BOMAG BW 125 ADH BW 135 AD BW138 AD BW138 AC SINGLE STANDEM VIBRATORY ROLLER OPERATING MAINTENANCE M

Operating instructions Maintenance instructions BW 125 ADH / BW 135 AD BW 138 AD / BW 138 AC S/N 101 650 12.... > S/N 101 170 21....> S/N 101 650 14 .... > S/N 101 650 15 .... >

Tandem Vibratory Roller Combination Roller

Catalogue number

008 138 01

04/2004

Foreword

BOMAG machines are products from the wide range of BOMAG compaction equipment.

F oreword

BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your machine.

You should only operate the machine after you have been instructed and in compliance with these instructions.

Strictly observe the safety regulations.

Please observe also the guidelines of the Civil Engineering Liability Association ”Safety Rules for the Operation of Road Rollers and Soil Compactors” and all relevant accident prevention regulations.

This manual comprises: l

Safety regulations

l

Operating instructions

l

Maintenance instructions

l

Trouble shooting

For your own personal safety you should only use original spare parts from BOMAG. 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.

Using these instructions will l

help you to become familiar with the machine.

l

avoid malfunctions caused by unprofessional operation.

Compliance with the maintenance instructions will l

enhance the reliability of the machine on construction sites,

l

prolong the lifetime of the machine,

l

reduce repair costs and downtimes.

BOMAG will not assume liability for the function of the machine l

if it is handled in a way that does not comply with the usual modes of use,

l

if it is used for purposes other than the ones it is intended for, see safety regulations.

Furthermore, the spare parts catalogue is available from your BOMAG dealer against the serial number of your machine.

Your BOMAG dealer will also supply you with information about the correct use of our machines in soil and asphalt construction.

The above notes do not constitute an extension of the warranty and liability conditions specified in the general terms of business of BOMAG. We wish you successful work with your BOMAG machine.

BOMAG GmbH Printed in Germany Copyright by BOMAG

No warranty claims can be lodged in case of damage resulting from l

operating errors,

l

insufficient maintenance and

l

wrong fuels and lubricants.

Please note!

This manual was written for operators and maintenance personnel on construction sites.

Always keep this manual close at hand, e.g. in the tool compartment of the machine or in a specially provided container. These operating and maintenance instructions are part of the machine.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

3

Foreword

Please fill in ............................

Machine type (Fig. 1) ............................

Serial-number (Fig. 1 and 2) ............................

Engine type (Fig. 3) ............................

Engine number (Fig. 3)

i

Note

Fig. 1

Supplement the above data together with the commissioning protocol.

During commissioning our organisation will instruct you in the operation and maintenance of the machine.

Please observe strictly the safety regulations and all notes on risks and dangers!

