Position “Right” ECONOMIZER display for
attached padfoot shell seg-
ments
The rotary switch for ECONOMIZER is located
B-SWI-1479
in the central electrics.
Fig. 55
The rotary switch for ECONO-
MIZER is without function on
machines with a padfoot drum.
80 BW 124 PDH-5
Checks prior to start up
5 Checks prior to start up
BW 124 PDH-5 81
Checks prior to start up – Notes on safety
5.1 Notes on safety

If the following tests reveal damages or other
defects, the machine must not be operated,
until these deficiencies have been corrected.
Do not operate the machine with defective indi-
cators and control elements.
Safety installations must not be removed or
made ineffective.
Do not change any fixed settings.
WARNING!
Health 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 30.
WARNING!
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 opened engine
hood.
Park the machine safely Ä Chapter 6.6

„Parking the machine in secured condi-
tion“ on page 106.
82 BW 124 PDH-5
Checks prior to start up – Notes on safety
Open and secure the engine hood.

Close the engine hood again after work is com-
pleted.
BW 124 PDH-5 83
Checks prior to start up – Visual inspections and function tests
5.2 Visual inspections and function tests

1. Check hydraulic oil tank and lines for con-
dition and leaks.
2. Check fuel tank and lines for condition and
leaks.
3. Check cooling system for contamination,
damage and leaks.
4. Check the bolted connections are tight and
secure.
5. Check the engine and exhaust system for
leaks.
6. Check 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.
84 BW 124 PDH-5
Checks prior to start up – Checking the engine oil level
5.3 Checking the engine oil level
NOTICE!
Danger of engine damage!
– If the engine is warm, shut it
down and check the oil level after
five minutes. With a cold engine
the oil level can be checked
immediately.
– Use only oil of the permitted
specification Ä Chapter 8.3.1
„Engine oil“ on page 133.
NOTICE!
During the regeneration process,
part of the fuel may mix with the
engine oil.
– If the engine oil level is higher
than the “MAX” mark, the engine
oil is excessively diluted. Immedi-
ately change the engine oil.
Protective equip- n Working clothes

ment: 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.
B-586-0294
3. For topping up, clean the area around the
Fig. 56 filler opening.
4. Unscrew the cap and fill in engine oil up to
the “MAX” mark.
5. Close the cap.
BW 124 PDH-5 85
Checks prior to start up – Checking the engine oil level
6. Push the dipstick in.
86 BW 124 PDH-5
Checks prior to start up – Checking the fuel level, topping up fuel
5.4 Checking the fuel level, topping up fuel

5.4.1 Checking the fuel level
1/ 2
1. Check the filling level on the fuel gauge.
1/ 4 3/ 4
2. Refuel if required, after first shutting down
the engine.
0 1
h
B-DIS-0005
Fig. 57
5.4.2 Refuelling
NOTICE!
– 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
„Fuel“ on page 134.
BW 124 PDH-5 87
Checks prior to start up – Checking the fuel level, topping up fuel

1. Clean the area around the filler opening.
2. Unscrew the cap and fill in fuel.
3. Close the cap.
B-586-0280
Fig. 58
88 BW 124 PDH-5
Checks prior to start up – Checking the hydraulic oil level
5.5 Checking the hydraulic oil level
NOTICE!
Components may get damaged!
– Check the hydraulic oil level at
room temperature (approx. 20 °C
(68 °F)).
– If, during the daily inspection of
the oil level the hydraulic oil level
is found to have dropped, check
all lines, hoses and components
for leaks.
„Hydraulic oil“ on page 137.

1. Check the oil level in the inspection glass.
Normal level approx. 3 cm (1.2 in)
below the top edge of the
inspection glass
Minimum level Middle of inspection glass
B-596-0281
Fig. 59
2. To refill remove the two rear screws from
the seat console.
3. Fold the seat console forward.
B-586-0310
Fig. 60
BW 124 PDH-5 89
Checks prior to start up – Checking the hydraulic oil level
4. Clean the area around the filler opening.

5. Remove the cap and fill in hydraulic oil.
6. Close the cap.
7. Push the seat console back again.
B-586-0283
Fig. 61
8. Screw the two rear screws tightly into the
seat console.
B-586-0282
Fig. 62
90 BW 124 PDH-5
Checks prior to start up – Checking the coolant level
5.6 Checking the coolant level
NOTICE!
– If, during the daily inspection the
coolant level is found to have
dropped, check all lines, hoses
and engine for leaks.
– Do not use radiator sealant to
seal leaks.
– Use only coolant of the permitted
„Coolant“ on page 135.
A coolant level which is too low is indicated by

the coolant level warning light.
B-SYM-0008
Fig. 63
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-
B-586-0323
tive equipment (protective
Fig. 64 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 coolant.
BW 124 PDH-5 91
Checks prior to start up – Checking the coolant level
3. Close the cap.
92 BW 124 PDH-5
Checks prior to start up – Checking wheels and tyres
5.7 Checking wheels and tyres
WARNING!
Danger of being injured by
bursting tyres!
equipment (safety shoes, gloves,
goggles, hard hat).
– When checking the tyre pressure
stand in the extended path of the
tyre track.
– Use an air hose with a length of
min. 6 meters.
– Never exceed the permitted max-
imum pressure.
The tire pressure can be adapted to

the operating conditions within the
specified limits.
A reduced tire pressure improves
the traction especially on sandy
soils.
Higher tires pressures improve the
driving stability of the machine.
The total height of the machine can
also be influenced by changing the
tire pressure.
BW 124 PDH-5 93
Checks prior to start up – Checking wheels and tyres
Protective equip- n Safety shoes

n Safety goggles
n Hard hat
1. Move the machine until the tire inflation
valve (1) is in top position.
2. Park the machine in secured condition
Ä Chapter 6.6 „Parking the machine in
secured condition“ on page 106.
3. Check the tyres for cuts, bulges, damaged
rims, missing wheel studs or nuts.
Fig. 65 4. Have damaged wheels or tyres replaced
immediately.
5. Unscrew the valve caps and check the
front and rear tire pressure, correct if nec-
essary.
Ensure equal pressure in all tires.
Tire pressure, nominal value

Ä Chapter 2 „Technical
data“ on page 13
6. Screw the valve caps back on again.
94 BW 124 PDH-5
Operation
6 Operation
BW 124 PDH-5 95
Operation – Setting up the work place
6.1 Setting up the work place

6.1.1 Adjust the driver’s seat

1. To adjust the inclination of the backrest
operate lever (c) and tilt the backrest for-
ward or back.
2. Adjust the seat in longitudinal direction, dis-
engage lever (b) and push the seat forward
or back to do so.
3. Adjust to the weight of the operator using
lever (a).
Fig. 66
a Weight adjustment The adjustment lever (a) is
b Longitudinal adjustment locked in upwards direction.
c Backrest adjustment
To release the lock press the
lever down against the end
stop.
Then adjust to the weight of the
operator by sliding the lever
down.
96 BW 124 PDH-5
Operation – Starting the engine
6.2 Starting the engine
WARNING!
Loss of hearing caused by too
high noise burdens!
equipment (ear protection).
Protective equip- n Hearing protection

ment:
Prerequisites:
n Main battery switch switched on
n Emergency stop switch unlocked
n Travel lever in position “Middle right”
(parking brake closed)
1. Turn the rotary switch for engine speed to
position “Middle” (ECO mode).
B-SWI-1089
Fig. 67
2. Turn the ignition key to position “I”.
ð All control and warning lights in the
instrument cluster light up for a moment.
B-ELE-0070
Fig. 68
BW 124 PDH-5 97
3. If the pre-heating control light lights up,

wait until it goes out before you start the
engine.
B-SYM-0010
Fig. 69 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.
NOTICE!
– Run the starting process for max-
imum 20 seconds without inter-
ruption and pause for a minute
between starting attempts.
– If the engine has not started after
two attempts, determine the
cause.
4. Turn the ignition key through position “II” to

position “III”.
ð The starter cranks the engine.
NOTICE!
B-ELE-0072 Danger of engine damage!
Fig. 70 – Warm up engine for a short while
before starting work. Do not
operate the engine immediately
under full load.
98 BW 124 PDH-5
NOTICE!
Low exhaust gas temperatures
result in increased soot loads in
the DPF!
– Short engine running times, low
engine loads or excessively long
engine idle times should be
avoided.
BW 124 PDH-5 99
Operation – Travel operation
6.3 Travel operation

6.3.1 Preliminary remarks and safety notes
Driving up and down
slopes DANGER!
Danger to life caused by the
machine turning over!
– Never drive across a slope.
– Always drive straight up or down
a slope.
Do not drive on gradients exceeding the max-

imum gradeability of the machine Ä Chapter 2
„Technical data“ on page 13.
Soil conditions and weather influences impair
the gradeability of the machine.
Wet and loose soil considerably reduces trac-
tion of the machine on inclinations and slopes.
Increased danger of accident!
Leaving the seat while

travelling
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
Fig. 71 a standstill.
Before being able to drive again, the travel
lever must first be shifted to the right into the
parking brake position.
100 BW 124 PDH-5