Fig. 2

Fig. 3

4

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Table of Contents

Technical Data

7

Safety regulations

15

Indicators and Controls

23

3.1 General notes

27

3.2 Description of indicators and control elements

27

Operation

35 4.1 General notes

36

4.2 Inspections before starting operation

36

4.3 Starting the engine

37

4.4 Starting with jump wires

39

4.5 Driving the machine

39

4.6 Stopping the machine / applying the brake

41

4.7 Switching the vibration on and off

41

4.8 Switching the vibration on or off

43

4.9 Switching the pressure sprinkler system on or off

44

4.10 Stopping the engine/machine

45

4.11 Adjusting the driver's seat

46

4.12 Towing

46

4.13 Loading and transport

48

4.14 Foldable roll over protection structure (ROPS)

49

Maintenance

51 5.1 General notes on maintenance

52

5.2 Fuels and lubricants

53

5.3 Table of fuels and lubricants

55

5.4 Running-in instructions

56

5.5 Maintenance chart

57

5.6 Check the engine oil level

59

5.7 Checking the dry air filter

59

5.8 Checking the hydraulic oil level

60

5.9 Checking the hydraulic oil filter element

60

5.10 Checking the fuel level

61

5.11 Checking the water level

61

5.12 Checking the emulsion oil level

62

5.13 Lubricating the articulated joint

62

5.14 Cleaning cooling fins and engine oil cooler

63

5.15 Cleaning the hydraulic oil cooler

64

5.16 Adjusting the scrapers

64

5.17 Checking the battery condition, greasing the poles

65

5.18 Draining the slurry from the fuel tank

66

5.19 Changing the engine oil

67

5.20 Change the engine oil filter cartridge

68

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

5

Table of Contents

5.21 Check, adjust the valve clearance

68

5.22 Checking, tensioning, changing the V-belt

70

5.23 Changing the fuel pre-filter

71

5.24 Change the fuel filter cartridge

72

5.25 Changing the hydraulic oil

73

5.26 Changing the hydraulic oil filter element

74

5.27 Checking the injection valves

75

5.28 Replacing the toothed belt

76

5.29 Checking the tire pressure

77

5.30 Cleaning, changing the dry air filter

77

5.31 Cleaning the water tank

78

5.32 Water sprinkler system, maintenance in the event of frost

79

5.33 Engine conservation

79

5.34 Tightening torques for screws with metric unified thread

80

Trouble shooting

6

81 6.1 General notes

82

6.2 Engine problems

83

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

1 Technical Data

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

7

Technical Data

Fig. 4

Dimensions in mm

A

B

C

D

H

H2

K

L

O

S

W

BW 125 ADH

1790

1280

650

800

1900

2700

320

2590

40

17,0

1200

BW 135 AD

1790

1380

650

800

1900

2700

320

2590

40

17,0

1300

BW 138 AD

1790

1460

650

810

1905

2705

325

2600

40

22

1380

*

Weights Operating weight (CECE) Mean axle load (CECE) Mean static linear load (CECE) Dimensions Oscillation angle Inner track radius

8

BW 125 ADH

BW 135 AD

BW 138 AD

kg kg kg/cm

3360 1680 14

3560 1780 13,7

4200 2100 15,2

+/-° mm

13 3700

13 3650

13 3610

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Technical Data

*

Travel characteristics Travel speed I Travel speed II Max. gradability/with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Fixed engine speed 1 Fixed engine speed 2 Fuel tank capacity Electrical equipment Drive system Driven axles

Vibration system Drive system Frequency Amplitude Vibrating drum Water sprinkler system Type of sprinkling Interval control Water tank capacity *

BW 135 AD

BW 138 AD

0...5,0 0...10 40/30

0...5,0 0...10 40/30

0...5,0 0...10 40/30

Deutz F3L 2011 Air-oil 3 34 2800 2200 2700 55 12 hydrost. front+rear

Deutz F3L 2011 Air-oil 3 34 2800 2200 2700 55 12 hydrost. front+rear

Deutz F3L 2011 Air-oil 3 34 2800 2500 2800 55 12 hydrost. front+rear

hydrost. hydr.-mech.

hydrost. hydr.-mech.

hydrost. hydr.-mech.

Oscill.-articul. hydrost.

25

Oscill.-articul. hydrost.

25

Oscill.-articul. hydrost.

25

hydrost.

50/60 0,45 front+rear

hydrost.

50/60 0,40 front+rear

hydrost.

46/52 0,50 front+rear

Pressure Standard 230

Pressure Standard 230

Pressure Standard 230

km/h km/h %

kW rpm rpm rpm l V

Brakes Service brake Parking brake Steering Type of steering Steering operation Steering angle +/-

BW 125 ADH

Degree

Hz mm

l

The right for technical modifications remains reserved

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

9

Technical Data

The following noise and vibration values according to the EC-directive for machines, edition (98/37/ EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with the vibration switched on. The machine was standing on an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level on the operator’s stand: BW 125 ADH LpA =79 dB(A) BW 135 AD LpA =83,5 dB(A) BW 138 AD LpA =86 dB(A) The nose emission value for the machine according to the noise emission regulation 2000/14/EG is guaranteed sound capacity level of the machine: BW 125 ADH LWA = 107 dB(A) BW 135 AD LWA = 107 dB(A) BW 138 AD LWA = 104 dB(A) These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO 11204 for sound pressure level (LpA) at the place of the operator.

Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire boy (driverâ&#x20AC;&#x2122;s seat) The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2.

Hand-arm vibration values The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2.

10

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Technical Data

Fig. 5

Dimensions in mm

A

B

C

D

H

H2

K

L

O

S

W

BW 138 AC

1790

1460

650

810

1905

2705

325

2580

40

22

1380

*

Weights Operating weight (CECE) Axle load, drum (CECE) Axle load, wheels (CECE) Mean static linear load Dimensions Oscillation angle Inner track radius

BW 125 ADH/ BW 135AD/138 AD/AC

BW 138 AC

kg kg kg kg/cm

4000 2050 1950 14,9

+/-° mm

13 3610

BOMAG

11

Technical Data

*

BW 138 AC

Travel characteristics Travel speed I Travel speed II Max. gradability/with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Fixed engine speed 1 Fixed engine speed 2 Fuel tank capacity Electrical equipment Drive system Driven axles

km/h km/h %

0...5,0 0...10 40/30

Deutz F3L 2011 Air-oil 3 34 2800 2250 2800 55 12 hydrostatic front+rear

kW rpm rpm rpm l V

Tires Number of tires Tire size

4 225/75 R16

Brakes Service brake Parking brake

hydrost. hydr.-mech.

Steering Type of steering Steering operation Steering angle +/Vibration system Drive system Frequency Amplitude Vibrating drum Water sprinkler system Type of sprinkling Interval control Water tank capacity Emulsion tank capacity *

12

Oscill.-articul. hydrost.

25

Degree

hydrost.

46/52 0,5 front

Hz mm

Pressure Standard 230 20

l l

The right for technical modifications remains reserved

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Technical Data

The following noise and vibration values according to the EC-directive for machines, edition (98/37/ EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with the vibration switched on. The machine was standing on an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level on the operatorâ&#x20AC;&#x2122;s stand: BW 138 AC LpA =81 dB(A) The nose emission value for the machine according to the noise emission regulation 2000/14/EG is guaranteed sound capacity level of the machine: BW 138 AC LWA = 102 dB(A) These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO 11204 for sound pressure level (LpA) at the place of the operator.

Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire boy (driverâ&#x20AC;&#x2122;s seat) The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2.

Hand-arm vibration values The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

13

Technical Data

14

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

2 Safety regulations

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

15

Safety regulations

General Notes

Unintended use

This BOMAG machine has been built in accordance 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:

However, dangers may arise from this machine if it is operated by untrained personnel or if it is subject of unintended use.

l

it is used for purposes other than the ones it is intended for

l

it is operated by untrained personnel

l

it is changed or converted in an unprofessional way

l

Each person involved in the operation, maintenance and repair of the machine must therefore read and comply with these safety regulations. If necessary, this must be confirmed by obtaining the signature of the customer.

Furthermore, the following instructions and regulations must obviously also be complied with: l

applicable accident prevention instructions

l

generally accepted safety and road traffic regulations

l

country specific safety regulations. It is the duty of the operator to be acquainted with these instructions and to apply these accordingly. This applies also for local regulations concerning different types of handling work.

Should the recommendations in these instructions be different from the regulations valid in your country, you must comply with the safety regulations valid in your country.

This machine must only be used for: l

compaction of bituminous material, e.g. road surface layers. (Only AC and AD machines)

l

medium to heavy compaction work in earth construction (road sub-bases)

l

You should only operate the unit with fully functional safety equipment.

l

Have the machine inspected by an expert once every year.

16

Starting and operation of the machine in explosive environments is prohibited.

Who has permission to operate the machine?

the safety instructions are not observed

Intended use

Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground.

Only trained and instructed persons of at least 18 years of age are permitted to drive and operate this machine. For operation of the machine the responsibilities must be clearly specified and complied with.

Persons under the influence of alcohol, medicine or drugs are not allowed to operate, service or repair the machine.

Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists.

Conversions and changes to the machine Unauthorized alterations to the machine are prohibited for safety reasons.

Original parts and accessories have been specially designed for this machine. We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive driving safety. The manufacturer explicitly excludes any liability for damage caused by the use of non-original parts or accessories.

Notes on safety in the operating and maintenance instructions: Danger Paragraphs marked like this highlight possible dangers for persons. !

Caution Paragraphs marked like this highlight possible dangers for machines or parts of the machine. !

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Safety regulations

i

Checking the roll over protection structure (ROPS)

Note

Paragraphs marked like this contain technical information for the optimal economical use of the machine.

The frame of the machine must not be warped, bent or cracked in the area of the ROPS fastening.

Environment Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.

Observe environmental regulations.

Information and safety stickers/decals on the machine Keep safety stickers in good and legible condition (see parts manual) and comply with their meaning.

The ROPS must not show any rust, damage, hairline cracks or open fractures.

The ROPS must not rattle about when driving.

This would indicate that it is not properly fastened.

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.

No accessories may be welded or bolted on and no additional holes must be drilled without the consent of the distributor, since this will impair the strength of the unit.

Replace damaged and illegible stickers/decals.

Starting the machine Loading the machine

Before starting

Use only strong and stable loading ramps of sufficient load bearing capacity. The ramp inclination must be less than the gradability of the machine.

Secure the machine against tipping or slipping off.

Secure the machine on the transport vehicle against rolling, slipping and turning over.

The machine must only be operated from the driver's seat.

Use only machines which are serviced at regular intervals.

Become acquainted with the equipment, the control elements, the working principle of the machine and the working area.

Persons are highly endangered when l

they step or stand under loads being lifted

l

they remain in the drive range of the machine during an instruction and during loading.

Wear your personal protective outfit (hard hat, safety boots, etc.).

Before climbing on the machine check whether:

The machine must not swing about when being lifted.

l

persons or obstructions are beside or under the machine

Use only safe lifting gear of sufficient load bearing capacity.

l

the machine is free of oily and combustible material

Fasten the lifting gear only at the specified lifting points.

l

all grips, steps and platforms are free of grease, oils, fuel, dirt, snow and ice

l

the engine hood is closed and locked

Towing the machine You should generally use a tow bar.

Max. towing speed 1 km/h, max. towing distance 500 m.