6.3.2 Driving the machine

1. Fasten your seat belt.
B-SWI-1089
Fig. 72
3. Disengage the travel lever to the left out of
parking brake position and move it slowly
to the desired travel direction.
ð The further the travel lever is moved for-
wards or backwards, the faster the
machine will travel.
B-ELE-0138
Fig. 73
4. Set the travel lever to “Middle” position to
stop the machine.
ð The machine decelerates to a standstill.
B-ELE-0142
Fig. 74
BW 124 PDH-5 101

5. Always apply the parking brake when stop-

ping on inclinations or slopes.
B-ELE-0143
Fig. 75
102 BW 124 PDH-5

Operation – Working with vibration
6.4 Working with vibration

NOTICE!
Possible damage to neigh-
bouring buildings!
– When compacting with vibration
you must always check the effect
of the vibration on nearby build-
ings and underground supply
lines (gas, water, sewage, elec-
tric power).
– If necessary stop compacting
with vibration.
NOTICE!
– Do not activate the vibration on
hard (frozen, concrete) ground.
Vibration at standstill causes transverse marks

n Switch the vibration on only after shifting the
travel lever to the desired travel direction.
n Switch the vibration off before stopping the
machine.
BW 124 PDH-5 103

Operation – Working with vibration
6.4.2 Switching the vibration on and off

1. Preselect the desired amplitude with the
rotary switch for amplitude pre-selection.
B-SWI-1083
Fig. 76
2. Shift the travel lever slowly in the desired
travel direction.
3. Press the vibration push button on the
travel lever.
ð Vibration is switched on.
4. Press the vibration push button on the
travel lever once again to switch off vibra-
tion.
ð Vibration is switched off.
B-ELE-0144
Fig. 77
5. After finishing work, turn the rotary switch
for amplitude pre-selection back to position
“0”.
B-SWI-1084
Fig. 78
104 BW 124 PDH-5

Operation – ECONOMIZER
6.5 ECONOMIZER
Optional equipment
The ECONOMIZER continuously informs the

driver about the compaction status of the layer
being compacted and enables the detection
and targeted post-compaction of local weak
spots.
The acceleration sensor on the drum measures
the reaction of the road subbase.
n With the vibration switched on, the meas-
uring value for the soil stiffness or the
asphalt density is shown on a scale (LED 1 -
10).
n If the display value does not increase any
further, no further compaction can be ach-
ieved with this machine. The maximum dis-
play value (10) is not always reached.
n If the drum is in jump operation, the display
(a) flashes.
In order to achieve the desired soil stiffness,
Fig. 79 one must always perform a suitable reference
measurement before compaction is started.
The reference measurement is used to deter-
mine which display value of the ECONOMIZER
corresponds with the measuring value for soil
stiffness.
In case of a malfunction the LEDs

will show a fault code Ä Chapter
9.5 „Trouble shooting ECONO-
MIZER“ on page 203.
BW 124 PDH-5 105

Operation – Parking the machine in secured condition
6.6 Parking the machine in secured condition

1. Drive the machine onto level and firm
ground.
2. To stop the machine return the travel lever
to “Middle” position and shift it to the right
to lock (parking brake position).
ð The parking brake warning light lights
up.
B-ELE-0122
NOTICE!
Fig. 80
– Do not shut down the engine all
of a sudden from full load speed,
but let it idle for about two
minutes.
3. Turn the ignition key to position “0” and pull

it out.
B-ELE-0069
Fig. 81
4. Turn the main battery switch anticlockwise
and pull it out.
B-SWI-0079
Fig. 82
106 BW 124 PDH-5

Operation – Regeneration of exhaust gas aftertreatment system
6.7 Regeneration of exhaust gas aftertreatment system

As the soot load in the DPF increases, the
deposited particles must be burned (regenera-
tion).
Depending on the soot load, the engine control
requests a certain regeneration level.
Request of regeneration levels

Warning light Description Measures
lights up off Active regeneration in Is carried out automatically.

normal operation As long as there is no
required. danger, do not stop or sup-
press regeneration.
flashes off Regeneration at stand- Perform regeneration at
still required. standstill as soon as pos-
sible Ä Chapter 6.7.3
„Running regeneration at
standstill“ on page 110.
flashes lights up Regeneration at stand- Perform regeneration at
still is urgently standstill immediately
required. Ä Chapter 6.7.3 „Running
Reduced engine regeneration at stand-
power. still“ on page 110.
BW 124 PDH-5 107

Warning light Description Measures
flashes lights up Regeneration by Inform our service depart-

authorised service per- ment.
sonnel required.
Engine power dramati-
cally reduced.
flashes lights up DPF overloaded. Inform our service depart-
Regeneration no ment.
longer possible. The
DPF must be removed
and cleaned.
During regeneration, the exhaust gas reaches
very high temperatures and the exhaust gas
quantity increases (warning light for exhaust
gas temperature lights up).
Fig. 83
WARNING!
materials!
– Keep a safe distance to combus-
tible or explosive materials.
If the interval for regeneration drops to under

five hours, find out why and rectify the cause
(e.g. DPF overloaded). Then change the
engine oil Ä Chapter 8.9.1 „Change engine oil
and oil filter cartridge“ on page 153.
108 BW 124 PDH-5

NOTICE!
Low exhaust gas temperatures
result in increased soot loads in
the DPF!
– Short engine running times, low
engine loads or excessively long
engine idle times should be
avoided.
6.7.2 Suppressing regeneration

As long as there is no danger, do not stop or
suppress regeneration.
As soon as there is danger due to high exhaust
gas temperatures and quantities, the operator
has to suppress regeneration.
1. Actuate the rotary button for regeneration
to the left.
ð Regeneration is suppressed.
2. To disable suppression, actuate the rotary
button briefly to the right.
After restarting the engine, the

suppression is automatically
Fig. 84
disabled.
BW 124 PDH-5 109

6.7.3 Running regeneration at standstill

Regeneration at standstill must be carried out if
the warning light for regeneration flashes.
Fig. 85
1.
WARNING!
materials!
– Keep a safe distance to com-
bustible or explosive mate-
rials.
Fig. 86 Stop the machine in open terrain.

2. Engage the travel lever to the right (parking
brake position).
When the travel lever is disen-

gaged out of parking brake
position to the left, regeneration
at standstill will be aborted.

Fig. 87
110 BW 124 PDH-5

4. Hold the rotary button for regeneration for

approx. 3 seconds in position “Right”.
Fig. 88
ð As soon as regeneration at standstill
starts, the engine speed will increase.
The regeneration warning light lights up.
Regeneration at standstill runs automati-
Fig. 89 cally and takes up to 30 minutes.
The increased exhaust gas temperature
is indicated by the exhaust gas tempera-
ture warning light.
5. After regeneration has finished the warning
Fig. 90 lights go out.
BW 124 PDH-5 111

Operation – Emergency procedures
6.8 Emergency procedures

6.8.1 Actuating the emergency stop switch
1. In events of emergency and in case of
danger actuate the emergency stop switch
immediately.
ð The engine is shut down and the parking
brake is closed.
Fig. 91
6.8.2 Disconnecting the battery

1. In events of emergency, e.g. in case of a
cable fire, disconnect the battery from the
vehicle network. For this purpose turn the
main battery switch anticlockwise and pull
it out or pull the battery terminal off the bat-
tery.
Fig. 92
6.8.3 Towing the machine

Tow the machine only in case of emergency or
to prevent an accident.
Towing distance max. 500 m (1600 ft), towing
speed max. 1 km/h (55 ft/min).
Before towing make sure that:
n the tractor vehicle has sufficient traction and
braking power for the non-braking towed
load;
n lifting tackle is of sufficient strength to with-
stand the load and is fastened at the points
provided for this purpose.
If no tow bar is used, towing is only permitted
uphill.
112 BW 124 PDH-5


ment: n Safety shoes
n Protective gloves
WARNING!
uncontrolled machine movement!
– Always secure the machine
1. Fasten the towing device reliably to the

towing points.
B-586-0324
Fig. 93
2. Remove the two rear screws from the seat
console.
B-586-0310
Fig. 94
BW 124 PDH-5 113

4. To by-pass both travel pumps undo the

1 2 3
locknuts (3) on the high pressure limiting
valves (1).
5. Tighten the socket head cap screws (2)
until the screw touches the spring cup
(increased resistance).
1 6. Tighten the socket head cap screws
B-586-0478
another half turn.

Fig. 95
7. Tighten the counter nuts, tightening torque:
22 Nm (16 ft·lbf).
8. Press the emergency operation button
completely in.
9. Insert a suitable pump lever extension and
operate the pump, until the brake is
released.
ð The machine can now be towed.
B-586-0479
Fig. 96
6.8.4 After towing
WARNING!
uncontrolled machine movement!
– Always secure the machine
1. If the engine cannot be started, pull the

emergency operation button completely out
after towing.
After starting the engine the

emergency operation button is
pushed out by hydraulic pres-
B-586-0480
sure.
Fig. 97
114 BW 124 PDH-5

2. Loosen the counter nuts (3) on the high

1 2 3
pressure limiting valves of the travel pump.
3. Unscrew the socket head cap screws (2)
against the end stop.
4. Tighten the counter nuts, tightening torque:
22 Nm (16 ft·lbf).
1
B-586-0478
Fig. 98
BW 124 PDH-5 115

Bleeding the hydraulic

circuit
The hydraulic circuit needs to be filled and bled
before the machine can be put back into opera-
tion (e.g. following repair).
1. Open the engine hood.
2. Pull plug (Y04) off the solenoid valve for
1 the parking brake, to prevent the parking
brake from opening.
3. Close the engine hood.
B-586-0326
Fig. 99
1 Plug (Y04)
position “Left”.
5. Start the engine and shut it down again
after approx. 2-3 seconds.
6. Repeat this process after a short break.
7. Pull off the ignition key.
B-SWI-1469
Fig. 100
116 BW 124 PDH-5

8. Open the engine hood and reconnect the

1 plug (Y04) to the solenoid valve for the
parking brake.
9. Close the engine hood.
B-586-0326
Fig. 101
1 Plug (Y04)
BW 124 PDH-5 117

118 BW 124 PDH-5

Loading / transporting the machine
7 Loading / transporting the machine
BW 124 PDH-5 119

Loading / transporting the machine – Preparation for transport
7.1 Preparation for transport

1. Close all flaps.
2. Remove all loose objects from the machine
or the driver's stand or fasten them
securely.
120 BW 124 PDH-5

Loading / transporting the machine – Loading the machine
7.2 Loading the machine

bearing capacity.
The ramp inclination must be less than the gra-
deability of the machine.
Make sure that any persons keep a safety dis-
tance of at least 2 metres while the machine is
driven onto or down from the transport vehicle.
The instructing person should not be inside the
travel range of the machine.
Centre-of-gravity posi-
tion
Distance from Height (mm)
middle of drum (mm)
925 ± 100 680 ± 70
H
L B-586-0332
Fig. 102
DANGER!
machine slipping or turning over!
– Make sure that no persons are in
the danger zone.
1. Drive the machine carefully onto the trans-

port vehicle.
2. Observe the centre of gravity.
3. Shut down the engine, pull off the ignition
key.
BW 124 PDH-5 121

Loading / transporting the machine – Loading the machine
4. Engage the articulation lock Ä Chapter

8.2.2.1 „Engaging the articulation
lock“ on page 130.
122 BW 124 PDH-5

Loading / transporting the machine – Lashing the machine to the transport vehicle
7.3 Lashing the machine to the transport vehicle

Do not use damaged or in any other way
impaired lifting points.
tackle on the lifting and lashing points.
Use lifting tackle only in the prescribed direc-
tion of load application.
components.
1. Fasten the lashing tackle at the marked
lashing points.
2. Lash the machine securely to the transport
vehicle.
Fig. 103
BW 124 PDH-5 123

Loading / transporting the machine – Loading by crane
7.4 Loading by crane

Loads may only be attached and hoisted by an
expert/qualified person.
Do not use lifting points that are damaged or
impaired in any other way.
Only use lifting and lashing tackle with suffi-
cient load bearing capacity for the weight to be
loaded. Minimum load bearing capacity of
lifting gear: see max. operating weight
Ä Chapter 2 „Technical data“ on page 13.
tackle on the lifting and lashing points.
Use lifting tackle only in the prescribed direc-
tion of load application.
components.
When lifting the machine avoid uncontrolled
movements of the load. If necessary, hold the
load with guide ropes.
1. Shut down the engine.
2. Engage the articulation lock Ä Chapter
8.2.2.1 „Engaging the articulation
3. Fasten the lashing tackle at the marked
lifting points.
4. Use a suitable crossbar to prevent the
machine from being damaged.
5. Adjust the length of the lifting tackle in such
a way that the crane hook is vertically
B-586-0333 above the centre of gravity of the machine.
Fig. 104
124 BW 124 PDH-5

Loading / transporting the machine – Loading by crane
DANGER!
Danger to life caused by sus-
pended loads!
– Do not step or stand under sus-
pended loads.
6. Lift the machine carefully and lower it again

at the intended location.
BW 124 PDH-5 125

Loading / transporting the machine – After transport
7.5 After transport

bearing capacity.
The ramp inclination must be less than the gra-
deability of the machine.
Make sure that any persons keep a safety dis-
tance of at least 2 metres while the machine is
driven onto or down from the transport vehicle.
The instructing person should not be inside the
travel range of the machine.
1. Loosen the articulation lock Ä Chapter

8.2.2.2 „Disengaging the articulation
2.
DANGER!
machine slipping or turning
over!
– Make sure that no persons
are in the danger zone.
Drive the machine carefully off the trans-

port vehicle.
126 BW 124 PDH-5

Maintenance
8 Maintenance
BW 124 PDH-5 127

Maintenance – Preliminary remarks and safety notes
8.1 Preliminary remarks and safety notes
DANGER!
Danger to life caused by an
operationally unsafe machine!
– The machine must only be serv-
iced by qualified and authorized
personnel.
– Follow the safety regulations for
maintenance work Ä Chapter
3.11 „Maintenance
work“ on page 53.
WARNING!
and lubricants!
CAUTION!
Danger of being injured by the
engine hood dropping down!
– Always secure an opened engine
hood.
Wear your personal protective equipment.

Do not touch hot components.
Park the machine on horizontal, level, firm
ground.
Perform maintenance work only with the
engine shut down.
128 BW 124 PDH-5

Maintenance – Preliminary remarks and safety notes
Make sure that the engine cannot be acciden-

tally started during maintenance work.
Thoroughly clean machine and engine before
starting maintenance work.
Before mounting the machine, check whether
all access steps, grips and platforms are free of
obstacles, grease, oils, fuel, dirt, snow and ice.
Use only the intended access steps and grips
to mount the machine.
For overhead maintenance work 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 maintenance work has been completed,
dispose of fuels and lubricants, filters, sealing
elements and cleaning cloths in an environ-
mentally friendly way.
After all maintenance work is completed rein-
stall all guards and safety installations.
Close all maintenance flaps and doors after
maintenance work has been completed.
The terms right/left are always in

relation to the travel direction.
BW 124 PDH-5 129

Maintenance – Preparations/concluding work
8.2 Preparations/concluding work

Certain maintenance tasks require prepara-
tions and concluding activities.
This includes e.g. opening and closing mainte-
nance flaps and maintenance doors as well as
securing certain components.
After this work close all maintenance flaps and
doors again and return all components to their
operating condition.
8.2.1 Opening/closing the engine hood

1. Shift the lever sideways.
ð The hood is raised by the gas springs.
2. To close the hood push it back into locked
position.
B-586-0285
Fig. 105
8.2.2 Articulation lock

8.2.2.1 Engaging the articulation lock
WARNING!
Danger of crushing by the articu-
lating machine!
– Do not step into the articulation
area of the machine while the
engine is running.
1. Move the steering to middle position and

stop the machine.
2. Shut down the engine, pull off the ignition
key.
130 BW 124 PDH-5

3. Pull the split pin out of the locking bolt for

the articulation lock.
4. Remove the locking bolt.
B-586-0286
Fig. 106
5. Insert the locking bolt into the articulation
lock and secure it with the split pin.
B-586-0287
Fig. 107
8.2.2.2 Disengaging the articulation lock
WARNING!
Danger of crushing by the articu-
lating machine!
– Do not step into the articulation
area of the machine while the
engine is running.
1. Pull the split pin out of the locking bolt for

the articulation lock.
2. Remove the locking bolt.
B-586-0287
Fig. 108
BW 124 PDH-5 131

3. Engage the articulation lock in the holding

fixture and secure it with the split pin.
B-586-0286
Fig. 109
8.2.3 Side engine covers
The side engine covers can be

removed for better access during
maintenance work.
1. Remove the two star bolts from each side

cover and take off the covers.
2. Place the covers in the mounting position
after the maintenance work and secure
with the star bolts.
B-586-0288
Fig. 110
132 BW 124 PDH-5

Maintenance – Fuels and lubricants
8.3 Fuels and lubricants

8.3.1 Engine oil
8.3.1.1 Oil quality
The following lubrication oil specifications are
permitted:
n Low-ash engine oils acc. to API-classifica-
tion CJ-4.
Avoid mixing of engine oils.
8.3.1.2 Oil viscosity

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, especially under low ambient temperatures.
Optimal operating conditions can be achieved
by using the following oil viscosity chart as a
reference:
Ambient temperature Oil viscosity

higher than 25 °C SAE 30
(77 °F) SAE 10W-30
SAE 15W-40
-10 °C to 25 °C (14 °F SAE 10W-30
to 77 °F) SAE 15W-40
below - 10 °C (14 °F) SAE 10W-30
BW 124 PDH-5 133

8.3.1.3 Oil change intervals

If the oil change intervals are not reached over
a period of one year, the oil change should be
performed at least 1 x per year, irrespective of
the operating hours reached.
However, engine oil must also be changed
when the maintenance interval for regeneration
of the exhaust gas aftertreatment system has
dropped to five hours or less.
8.3.2 Fuel
8.3.2.1 Fuel quality
In order to fulfil the regulations of the exhaust
gas legislation, diesel engines equipped with
an exhaust gas after-treatment system, must
only be operated with sulphur-free diesel fuel.
The following fuel specifications are permitted:
n EN 590
n ASTM D975 Grade-No. 1-D S15 and
2-D S15
The recommended Cetan index number is 45.
A Cetan index number higher than 50 should
preferably be used, especially at ambient tem-
peratures below -20 °C (-4 °F) and when
working at altitudes of 1500 m (4921 ft) and
more.
8.3.2.2 Winter fuel