Before releasing the multi-disc brake secure the machine against unintended rolling.

BW 125 ADH/ BW 135AD/138 AD/AC

Use steps and grips to climb onto the machine.

Before starting the machine check whether: l

the machine shows any obvious faults

l

all guards and safety elements are in place

l

steering, brakes, control elements, light system and warning horn work correctly

BOMAG

17

Safety regulations

l

the seat is correctly adjusted

l

mirrors (if present) are clean and correctly adjusted.

Do not start the machine with defective gauges, control lights or control elements.

not use the emergency stop switch as service brake.

Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.

If the engine oil pressure control light lights up stop the engine immediately.

Do not take any loose objects with you or fasten them to the machine.

If the machine has contacted high-voltage power lines:

On machines with roll over protection system you must always wear your seat belt.

l

Do not leave the operator's platform

l

Warn others from coming close to or touching the machine

l

if possible drive the machine out of the danger zone

l

Have the electric power switched off

Starting Start and operate the machine only from the driver's seat.

For starting set all control levers to 'neutral position'.

Do not use any starting aids like start pilot or ether.

After starting check all gauges and control lights.

Operate the machine only from the operator's stand.

Starting with jump wires

Keep the cabin doors closed.

Connect plus with plus and minus with minus (ground cable) - always connect the ground strap last and disconnect it first! A wrong connection will cause severe damage in the electric system.

Do not adjust the driver's seat while driving.

Do not climb onto or off the machine while the machine is driving.

Do not start the engine by shorting the electric terminals on the starter motor, because the machine may start to drive immediately.

Starting in closed rooms Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!

Do not use the machine to transport persons.

In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected.

Always keep a sufficient distance to excavation walls and embankments and do not use working methods that could impair the stability of the machine.

Driving the machine

Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground.

Persons in the danger area

Always keep a sufficient distance when passing through subways, under bridges, tunnels, electric power lines etc.

Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions, especially when driving in reverse.

Driving on inclinations and slopes

If necessary give warning signals. Stop work immediately if persons remain in the danger zone, despite the warning.

Do not drive on gradients exceeding the maximum gradability of the machine.

On slopes drive extremely carefully and always directly up or down the slope. Change to a lower gear before starting to drive.

Do not step or stand in the articulation area of the machine when the engine is running. Danger of squashing!

Driving In events of emergency and in case of danger actuate the emergency stop switch immediately. Do

18

Change the travel direction only at standstill.

Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes. Higher risk of accident!

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Safety regulations

Leaking fuel tanks can cause explosions. Ensure tight fit of the fuel tank cover, if necessary replace immediately.

Behaviour in traffic Match the speeds to the working conditions.

Always allow loaded transport vehicles to pass.

Switch the lights on if the visibility is poor.

Fire protection measures

Keep away from edges and embankments.

Familiarise yourself with the location and the operation of fire fighting equipment. Observe all fire reporting and fire fighting possibilities.

Check the effect of 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) and stop compaction work with vibration, if necessary.

Do not switch the vibration on when working on hard (frozen, concrete) ground. Danger of bearing damage!

Maintenance work Comply with the maintenance work described in the operating and maintenance instructions, including the information concerning the replacement of parts.

Maintenance work must only be performed by qualified and authorized persons.

For overhead maintenance and assembly work use the access steps and working platforms provided or other secure means. Do not use machine parts as access steps.

Parking the machine Park the machine on level and firm ground.

Before leaving the machine:

Keep unauthorized persons away from the machine.

l

return the control lever to neutral position

l

apply the parking brake

l

shut the engine down and pull the ignition key out

l

lock the cabin door

Park the machine on horizontal, level and firm ground.

l

secure the machine against unintended use.

Pull the key out of the ignition switch.

Do not perform maintenance work while the machine is driving or the engine is running.

Do not jump off the machine, but use access steps and grips.

Secure the articulated joint with the articulation lock.

Mark machines, which could be in the way, with a clearly visible sign.

Working on hydraulic lines

Parking on slopes and inclinations Secure the machine against rolling, place metal chocks in front of and behind the drums.

Filling the fuel tank Do not inhale any fuel fumes.

Refuel only with the engine stopped and the auxiliary heater switched off.

Do not refuel in closed rooms.

Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. When being injured by hydraulic oil consult a medical doctor immediately, as otherwise this may cause severe infections.

Do not step in front of or behind the drums/rubber wheels when performing adjustment work in the hydraulic system.

Do not change the setting of pressure relief valves.

No open fire, do not smoke.

Drain hydraulic oil at operating temperature - danger of scalding!

Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.

Catch running out hydraulic oil and dispose of environmentally.

Wipe off spilled fuel. Keep dirt and water away from the fuel.

Always catch and dispose of biodegradable hydraulic oils separately.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

19

Safety regulations

Do not start the engine after draining the hydraulic oil.