For winter operation use only winter diesel fuel,
to avoid clogging because of paraffin separa-
tion.
At very low temperatures disturbing paraffin
separation can also be expected when using
winter diesel fuel.
134 BW 124 PDH-5

Diesel fuels suitable for temperatures down to

-44 °C (-47 °F) are available for Arctic climates.
NOTICE!
– 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 cause
deposits in the injection nozzles, especially in
modern Common-Rail injection systems.
Zinc and lead coatings in refuelling systems
and fuel lines are not permitted.
Copper containing materials (copper lines,
brass items) should be avoided, because they
can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.
8.3.3 Coolant
Always use a mixture of anti-freeze agent and
clean, dehardened water with a mixing ratio of
1:1.
Under particularly extreme temperature condi-
tions you should consult our customer service
concerning the anti-freeze agent to be used.
There are various types of anti-freeze agents
available. For this engine you should use eth-
ylene glycol.
BW 124 PDH-5 135

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!
– Do not mix different coolants and
additives of any other kind.
Mixing the coolant:

n Prepare a mixture of 50% anti-freeze agent
and 50% low mineral, clean water.
n Stir well before filling it into the radiator.
n The method of mixing water and anti-freeze
depends on the brand of the anti-freeze
agent (see standard SAE J1034 and also
standard SAE J814c).
Add anti-freeze agent:
n If the coolant level drops because of evapo-
ration,only clean water is to be used for top-
ping up.
n In case of leakages you must always fill in
anti-freeze agents of the same brand and
the same mixing ratio.
Do not use any radiator cleaning agent after
the anti-freeze agent has been mixed in. The
anti-freeze agent also contains a corrosion pro-
tection agent. If this mixes with cleaning agent
it may cause the development of sludge, which
could damage the cooling system.
Anti-freeze concen- Freezing point

tration
50 % -37 °C (-35 °F)
136 BW 124 PDH-5

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 HVLP according to DIN
51524, part 3, or hydraulic oil type HV
according to ISO 6743/4.
The viscosity index must be at least 150
(observe information of manufacturer).
8.3.4.2 Bio-degradable hydraulic oil

The hydraulic system can also be operated
with a synthetic ester based biodegradable
hydraulic oil.
The biodegradable hydraulic oil
Panolin HLP Synth. 46 or Plantohyd 46 S
meets all the requirements of a mineral oil
based hydraulic oil according to DIN 51524.
In hydraulic systems filled with biodegradable
hydraulic oil, always use the same oil to top up
and do not mix oil types.
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.
BW 124 PDH-5 137

NOTICE!
Danger of damage to the
hydraulic system!
– After the changeover check the
hydraulic oil filters increasingly
for contamination.
– Have regular oil analyses per-
formed regarding the water con-
tent and mineral oil.
– Replace the hydraulic oil filter at
the latest after 500 operating
hours.
8.3.5 Gear oil SAE 80W-140

Use a fully synthetic gear oil in accordance with
SAE 80W-140, API GL5 with a kinematic vis-
cosity of at least 20 mm2/s at 100 °C (212 °F).
It is a hypoid lubricant of highest quality class
for transmissions under extreme strain.
138 BW 124 PDH-5

Maintenance – List of fuels and lubricants
8.4 List of fuels and lubricants

Assembly Fuel or lubricant Spare Filling
group parts quantity
Summer Winter number Observe
the level
mark!
Engine oil SAE 15W-40 009 920 09 8.5 l
Specification: Ä Chapter 8.3.1 20 l (2.2 gal us)
„Engine oil“ on page 133
SAE 10W-40
SAE 10W-30
SAE 30
Fuel Diesel Winter diesel 60 l
fuel (16 gal us)
Specification: Ä Chapter 8.3.2
„Fuel“ on page 134
Coolant Mixture of water and anti-freeze 009 940 03 7.0 l
agent 20 l (1.8 gal us)
Specification: Ä Chapter 8.3.3
„Coolant“ on page 135
Hydraulic Hydraulic oil (ISO), HVLP 46 009 930 09 45 l
system Specification: Ä Chapter 8.3.4.1 20 l (12 gal us)
„Mineral oil based hydraulic
oil“ on page 137
or ester based biodegradable
hydraulic oil
Specification: Ä Chapter 8.3.4.2
„Bio-degradable hydraulic
oil“ on page 137
Drum drive gear Gear oil SAE 80W-140 009 925 07 0.8 l
„Gear oil SAE
80W-140“ on page 138
BW 124 PDH-5 139

Maintenance – List of fuels and lubricants
Assembly Fuel or lubricant Spare Filling

group parts quantity
Summer Winter number Observe
the level
mark!
Drive axle Gear oil SAE 80W-140 009 925 07 3.4 l
„Gear oil SAE
80W-140“ on page 138
Bevel gear Gear oil SAE 80W-140 009 925 07 0.45 l
housing Specification: Ä Chapter 8.3.5 20 l (0.1 gal us)
„Gear oil SAE
80W-140“ on page 138
Wheel hubs Gear oil SAE 80W-140 009 925 07 0.4 l each
„Gear oil SAE
80W-140“ on page 138
Tyres Water + calcium chloride 35 l + 20 kg
(9.2 gal us
+ 44 lbs)
or water + magnesium chloride 43 l + 12 kg
(11.4 gal us
+ 26.5 lbs)
140 BW 124 PDH-5

Maintenance – Running-in instructions
8.5 Running-in instructions

8.5.1 General
The following maintenance work must be per-
formed when running in new machines or over-
hauled engines.
NOTICE!
– Up to approx. 250 operating
hours check the 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.

1. Retighten the wheel nuts Ä Chapter
8.10.11 „Retightening the wheel
nuts“ on page 175.
2. Oil and filter change on diesel engine
Ä Chapter 8.9.1 „Change engine oil and oil
filter cartridge“ on page 153.
3. Oil change in drive axle Ä Chapter 8.10.6
„Change the oil in the drive
axle“ on page 169.
BW 124 PDH-5 141

Maintenance – Running-in instructions
4. Oil change in bevel gear housing

Ä Chapter 8.10.7 „Changing the oil in the
bevel gear housing“ on page 171.
5. Oil change in wheel hubs Ä Chapter 8.10.8
„Changing the oil in the wheel
hubs“ on page 172.
6. Oil change in drum drive reduction gear
Ä Chapter 8.10.9 „Change the oil in the
drum drive reduction gear“ on page 173.

1. Oil and filter change on diesel engine
Ä Chapter 8.9.1 „Change engine oil and oil
filter cartridge“ on page 153.

1. Retighten the wheel nuts Ä Chapter
8.10.11 „Retightening the wheel
nuts“ on page 175.
2. Oil change in drive axle Ä Chapter 8.10.6
„Change the oil in the drive
axle“ on page 169.
3. Oil change in bevel gear housing
Ä Chapter 8.10.7 „Changing the oil in the
bevel gear housing“ on page 171.
4. Oil change in wheel hubs Ä Chapter 8.10.8
„Changing the oil in the wheel
hubs“ on page 172.
142 BW 124 PDH-5

Maintenance – Maintenance Table
8.6 Maintenance Table

No. Maintenance works Page
Every 50 operating hours
8.7.1 Checking radiator hoses and hose clamps 145
8.8.1 Check the air intake lines 146
8.8.2 Checking radiator hoses and hose clamps 146
8.8.3 Checking, tensioning the V-belt 147
8.8.4 Cleaning the radiator module 148
8.8.5 Checking the oil level in the drive axle 149
8.8.6 Check the oil level in the bevel gear housing 150
8.8.7 Checking the oil level in the wheel hubs 151
8.8.8 Checking the oil level in the drum drive reduction 151
gear
8.8.9 Check the parking brake 152
8.9.1 Change engine oil and oil filter cartridge 153
8.9.2 Replacing the fuel filter, bleeding the fuel system 155
8.9.3 Replacing the V-belt 158
8.9.4 Checking the anti-freeze concentration and the con- 159
dition of the coolant
8.9.5 Checking the hydraulic lines 159
8.9.6 Servicing the battery, checking the main battery 161
shutoff
8.10.1 Adjusting the valve clearance 163
8.10.2 Checking the lines on the diesel engine 165
8.10.3 Checking the exhaust manifold 166
8.10.4 Checking the engine mounts 166
8.10.5 Replacing the hydraulic oil filter 166
BW 124 PDH-5 143

Maintenance – Maintenance Table
No. Maintenance works Page

8.10.6 Change the oil in the drive axle 169
8.10.7 Changing the oil in the bevel gear housing 171
8.10.8 Changing the oil in the wheel hubs 172
8.10.9 Change the oil in the drum drive reduction gear 173
8.10.10 Retightening the fastening of the axle on the frame 175
8.10.11 Retightening the wheel nuts 175
8.10.12 Checking the ROPS 175
8.10.13 Checking the travel lever control 176
8.11.1 Changing the hydraulic oil 177
8.11.2 Changing the coolant 180
8.11.3 Replacing the oil separator element 183
8.11.4 Checking the exhaust gas recirculation cooler 183
8.11.5 Replacing hoses 183
8.12.1 Checking the turbo charger 184
8.12.2 Cleaning the DPF 184
8.12.3 Checking the exhaust gas recirculation system 184
As required
8.13.1 Air filter maintenance 185
8.13.2 Checking and cleaning the water separator 188
8.13.3 Adjusting the scrapers 189
8.13.4 Cleaning the machine 190
8.13.5 Draining the fuel tank sludge 191
8.13.6 Measures prior to extended shutdown period 191
144 BW 124 PDH-5