Do not leave any tools or other objects, that could cause damage, in the engine compartment.

Once all work is completed (with the system still depressurized!) check all connections and fittings for leaks.

Working on electric components Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.

Changing hydraulic hoses Hydraulic hoses must be visually inspected at regular intervals.

Hydraulic hoses must be immediately replaced if: l

the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks)

l

the outer layer is brittle (formation of cracks in the hose material)

l

Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fire hazard!

Before starting welding work on the machine disconnect the battery.

Working on the battery When working on the battery do not smoke, do not use open

the hose shows deformations in pressurized and depressurized condition, which do not comply with the genuine shape of the hydraulic hose

Do not let acid come in contact with hands or clothes! When injured by acid flush off with clear water and seek medical advice.

l

the hose shows deformations in bends, e.g. squeezing, buckling, layer separation, formation of blisters

Metal objects (e.g. tools, rings, watch straps) must not come in contact with the battery poles - danger of short circuit and burning!

l

leakages.

l

incorrect installation.

When recharging serviceable batteries remove all plugs, to avoid the accumulation of explosive gases.

l

the hydraulic hose has separated from the fitting

l

mixing up of hoses by mistake.

l

the fitting shows corrosion that impairs both function and strength.

l

Observe the applicable instructions when starting with an auxiliary battery.

Dispose of old batteries in accordance with valid regulations.

Switch off the charging current before removing the charging clamps.

fittings are damaged or deformed, whereby the function and strength of the hose/hose connection is impaired.

Ensure sufficient ventilation, especially if the battery is to be charged in a closed room.

Only genuine BOMAG replacement hydraulic hoses ensure that the correct hose type (pressure range) is used at the right location.

Working on the engine Shut the engine down before opening the engine hood.

Drain the engine oil at operating temperature danger of scalding!

Working on the fuel system Do not inhale any fuel fumes.

No open fire, do not smoke, do not spill any fuel.

Catch running out fuel, do not let it seep into the ground and dispose of environmentally.

Working on wheels and tires

Wipe off spilled oil, catch running out oil and dispose of environmentally.

Explosion-like bursting of tires or parts of tires and rims can cause most severe or even deadly injuries.

Store used filters and other oil contaminated materials in a separate, specially marked container and dispose of environmentally.

Assembly of tires must only be performed with appropriate experience and tools. If necessary have tires assembled in a qualified workshop.

20

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Safety regulations

Always ensure the correct tire pressure and do not exceed the specified maximum pressure.

Check tires and wheels every day for specified pressure, cuts, bulges, damaged rims, missing wheel studs or nuts. Do not drive with damaged tires or wheels.

Anti-sticking emulsions for tires must only consist of water and anti-sticking agent, in a concentration in accordance with the specifications of the manufacturer of the anti-sticking agent. Observe applicable environmental regulations.

Cleaning work Do not clean the machine while the engine is running.

Do not use gasoline or other inflammable substances for cleaning.

When cleaning with steam cleaning equipment do not subject electrical parts and insulation material to the direct jet of water, or cover it beforehand.

Do not guide the water jet into the exhaust and into the air filter.

After maintenance work After completion of maintenance work reinstall all guards and safety features.

Repair Mark a defective machine by attaching a warning tag to the steering wheel.

Repair work must only be performed by qualified and authorized persons. Use our repair instructions for this work.

Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!

Test The safety of compaction equipment must be checked by a specialist as required in dependence on the application and the operating conditions, however at least once every year.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

21

Safety regulations

22

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

3 Indicators and Controls

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

23

Indicators and Controls

Fig. 6

24

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Indicators and Controls

Fig. 7

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

25

Indicators and Controls

1

Hydraulic oil temperature control light

15 Momentary contact switch for edge cutter*

2

Oil pressure control light

16 Seat contact control light

3

Oil temperature control light

17 Throttle lever

4

Charge control light

18 Locking lever for throttle lever

5

Emergency stop push button

19 Travel lever / brake

6

Brake control light

20 Push button for vibration

7

Rotary switch for pressure sprinkler system

21 Ball valve, vibration (only AD)

8

Interval switch for pressure sprinkler system

22 Lever for transverse sliding seat adjustment

9

Rotary switch for lighting (STVZO)

*

10 Rotary switch for indicator light, with control light * 11 Rotary switch for hazard light system, with control light *

23 Foot switch for rubber tire sprinkling system (only BW 138 AC) or foot switch for flow divider on AD-machines* 24 Ball valve, brake releasing device (only AC) 25 Fuse box B, bottom

12 Push button for warning horn

26 Fuse box A, top

13 Rotary switch for working light

27 not used

14 Rotary switch for flashing beacon*

28 Ignition switch

*

26

Optional equipment

29 Operating hour meter, in engine compartment

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Indicators and Controls

3.1

General notes

3.2

Description of indicators and control elements

Please read this section thoroughly before operating this machine if you are not yet conversant with the indicators and control elements. All functions are described in detail hereunder.

Paragraph 4 "Operation" contains only concise descriptions of the individual operating steps.

Fig. 8

No. 1 = Hydraulic oil temperature control light lights up

= if the hydraulic oil overheats (the warning buzzer sounds at the same time), shut down the engine and perform trouble shooting.

No. 2 = Oil pressure control light lights up

= when switching the ignition on, in case of an engine oil pressure drop, shut the engine down immediately.

goes out

= after starting the engine

No. 3 = Oil temperature control light lights up

= if the engine overheats (the warning buzzer sounds at the same time), shut the engine down immediately.

No. 4 = Charge control light

BW 125 ADH/ BW 135AD/138 AD/AC

lights up

=

goes out

= after starting the engine

BOMAG

when switching the ignition on, in case of charge failures during operation, perform trouble shooting.

27

Indicators and Controls

goes out

= with travel lever in positions "I", "II" or "III".

Fig. 9

No. 5 = Emergency stop push button Fig. 11

Danger Danger of accident!

No. 7 = Rotary switch for pressure sprinkler system

Use only in events of emergency during operation.

Position "left"

Do not use as parking brake.

No. 8 = Interval switch for pressure sprinkler system

!

Position "right" = Sprinkling "ON"

Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.

turn clockwise Position "left"

The machine is braked immediately, the engine is shut down. actuate

switch off/unlock

= Sprinkling "OFF"

further positions

= press the button completely down, it automatically locks in fully pressed position.

= permanent sprinkling = various sprinkling intervals from 4...32 seconds, activation time always 5 seconds.

= Turn button clockwise. Restart the engine.

Fig. 12

No. 9 = Rotary switch for lighting (STVZO)* Position "left"

= Light off

Position "middle" = Parking light on

Fig. 10

No. 6 = Brake control lamp lights up

28

= with travel lever in position "0".

*

BOMAG

Optional equipment

BW 125 ADH/ BW 135AD/138 AD/AC

Indicators and Controls

Position "right" = Travel light and parking light on, with ignition switch 28 in position "I".

No. 10 = Rotary switch for direction indicators with control light * Position "middle" = direction indicators off Position "left"

= direction indicator left,the control light in the rotary switch lights up.

Position "right" = direction indicator right,the control light in the rotary switch lights up.

No. 14 = Rotary switch for flashing beacon***

No. 11 = Rotary switch for hazard light with control light ** Position "left"

Fig. 14

Position "left"

= hazard light switched off

= Flashing beacon off

Position "right" = Flashing beacon on

Position "right" = hazard light switched on, the control lights in the rotary switches (10) and (11) light up.

No. 15 = Rotary key switch for edge cutter**** POsition "middle" = the edge cutter remains in the current position Position "left"

= the edge cutter is lifted up

Position "right" = the edge cutter is lowered down

Fig. 13

No. 12 = Push button for warning horn No. 13 = Rotary switch for work light Position "left"

= work light off

Position "right" = work light on with the ignition switch 28 in position "I".

Fig. 15

No. 16 = Seat contact control light* goes out

= when the driverâ&#x20AC;&#x2122;s seat is occupied.

lights up when the machine is at rest = when the driverâ&#x20AC;&#x2122;s seat is unoccupied. Drive operation is not possible. (The brake is closed). * **

Option Option

BW 125 ADH/ BW 135AD/138 AD/AC

*** Optional equipment **** Option

BOMAG

29

Indicators and Controls

i

Note

Standard design

pull

= the throttle lever can be moved

release

= the throttle lever will engage in position "I" and "II".

lights when the machine is driving = when the driverâ&#x20AC;&#x2122;s seat is unoccupied.

i

Note

Design with seat contact for engine shut-down lights when the machine is driving* = when the driverâ&#x20AC;&#x2122;s seat is unoccupied. Warning buzzer sounds. Engine is shut down after 8 seconds.

Fig. 17

No. 19 = Travel lever / brake Position "0"

= Neutral position for engine start, brake closed.

Position "I"

= Forward travel without vibration, brake is released.

Position "II"

= Backward travel without vibration, brake is released.

Position "III"

= max. forward/reverse travel with vibration, brake is released.

No. 20 = Push button for vibration press

Fig. 16

= to switch the vibration on or off

No. 17 = Throttle lever Position "0"

= Idle speed position, engine start.

Position "I"

= Full load position (2200 rpm), operating position for driving and vibration, BW125ADH and BW135AD. = Full load position (2500 rpm), operating position for driving and vibration, BW138 AD/AC.