Maintenance – Every 50 operating hours
8.7 Every 50 operating hours

8.7.1 Checking radiator hoses and hose clamps
2. Allow the engine to cool down.
3. Check the condition and tight fit of all fuel
lines and hose clamps.
4. If fuel lines or hose clamps are found to be
damaged, the corresponding parts must be
immediately repaired or replaced by
authorized service personnel.
NOTICE!
– After work on the fuel system
bleed the system, perform a
test run and check for leaks.
BW 124 PDH-5 145


8.8.1 Check the air intake lines
3. Check the condition and tight fit of all air
intake lines and hose clamps.
4. If fuel lines or hose clamps are found to be
damaged, the corresponding parts must be
immediately replaced.
8.8.2 Checking radiator hoses and hose clamps

3. Check the condition and tight 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.
146 BW 124 PDH-5

8.8.3 Checking, tensioning the V-belt

8.8.3.1 Checking the V-belt
3. Check the entire circumference of the V-
belt for damage and cracks.
4. Replace a damaged or cracked V-belt
Ä Chapter 8.9.3 „Replacing the V-
belt“ on page 158.
5. Check with thumb pressure whether the V-
belt can be depressed more than
7 to 9 mm (0.28 – 0.35 inch) between the
Fig. 111 V-belt pulleys, retighten if necessary.
8.8.3.2 Tightening the V-belt

1. Loosen the tensioning screw (1) and the
screw (2) 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).
Fig. 112
BW 124 PDH-5 147

8.8.4 Cleaning the radiator module
NOTICE!
– Do not bend or damage cooling
fins.
– Do not clean with high pressure.

Cleaning with com- Protective equip- n Working clothes

pressed air ment: n Protective gloves
n Safety goggles
CAUTION!
Danger of eye injuries caused by
particles flying around!
equipment (safety gloves, protec-
tive working clothes, goggles).
LUFT 1. Blow the radiator out with compressed air

from inside the engine compartment.
AIR
B-586-0289
Fig. 113
148 BW 124 PDH-5

LUFT 2. Blow the radiator out with compressed air

from the outside.
AIR
B-586-0290
Fig. 114
Cleaning with cold Protective equip- n Working clothes
cleansing agent ment: n Protective gloves
NOTICE!
Electric components can be dam-
aged by water entering into the
system!
– Protect electrical equipment such
as generator, regulator and
starter against the direct water
jet.
1. Spray engine and radiator with a suitable

cleansing agent, let it soak in for a while,
and then wash off with a strong water jet.
2. Warm up the engine for a while to avoid
corrosion.
8.8.5 Checking the oil level in the drive axle
NOTICE!
– Use only gear oil of the permitted
„Gear oil SAE
80W-140“ on page 138.
BW 124 PDH-5 149


2. Clean the area around the oil level inspec-
tion plug and unscrew the plug.
3. The oil level must reach the bottom edge of
the bore; top up oil if necessary.
4. Screw the oil level inspection plug back in
tightly.
B-586-0291
Fig. 115
8.8.6 Check the oil level in the bevel gear housing
NOTICE!
„Gear oil SAE
80W-140“ on page 138.

tion plug.
2. Unscrew the oil level inspection plug.
ð The oil level must reach the bottom
edge of the level bore.
3. Top up oil if necessary.
B-586-0292
4. Turn the oil level inspection plug tightly

Fig. 116 back in.
150 BW 124 PDH-5

8.8.7 Checking the oil level in the wheel hubs
NOTICE!
„Gear oil SAE
80W-140“ on page 138.

1. Move the machine until the oil level inspec-
tion plug is in horizontal position.
tion plug.
Fig. 117 4. Unscrew the oil level inspection plug.
5. Top up oil if necessary.
back in.
7. Change the oil in both wheel hubs.
8.8.8 Checking the oil level in the drum drive reduction gear
NOTICE!
„Gear oil SAE
80W-140“ on page 138.
BW 124 PDH-5 151


tion plug (1) is horizontal and the filler plug
(2) is in top position.
Fig. 118
4. For topping up, clean the area around the
filler plug.
5. Unscrew the filler screw.
6. Refill with oil until it reaches the bottom
edge of the inspection bore.
7. Retighten the oil level inspection and filler
plug.
8.8.9 Check the parking brake

This work must only be performed by
152 BW 124 PDH-5


8.9.1 Change engine oil and oil filter cartridge
Perform this maintenance work at

the latest after one year.
NOTICE!
– Change the oil only with the
engine at operating temperature.
„Engine oil“ on page 133.
– Filling quantity: Ä Chapter 8.4
„List of fuels and lubri-
cants“ on page 139
BW 124 PDH-5 153


n Protective gloves
1. Park the machine safely Ä Chapter 6.6
„Parking the machine in secured condi-
WARNING!
Danger of burning on hot compo-
nents!
– Avoid touching hot components.
2. Unscrew the drain plug and collect any oil

running out.
3. Screw the drain plug back in tightly.
B-586-0461
Fig. 119
4. Thoroughly clean the outside of the oil filter
cartridge.
5. Unscrew the oil filter cartridge using an
appropriate strap wrench.
6. Remove any dirt from the sealing face of
the filter carrier.
B-586-0295
7. Thinly apply oil to the rubber seal of the
Fig. 120 new oil filter cartridge.
8. Screw on the new oil filter cartridge tightly
by hand.
154 BW 124 PDH-5

9. Fill with new engine oil.

10. After a short test run check the oil level on
the dipstick; if necessary, top up to the top
dipstick mark.
11. Check the oil filter cartridge and drain plug
for leaks.
B-586-0294
12. Dispose of the oil and filters in line with
Fig. 121 environmental regulations.
8.9.2 Replacing the fuel filter, bleeding the fuel system

8.9.2.1 Preliminary remarks
NOTICE!
– Ensure strict cleanliness! Thor-
oughly clean the area around the
fuel filters.
– Air in the fuel system causes
irregular running of the engine, a
drop in engine power, stalls the
engine and makes starting
impossible.
– After work on the fuel system
bleed the system, perform a test
run and check for leaks.
– Additional bleeding of the fuel
system by a 5 minute test run in
idle speed or low load is manda-
tory.

BW 124 PDH-5 155

8.9.2.2 Replacing the fuel filter, fuel pre-filter and fuel line filter


Fuel pre-filter
1. Pull the plug-in connection off the fuel pre-
filter sensor on the water separator.
2. Place a collecting vessel under the drain
2
bore.
3
3. Unscrew the drain plug (1) and collect the
escaping fuel.
1
B-586-0297
4. Open the quick lock (2) and take off the
Fig. 122 fuel pre-cleaner (3).
5. Clean the sealing face on the filter carrier
from any dirt.
6.
NOTICE!
2 – Never fill filters beforehand,
1
to avoid the entry of dirt into
the clean side.
3
B-586-0311
Slightly oil the rubber seal on the new fuel
Fig. 123 pre-filter.
7. Attach the fuel pre-filter (1) with quick lock
and ensure correct coding.
8. Close the quick lock (2) so that it engages
noticeably.
9. Screw in the drain plug (3).
10. Push the plug-in connection onto the
sensor on the water separator.
156 BW 124 PDH-5

Fuel filter
11. Place a collecting vessel under the drain
bore.
12. Unscrew the drain plug (1) and collect
2 leaking fuel.
3
13. Open the quick lock (2) and remove the
fuel filter (3).
1 B-586-0297
B-586-0298
14. Clean the sealing face on the filter carrier
Fig. 124 from any dirt.
15.
NOTICE!
2
1 – Never fill filters beforehand,
to avoid the entry of dirt into
the clean side.
3
B-586-0297
Slightly oil the rubber seal on the new fuel
B-586-0312
Fig. 125 filter.

16. Attach the fuel filter (1) with quick lock and
ensure correct coding.
17. Close the quick lock (2) so that it audibly
engages.
18. Screw in the drain plug (3).
Fuel line filter
19. Loosen the hose clamps on the fuel filter
and pull off the hoses.
20. Install the new line filter and observe the
flow direction (arrow).
21. Connect the hoses to the line filter with
hose clamps.
B-586-0299
22. Dispose of fuel and filter in an environmen-
Fig. 126 tally friendly way.
BW 124 PDH-5 157

8.9.2.3 Bleeding the fuel system

1. Unscrew the bleed screw (1) on the fuel
filter and fuel pre-filter 2 to 3 turns.
B-586-0329
Fig. 127
2. Hold the ignition key in position “I” until
clean fuel starts to run out at the bleed
screws.
3. Tighten the bleed screws.
4. Start the engine and run it for 5 minutes at
idle speed.
B-ELE-0070
5. Shut down the engine and check the fuel
Fig. 128 filter and fuel pre-filter for leaks.
8.9.3 Replacing the V-belt

the latest after two years.


158 BW 124 PDH-5

3. Loosen the tensioning screw (1) and the

screw (2) on the generator.
4. Relieve and remove the V-belt.
5. Assemble a new V-belt at the generator.
6. Tension the V-belt to the specified value
Ä Chapter 8.8.3 „Checking, tensioning the
V-belt“ on page 147.
Fig. 129 7. Retighten clamping screw (1) and screw
(2).
8.9.4 Checking the anti-freeze concentration and the condition

of the coolant
n Safety goggles
3. Remove the cap and check the coolant
level and anti-freeze concentration with a
conventional tester.
4. Check the condition of the coolant.
5. Thoroughly flush the cooling system if the
coolant is contaminated by corrosion resi-
B-586-0284 dues or other suspended matter Ä Chapter
8.11.2 „Changing the coolant“ on page 180.
Fig. 130
6. Close the cover again.
8.9.5 Checking the hydraulic lines

This work must only be performed by an
expert / qualified person!
BW 124 PDH-5 159


2. Check all hydraulic lines.
Hydraulic hoses must be immediately
replaced if:
n the outer layer is damaged down to the
inlay (e.g. chafing, cuts, cracks),
n embrittlement of the outer layer or for-
mation of cracks in the hose material,
n the hose shows deformation in pressur-
ized and depressurized condition, which
do not comply with the genuine 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 (squeezing,
shearing or chafing points),
n paint covered hydraulic hoses (no detec-
tion of identifications or cracks),
n shelf life and service life exceeded.
3. Replace damaged hydraulic hoses immedi-
ately, fasten these properly and avoid
chafing.
4. Only operate the machine after it has been
repaired.
160 BW 124 PDH-5

8.9.6 Servicing the battery, checking the main battery shutoff

8.9.6.1 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 of sulphate on the plates)
are not covered under warranty!

n Safety goggles
console.
B-586-0310
Fig. 131
BW 124 PDH-5 161

4. Remove the battery and clean the battery

compartment.
5. Clean the outside of the battery.
6. Clean battery poles and pole clamps and
grease them with pole grease (Vaseline).
7. Install the battery and check the battery
B-586-0300
fastening.
Fig. 132 8. On serviceable batteries check the acid
level, if necessary top up to the filling mark
with distilled water.
seat console.
B-586-0282
Fig. 133
8.9.6.2 Checking the main battery shutoff

1. Turn the main battery switch counter-clock-
wise and pull it out.
2. Check by turning the ignition key, whether
the battery is disconnected from the elec-
tric system of the machine.
Fig. 134
162 BW 124 PDH-5


8.10.1 Adjusting the valve clearance
NOTICE!
We recommend to have this work
carried out by trained personnel or
our after sales service.
– Before checking the valve clear-
ance let the engine cool down for
at least 30 minutes. The engine
oil temperature must be below
80 °C (176 °F).
Valve clearance
Intake / exhaust 0.18 mm to 0.22 mm
valve 0.007 in to 0.009 in
3. Remove the valve cover.
Fig. 135
BW 124 PDH-5 163

4. Align the marking “1TC” on the flywheel

and the marking on the housing.
Fig. 136
5. Check if cylinder 1 is overlapping, if neces-
sary rotate the flywheel by another 360°.
6. Check the valve clearance on the valves
marked black, adjust if necessary.
Fig. 137
I Intake valve
E Exhaust valve
7. Rotate the flywheel by another 360°.
8. Check the valve clearance on the valves
marked black, adjust if necessary.
Fig. 138
164 BW 124 PDH-5

9. Install the cylinder head cover with a new

gasket.
10. After a short test run check the engine for
leaks.
Fig. 139
Checking the valve clear-
ance
1. Check valve clearance (A) between rocker
arm and valve with a feeler gauge. The
feeler gauge must fit through the gap with
little resistance.
2. If the gap is too narrow or too wide for the
feeler gauge, adjust the valve clearance.
Fig. 140
8.10.2 Checking the lines on the diesel engine


Check the following lines:

n Lines of the exhaust gas recirculation
system,
n DPF-lines,
n lines of the lubrication system.
BW 124 PDH-5 165

8.10.3 Checking the exhaust manifold


8.10.4 Checking the engine mounts

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.
8.10.5 Replacing the hydraulic oil filter

166 BW 124 PDH-5

NOTICE!
– If the filter has to be changed
together with the hydraulic oil,
the filter must only be changed
after the oil change and after the
test run.
– Do not use the oil in the filter
bowl again.
– Apart from the normal oil change
intervals, the filter element must
also be changed after major
repairs in the hydraulic system.

3. Unscrew filter bowl (4) and take it off with
1
filter element (3).
2
3
4
B-586-0301
Fig. 141
BW 124 PDH-5 167

NOTICE!
Negligence may cause destruc-
tion to the entire hydraulic
system!
– Visible dirt may be an early sign
for the failure of system compo-
nents and indicate the possible
failure of components.
– In this case determine the cause
and replace or repair the defec-
tive components, if necessary.
– Do not clean or reuse the filter
element.
4. Take out the old filter element and clean

the filter bowl.
5. Clean the thread on the filter bowl.
6. Reassemble the filter bowl with a new filter
element and new O-rings (1, 2).
7. After a short test run check the filter for
leaks.
8. Dispose of oil and filter in an environmen-
tally friendly way.
168 BW 124 PDH-5

8.10.6 Change the oil in the drive axle
NOTICE!
– Drain gear oil only at operating
temperature.
„Gear oil SAE
80W-140“ on page 138.

WARNING!
nents!

B-586-0291
Fig. 142
BW 124 PDH-5 169

3. Clean the area around the drain plug.

4. Unscrew the drain plug and collect any oil
running out.
5. Turn the drain plug tightly back in.
B-586-0302
Fig. 143
6. Fill in fresh gear oil through the oil level
inspection bore, until it has reached the
bottom edge of the bore.
7. After filling with oil, wait until the oil has
evenly distributed itself inside the axle, if
necessary fill with some more oil.
B-586-0291 8. Screw the oil level inspection plug back in
tightly.
Fig. 144
9. Dispose of oil in an environmentally friendly
way.
170 BW 124 PDH-5

8.10.7 Changing the oil in the bevel gear housing
NOTICE!
„Gear oil SAE
80W-140“ on page 138.

1. Clean the area around the drain plug and
the oil level inspection plug.
2. Unscrew the oil drain screw and collect any
oil running out.
3. Screw the drain plug back in.
B-586-0304
Fig. 145
tion plug.
5. Unscrew the oil level inspection plug.
6. Fill with new oil through the oil level inspec-
tion plug, until the oil level reaches the
B-586-0292
7. Screw the oil level inspection plug back in
Fig. 146 tightly.
way.
BW 124 PDH-5 171

8.10.8 Changing the oil in the wheel hubs
NOTICE!
temperature.
„Gear oil SAE
80W-140“ on page 138.

1. Move the drum, until the oil level inspection
plug is in bottom position.
WARNING!
Fig. 147 nents!

tion plug.
4. Unscrew the oil level inspection plug and
catch any oil running out.
172 BW 124 PDH-5

5. Move the drive wheel, until the oil level

inspection plug (1) is in horizontal position.
6. Fill in fresh gear oil through the oil level
inspection bore, until it has reached the
back in.
Fig. 148 8. Change the oil in both wheel hubs.
way.
8.10.9 Change the oil in the drum drive reduction gear
NOTICE!
temperature.
„Gear oil SAE
80W-140“ on page 138.
BW 124 PDH-5 173


tion plug (2) is in bottom position.
WARNING!
Fig. 149 nents!

tion plug.
4. Unscrew the oil level inspection plug and
catch any oil running out.
5. Once all oil has been drained off, move the
machine until the oil level inspection plug
(1) is in a horizontal position and the filler
screw is in (2 ) top position.
7. Clean the area around the filler plug and
Fig. 150 unscrew the filler plug.
8. Fill in oil, until it reaches the bottom edge of
the inspection bore.
9. Turn the oil level inspection plug and filler
screw back in with new seal rings.
way.
174 BW 124 PDH-5

8.10.10 Retightening the fastening of the axle on the frame

1. Check all fastening nuts on axle mounting
bolts for tight fit, retighten if necessary,
tightening torque: 463 Nm (341 ft·lbf).
463 Nm
B-586-0305
Fig. 151
8.10.11 Retightening the wheel nuts

1. Tighten the wheel nuts cross-wise, tight-
ening torque: 550 Nm (405 ft·lbf).
Fig. 152
8.10.12 Checking the ROPS

All bolted connections must comply with the
specifications and should be absolutely tight
(observe the tightening torques).
Screw and nuts must not be damaged, bent or
deformed.
Unusual movements and noises (vibrations)
during operation are signs for damage or loos-
ened fastening elements.
BW 124 PDH-5 175

1. Inspect the cabin, especially the ROPS, for

cracks, corrosion, damage and missing
fastening parts.
2. Check the fastening screws for the cabin
(ROPS) to the operator’s platform for tight
fit.
3. Check the rubber buffers of the operator’s
platform suspension for condition and tight
fit.
4. Check the condition and fastening of the
seat belts.
8.10.13 Checking the travel lever control

2. Move the travel lever forward, backwards
and to braking position. Thereby check for
function, light movement, clearance and
damage.
3. In case of malfunction perform trouble-
shooting and replace the corresponding
parts.
B-ELE-0138
4. Only operate the machine after it has been

Fig. 153 repaired.
176 BW 124 PDH-5


8.11.1 Changing the hydraulic oil

The hydraulic oil must also be changed after

major repairs in the hydraulic system.
Always replace the hydraulic oil filter after each
hydraulic oil change. Change the hydraulic oil
filter only after the hydraulic oil change and
after the test run.
hydraulic 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.
– Use only hydraulic oil of the per-
mitted specification Ä Chapter
8.3.4 „Hydraulic oil“ on page 137.
BW 124 PDH-5 177


console.
B-586-0310
Fig. 154
4. Clean the area around the filler opening
and remove the cap.
WARNING!
nents!
B-586-0283
Fig. 155 protective clothing).
5. Connect the drain hose and collect running

out oil.
ð The drain valve opens when the drain
hose is screwed on.
6. Unscrew the drain hose again.
B-586-0306
Fig. 156
178 BW 124 PDH-5

We recommend to use our filling

and filtering unit with fine filter to fill
the system. This ensures finest fil-
tration of the hydraulic oil, prolongs
the lifetime of the hydraulic oil filter
and protects the hydraulic system.
7. Fill with hydraulic oil.