Position "II"

= Full load position (2700 rpm), operating position for driving and vibration, BW125ADH and BW135AD. = Full load position (2850 rpm), operating position for driving and vibration, BW138 AD/AC.

Fig. 18

No. 21 = Cock valve for vibration (only AD) Position "I"

= vibration of both drums

Position "II"

= vibration of front drum only

No. 18 = Locking lever for throttlelever

30

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Indicators and Controls

Fig. 19

Fig. 21

Ball valve for 3-stage vibration*

No. 23 = Foot switch for tire sprinkler system (only AC)

Position upward

press

= sprinkling on.

release

= sprinkling off.

= Vibration of rear drum only

Position horizontal = Vibration of both drums Position downward = Vibration of front drum only

Fig. 22

Foot switch for flow divider* (only AD) Fig. 20

No. 22 = Lever for lateral seat adjustment pull

= to adjust the seat console to right or left

lock

= the seat console locks in the chosen position

!

press

= flow divider switched on

release

= flow divider switched off

Danger

Danger of accident!

Do not adjust the driver's seat while driving.

*

Optional equipment

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

31

Indicators and Controls

(2) 15A = (F12) working lights, right* (3) 15A = (F08) direction indicators* and working head lights (4) 15A = (F10) parking and tail light, right hand side* (5) 15A = (F09) parking and tail light, left hand side* (6) 15A = (F11) head lights, left* (7) 10A = (F142) seat contact (8) 10A = (F36) fault indicator No. 26 = Fuse box A, top Fig. 23

(1) 40A = (F01) Main fuse

No. 24 = Ball valve, brake releasing device (only AC-machines)

(2) 15A = (F06) sprinkler system (only AD **)

Position "I"

(3) 10A = (F41) flashing beacon * / backup alarm *

i

= Brake released

(4) 10A = (F45) edge cutter *

Note

Release brake by turning the steering wheel in clockwise direction.

Position "II"

= Brake applied

(5) 15A = (F27) wiper/washer, front* (6) 20A = (F141) hydraulic oil cooler (7) 10A = (F03) vibration (8) 15A = (F37) sprinkler pump

Danger Danger of accident! !

No. 27 = not used

Always secure with locking screw.

Fig. 25

No. 28 = Ignition switch Fig. 24

Position "0"/"P" = ignition off, key can be pulled out.

Position "I"

Danger Fire hazard! !

= ignition on, oil pressure control light (2) and charge control light (4) light up.

Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire.

No. 25 = Fuse box B, bottom (1) 15A = (F07) hazard light* 32

* **

BOMAG

Optional equipment Optional equipment

BW 125 ADH/ BW 135AD/138 AD/AC

Indicators and Controls

i

Note

For starting the driver's seat must be occupied and the emergency stop switch must be unlocked.

Position "II"

i

= turn further against spring pressure, start the engine. Release the ignition key, the control lights go out.

Note

The ignition switch is designed with a lock to prevent repetitive starting. For a new starting attempt the ignition key must first be turned back to position "0".

No. 29 = Operating hour meter, in engine compartment counts the operating hours while the engine is running All maintenance work must be performed according to the indicated operating hours.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

33

Indicators and Controls

34

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

4 Operation

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

35

Operation

4.1

General notes

Please read section 3 Indicators and Control Elements thoroughly before operating the machine if you are not yet fully familiar with the indicators and control elements of the machine.

All indicators and control elements are described in detail in this chapter.

4.2

Inspections before starting operation

Before the everyday use or before a longer working period the following tests and inspections must be performed.

Danger Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions. !

Park the machine on level ground.

l

Test: l

Check fuel tank and fuel lines for leaks

l

Screw connections

l

Function of steering

l

Function of parking brake

l

Machine for damage

i

Note

The following inspection work is described in chapter 'Maintenance every 10 Operating Hours'.

36

l

Engine oil level

l

Dry air filter service indicator

l

Hydraulic oil level

l

Fuel level

l

Water level in sprinkler system

l

Emulsion level

l

Tire pressure

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Operation

4.3

Starting the engine

Fasten/release your seat belt *.

!

Caution In this chapter it is assumed that the operator is fully acquainted with the functions of the various control elements on the machine.

Fig. 28

Fasten l

Press the releasing button 1 (Fig. 28), pull the seat belt vertically out of the retractor unit and press the tongue into the buckle on the right hand side of the driverâ&#x20AC;&#x2122;s seat.

Fig. 26

Always start the engine from the driverâ&#x20AC;&#x2122;s seat with seat contact switch (Fig. 26).

l

Open

Danger Danger of accident! !

Always wear your seat belt.

Fig. 29 l

Press the release button on the buckle and pull the tongue out.

l

Press the button 1 (Fig. 29) on the retractor unit until the seat belt is completely retracted.

Fig. 27 l

Fasten your seat belt (Fig. 27).