8.
The breather filter for the
hydraulic oil tank is integrated in
the cap, you must therefore
replace the complete cap.
B-586-0283
Close the tank with a new cap.
Fig. 157
9. Check the oil level in the inspection glass.
Normal level approx. 3 cm (1.2 in)
below the top edge of the
inspection glass
Minimum level Middle of inspection glass
B-596-0281
Fig. 158
seat console.
way.
B-586-0282
Fig. 159
BW 124 PDH-5 179

8.11.2 Changing the coolant


coolant.
In case of lubrication oil entering into the
cooling system or a suspicious turbidity caused
by corrosion residues or other suspended
matter, the coolant must be drained off and the
complete cooling system needs to be cleaned.
Oil can damage 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!
– Use only coolant of the permitted
„Coolant“ on page 135.
– Do not mix different coolants and
additives of any other kind.
cants“ on page 139
180 BW 124 PDH-5


n Safety goggles
3. Remove the cap.
B-586-0284
Fig. 160
4. Connect the drain hose and collect leaking
coolant.
ð The drain valve opens when the drain
hose is screwed on.
5. Unscrew the drain hose again.
6. Check the condition of the coolant.
B-586-0307
7. Thoroughly flush the cooling system if the
Fig. 161 coolant is contaminated by corrosion resi-
dues or other suspended matter.
8. Remove the thermostat.
9. Fill in clean water.
BW 124 PDH-5 181

10. Close the cap.

11. Start the engine and run to operating tem-
perature.
12. Allow the engine to cool down to approx.
50 °C (122 °F).
13. Drain off all water.
B-586-0284
14. When using a cleansing agent repeat the
Fig. 162 flushing process twice with clear water.
15. Reinstall the thermostat.
16.
NOTICE!
The anti-freeze concentration
(additive) must be at least 35
Vol% and maximum 45 Vol%.
Open the cover and top up with coolant.

17. Close the cap.
18. Start the engine and run to operating tem-
perature.
19. Allow the engine to cool down and refill if
necessary.
20. Check the coolant level and refill if neces-
sary.
21. Dispose of coolant in an environmentally
friendly way.
B-586-0323
Fig. 163
182 BW 124 PDH-5

8.11.3 Replacing the oil separator element

3. Unscrew the cover (1).
4. Renew oil separator element (3) and seal
ring (2).
5. Re-assemble the oil separator.
6. Dispose of the oil separator element envi-
ronmentally.
Fig. 164
8.11.4 Checking the exhaust gas recirculation cooler

8.11.5 Replacing hoses


The following hoses need to be renewed:

n fuel hoses,
n air intake hoses,
n hoses in connection with the oil separator.
BW 124 PDH-5 183


8.12.1 Checking the turbo charger
8.12.2 Cleaning the DPF

8.12.3 Checking the exhaust gas recirculation system

184 BW 124 PDH-5

Maintenance – As required
8.13 As required
8.13.1 Air filter maintenance
NOTICE!
– Do not start the engine after
having removed the air filter.
– If necessary, the air filter may be
cleaned up to six times. After one
year at the latest it must be
replaced together with the safety
element.
– Cleaning does not make sense if
the air filter element 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 renew

the air filter. A new filter element is
far less expensive than a possible
engine damage.
BW 124 PDH-5 185


n Safety goggles
1. Maintenance of the air filter is due when
the air filter warning light lights up, but at
Fig. 165 Ä Chapter 6.6 „Parking the machine in
4. Loosen both locking hooks on the housing
cover and take the cover off.
5. Clean housing cover and dust discharge
valve.
Fig. 166
6. Pull out the air filter with light turning move-
ments.
Fig. 167
186 BW 124 PDH-5

CAUTION!
Danger of eye injuries caused by
particles flying around!
equipment (safety gloves, protec-
tive working clothes, goggles).
7. Blow the air filter out with dry compressed

air (max. 2.1 bar (30 psi)) from inside to
outside by moving the gun up and down
inside the element, until it is free of dust.
Fig. 168
8. Examine the air filter with a torch for cracks
and holes in the paper bellows.
9. In case of damage replace the air filter and
the safety element.
Fig. 169
10. Slide the air filter carefully into the housing.
NOTICE!
– The dust discharge valve must
point vertically downwards.
– Make sure that the cover locks
engage correctly.
Fig. 170
11. Reassemble the housing cover.
BW 124 PDH-5 187

8.13.1.1 Replacing the safety element
NOTICE!
The safety element must not be
cleaned and should not be used
again after it has been removed.
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. 171
8.13.2 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 determined precisely.
After taking the engine into opera-
tion you should check for signs of
water and dirt initially every day.
188 BW 124 PDH-5


n Protective gloves
1. If the “water in fuel” warning light lights up
when starting or during operation, drain the
water from the fuel pre-filter immediately.
B-SYM-0011
2. Park the machine safely Ä Chapter 6.6
Fig. 172 „Parking the machine in secured condi-
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.
ð Once the water separator is empty, the
B-586-0308
warning light for water in fuel must go
Fig. 173 out.
6. Dispose of collected fluid in an environ-
mentally friendly way.
8.13.3 Adjusting the scrapers

1. Check adjustment and condition of scra-
pers, adjust or replace the teeth if neces-
sary.
2. In order to adjust the scrapers loosen the
fastening screws in the slots and push the
scrapers towards the drum, leaving a gap
between the drum and scraper of about
25 mm.
Fig. 174 3. Fasten the fastening screws again.
BW 124 PDH-5 189

8.13.4 Cleaning the machine

Clean the machine thoroughly at least once a
week.
If necessary, clean the machine daily
for example when used on highly cohesive
soils or cement.
Do not climb on the machine to clean it.
WARNING!
falling off the platform!
– Always ensure safe standing.

n Safety goggles
3. When cleaning with a high pressure
cleaner, do not subject electrical parts and
insulation material to the direct jet of water,
or cover them beforehand.
4. If necessary, clean the windows using a
telescopic rod.
190 BW 124 PDH-5

8.13.5 Draining the fuel tank sludge

2. Disconnect the hose at the connection
between the two fuel tanks and collect
around 5 litres of fuel.
3. Reattach the hose.
4. Dispose of fuel in an environmentally
friendly way.
B-586-0309
Fig. 175
8.13.6 Measures prior to extended shutdown period

8.13.6.1 Measures before shutting down
If the machine is shut down for a longer period
of time (e.g. winter season), the following work
must be carried out:
1. Clean the machine thoroughly.
2. Clean the water separator.
3. Fill the fuel tank with diesel fuel, to prevent
the formation of condensation water in the
tank.
4. Change engine oil and oil filter if the oil has
been changed more than 300 hours ago, or
if the oil is older than 12 months.
5. After shutting down store the machine
under cover in a dry and well ventilated
room.
6. Check the anti-freeze concentration and
the coolant level.
BW 124 PDH-5 191

7. Disconnect the ground strap from the bat-

tery (this avoids self-discharge caused by
closed-circuit consuming devices).
8.13.6.2 Battery service during prolonged machine downtimes
WARNING!
exploding gas mixture!
– Remove the plugs before starting
to recharge the battery.
– Ensure adequate ventilation.
hibited!
– Do not lay any tools or other
metal objects on the battery.
– Do not wear jewellery (watch,
bracelets, etc.) when working on
the battery.

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%.
192 BW 124 PDH-5

3. Recharge the battery immediately after an

open-circuit voltage of 12.25 V or less is
reached. Do not perform boost charging.
ð The open-circuit voltage of the battery
occurs approx. 10 hours after the last
charging process or one hour after the
last discharge.
4. Switch off the charging current before
removing the charging clamps.
5. After each charging process allow the bat-
tery to rest for one hour before taking it into
service.
6. For standstill periods of more than one
month you should always disconnect the
battery. Do not forget to perform regular
open-circuit voltage measurements.
8.13.6.3 Measures before restarting

1. Replace the fuel filter.
2. Replace the air filter.
3. Change engine oil and oil filter.
4. Check the coolant 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 cou-
plings.
7. Check the function of the electric system.
8. Check cables, hoses and lines for cracks
and leaks.
9. Start the engine and run it for 15 to 30
minutes with idle speed.
10. While the engine is running keep an eye on
the gauges for oil pressure and coolant
temperature.
BW 124 PDH-5 193

11. Check the oil levels.

12. Check the function of electric system,
steering and brakes.
13. Clean the machine thoroughly.
194 BW 124 PDH-5

Troubleshooting
9 Troubleshooting
BW 124 PDH-5 195

Troubleshooting – Preliminary remarks
9.1 Preliminary remarks

Malfunctions are frequently caused by incorrect
operation of the machine or insufficient mainte-
nance. Whenever a fault occurs you should
therefore thoroughly read these instructions on
correct operation and maintenance.
If you cannot locate the cause of a fault or rec-
tify it yourself by following the trouble shooting
chart, you should contact our customer service
department.
196 BW 124 PDH-5

Troubleshooting – Starting the engine with jump leads
9.2 Starting the engine with jump leads
NOTICE!
A wrong connection will cause
severe damage in the electric
system.
– Bridge the machine only with a
12 Volt auxiliary battery.
1. Connect the plus pole of the external bat-

tery first with the plus pole of the vehicle
battery using the first jump lead.
2. Then connect the second battery cable first
to the minus pole of the current supplying
auxiliary battery and then to engine or
chassis ground, as far away from the bat-
tery as possible.
Fig. 176 3. Start the engine Ä Chapter 6.2 „Starting
the engine“ on page 97.
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

powerful consumer (working light, etc.).
5. After starting disconnect the negative poles
first and the positive poles after.
6. Switch off the consumer.
BW 124 PDH-5 197

Troubleshooting – Fuse assignment
9.3 Fuse assignment

9.3.1 Notes on safety
WARNING!
Danger of injury by fire in the
machine!
– Do not use fuses with higher
ampere ratings and do not bridge
fuses.
9.3.2 Central electrics

The central electrics are to the right of the driv-
er’s stand underneath the cover.
Fuse Amperage Designation

F03 10 A Vibration
F04 7.5 A Instrument cluster
F05 10 A 12-V socket
F11 15 A Working head lights, rear
F23 10 A Warning horn
F48 40 A Preheating system
F50 25 A BOMAG TELEMATIC (potential 30)
F68 10 A Reserve (potential 30)
F103 10 A Reserve (potential 15)
F119 10 A Engine control unit
F139 30 A Engine control unit
F153 10 A Control (potential 15)
F154 10 A BOMAG TELEMATIC (potential 30)
F156 15 A Working head lights, front
F157 30 A Starter
198 BW 124 PDH-5

Troubleshooting – Fuse assignment

F158 5A BOMAG TELEMATIC (potential 30)
F241 15 A Optional headlights
F243 5A BOMAG TELEMATIC (potential 30)
F275 5A ECONOMIZER
9.3.3 Main fuse

The main fuse is located underneath the driv-
er's seat.
B-586-0398
Fig. 177

F00 80 A Main fuse for battery
BW 124 PDH-5 199

Troubleshooting – Engine faults
9.4 Engine faults

Fault Possible cause Remedy
Engine does Fuel tank empty Refuel, bleed the fuel system
not start Fuel filter clogged, in winter Change the fuel filter, use
due to paraffin separation winter fuel
Fuel lines leaking Check all line connections for
leaks and tighten the fittings,
bleed the fuel system
Battery not charged or not Tighten the terminal clamps
connected on the battery, check all cable
connections.
Starter defective Have examined by a spe-
cialist
Poor starting Battery power too low, ter- Check the battery charge
of engine or minal clamps loose or oxi- condition, clean the terminal
engine works dized causing the starter to clamps, tighten and cover
irregularly turn too slowly them with acid-free grease
with poor Fuel supply too low, fuel Replacing the fuel filter
power system clogged by paraffin Check all line connections for
separation during winter leaks and tighten the fittings,
bleed the fuel system
Use winter fuel in winter
Engine oil with wrong SAE Change the engine oil
viscosity class
Air filter dirty Clean, replace if necessary
Turbo charger defective Have examined by a spe-
cialist
Excessive Engine oil level too high Check, drain off if necessary
exhaust Air filter dirty Clean, replace if necessary
smoke
Poor compression because Have examined by a spe-
of burned or broken compres- cialist
sion rings
200 BW 124 PDH-5


Engine over- Cooling fins on radiator are Clean the cooling fins
heating, extremely dirty (the warning
engine must lamp for engine oil tempera-
be shut down ture lights)
immediately! 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 Use coolant with the speci-
high fied mixing ratio
Thermostat defective Check the thermostat,
replace if necessary
Interior parts of radiator cor- Clean or replace the radiator
roded
Insufficient cooling air supply Remove any clogging from
to the cooling fan the cooling air duct
Fan, radiator or radiator cap Have examined by a spe-
defective cialist
Engine has Engine oil level too low Check, fill up if necessary
insufficient
engine oil
pressure
(engine oil
pressure
warning lamp
lights)
BW 124 PDH-5 201


The charge Generator speed too low Check the generator belt for
control light tension, replace the belt if
lights during necessary
operation, the Generator or regulator defec- Have examined by a spe-
warning tive cialist
buzzer
sounds
202 BW 124 PDH-5

Troubleshooting – Trouble shooting ECONOMIZER
9.5 Trouble shooting ECONOMIZER

In case of a malfunction the LEDs will show a
fault code.
At first, the display (a) and the LED 10 flash
alternately for five seconds.
Then the four digits of the fault code are dis-
played in order via the LEDs 1 - 10 (e.g. 4777).
LED 10 corresponds to 0.
Please contact our Customer

Service with your fault codes.
Fig. 178
BW 124 PDH-5 203

Troubleshooting – Trouble shooting ECONOMIZER
204 BW 124 PDH-5

Disposal
10 Disposal
BW 124 PDH-5 205

Disposal – Final shut-down of machine
10.1 Final shut-down of machine

If the machine can no longer be used and
needs to be finally shut down you must carry
out the following work and have the machine
disassembled by an officially recognized spe-
cialist workshop.
WARNING!
and lubricants!

n Protective gloves
n Safety goggles
1. Remove the batteries and dispose of in
compliance with legal regulations.
2. Empty the fuel tank.
3. Drain the hydraulic oil tank.
4. Drain coolant from cooling system and
engine.
5. Drain off engine oil.
6. Drain off gear oil.
206 BW 124 PDH-5

List of special tools
11 List of special tools
BW 124 PDH-5 207

List of special tools
208 BW 124 PDH-5

Head Office/Hauptsitz
BOMAG
Hellerwald
D-56154 Boppard
Germany
Telefon: +49 6742 100-0
Fax: +49 6742 3090
e-mail: info@bomag.com
BOMAG BOMAG BOMAG

Niederlassung Berlin Niederlassung Boppard Niederlassung Chemnitz
Gewerbestraße 3 Hellerwald Querstraße 6
15366 Hoppegarten 56154 Boppard 09247 Chemnitz
GERMANY GERMANY GERMANY
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BW 124 pdh5 Manual

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BW 124 pdh5 Manual

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Operating Instruction

S/N 101 586 85 1001>

Single drum roller

008 202 90 EN © 01/2019

Always start and operate the engine in a well-ventilated area.

For more information go to www.P65warnings.ca.gov/diesel.

WARNING: Crude oil, gasoline, diesel fuel and other petroleum

For more information go to www.P65Warnings.ca.gov/petroleum.

3.4.6 Safety regulations and environmental protection regulations for

4.1.3 Travel lever.................................................................................. 77

6.8.3 Towing the machine................................................................... 112

8.8.5 Checking the oil level in the drive axle...................................... 149

8.12.2 Cleaning the DPF.................................................................... 184

A description of all necessary maintenance

1.2 Machine type plate and engine type plate

Fig. 1: Machine type plate

Please enter here:

Fig. 2: Engine type plate

2.1 Noise and vibration data

2.1.1 Noise data

Guaranteed sound LWA = 106 dB(A), determined acc. to ISO 3744

2.1.2 Vibration data

Hand-arm vibration The weighted effective acceleration value

3 Concerning your safety

3.1 Basic prerequisites

3.1.2 Explanation of signal words used:

Sections marked accordingly indi-

3.1.3 Personal protective equipment

Protective gloves To protect the hands against excoria-

Face protection To protect the face against airborne par-

Hard hat To protect the head against falling parts

Hearing protection To protect hearing against excessive

Respiratory protection To protect respiratory tracts against sub-

3.1.4 Intended use

3.1.5 Improper use

Examples of improper use are:

3.2 Definition of responsible persons

3.2.2 Expert / qualified person

This person is acquainted with the applicable

3.2.3 Driver / operator

3.3 Fundamentals for safe operation

3.3.2 Regular safety inspections

3.3.3 Modifications and alterations to the machine

We wish to make explicitly clear that we have

3.3.4 Damage, defects, misuse of safety devices

3.3.5 Roll Over Protective Structure (ROPS)

On machines with cab the ROPS is

The frame of the machine must not be warped,

A defect ROPS must generally be replaced

3.4 Handling fuels and lubricants

3.4.2 Safety regulations and environmental protection regula-

3.4.3 Safety regulations and environmental protection regula-

– Immediately bind spilled oil with

3.4.4 Safety regulations and environmental protection regula-

Should pressure fluid penetrate the

3.4.5 Safety regulations and environmental protection regula-

– Immediately bind spilled coolant

3.4.6 Safety regulations and environmental protection regula-

Rinse acid off clothes, skin or eyes

3.5 Load/transport the machine

After the transport loosen the articulation lock

3.6 Starting up the machine

If the tests reveal damages or other defects,