*

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

Optional equipment

37

Operation

Fig. 30 l

Shift travel lever 19 (Fig. 30) to position '0'. The brake is closed.

Fig. 33

Turn ignition key 28 (Fig. 33) to position "I".

Charge control light (4) and oil pressure warning light (2) light up.

l

i

Note

If the vibration starts to run in ignition switch position "II", press the vibration push button (20) to switch the vibration off. l

Then turn the ignition key further to position "II" to start the engine.

l

As soon as the engine is running turn the ignition key back to position "I", charge control light and oil pressure control light go out.

Fig. 31 l

Pull the locking lever 18 (Fig. 31) and shift the throttle lever (17) to position '0', idle speed.

i

Note

Run the engine warm for a short while before starting work.

Fig. 32 l

38

Check, whether the emergency stop switch (Fig. 32) is unlocked.

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Operation

4.4

Starting with jump wires

4.5 !

Driving the machine

Danger

Danger of accident!

Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes.

Soil conditions and weather influences impair the gradability of the machine.

Do not drive on gradients exceeding the maximum gradability of the machine.

Before starting to drive make sure that the drive range is absolutely safe.

Fig. 34

Always give way to loaded transport vehicles!

Caution A wrong connection will cause severe damage in the electric system. !

l

Only use a 12 Volt battery to bridge the machine.

l

When jump starting with an external battery connect both plus poles first.

l

Then connect the ground cable first to the minus pole of the current supplying battery and then to engine or chassis ground, as far away from the battery as possible (Fig. 34).

l

Start as described under 'Starting the engine'.

l

Once the engine is running switch on a powerful consumer (working light, etc.).

Fig. 35

i

Note

Seat contact control light (Fig. 35): !

Caution

goes out

If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components. l

After starting disconnect the negative poles (ground cable) first and the positive poles after.

l

Switch off the consumer.

= when the driverâ&#x20AC;&#x2122;s seat is occupied.

lights up when the machine is at rest = when the driverâ&#x20AC;&#x2122;s seat is unoccupied. Drive operation is not possible. (The brake is closed).

i

Note

Standard design

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

39

Operation

lights when the machine is driving = when the driverâ&#x20AC;&#x2122;s seat is unoccupied.

i

Note

Design with seat contact for engine shut-down* lights when the machine is driving* = when the driverâ&#x20AC;&#x2122;s seat is unoccupied. Warning buzzer sounds. Engine is shut down after 8 seconds.

Fig. 37

!

Caution

Do not operate jerkily! l

Shift the travel lever 19 (Fig. 37) slowly to the desired travel direction.

Position "I"

= max. forward travel without vibration

Position "II"

= max. backward travel without vibration

Position "III"

= Max. forward/backward travel with vibration.

Fig. 36

Pull locking lever 18 (Fig. 36) and shift throttle lever (17) to full load position "I" or "II".

l

Position "I"

= Full load position 2200 rpm, BW125ADH/BW135AD = Full load position 2500 rpm, BW138AD/AC

Position "II"

= Full load position 2700 rpm, BW125ADH/BW135AD = Full load position 2850 rpm, BW138AD/AC

i

Note

During operation the throttle lever always remains locked in one of the full load positions.

Control the travel speed with the travel lever.

*

40

Optional equipment

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Operation

4.6

Stopping the machine / applying the brake

4.7

!

Switching the vibration on and off

Danger

Risk of damage When compacting with vibration you must check the effect of nearby buildings and underground supply lines (gas, water, sewage, electric power), if necessary stop compaction with vibration.

Caution Danger of bearing damage! !

Do not activate the vibration on hard (frozen, concrete) ground.

Fig. 38 l

Move the travel lever 19 (Fig. 38) slowly to position "0". The machine is automatically braked by the hydrostatic drive. The brake closes.

i

Note

Activate the vibration only at full engine speed, with the throttle lever in full load positions "I" or "II" 17 (Fig. 41).

Vibration at standstill causes transverse ruts, therefore:

BW 125 ADH/ BW 135AD/138 AD/AC

l

switch the vibration on only after shifting the travel lever to the desired travel direction.

l

Switch the vibration off before stopping the machine.

BOMAG

41

Operation

Pre-selecting vibration (only AD)

Switch over only with the vibration switched off. l

Pre-select the desired drum or drums with the ball valve (Fig. 40).

Position upward

= Vibration of rear drum only

Position horizontal = Vibration of both drums Position downward = Vibration of front drum only

Switch the vibration on Fig. 39

!

Caution

Destruction of hydraulic components!

Switch over only with the vibration switched off.

Pre-select the desired drum or drums with ball valve 21 (Fig. 39).

l

Position "I"

= Vibration of both drums

Position "II"

= Vibration of front drum only Fig. 41

Pre-selecting vibration (3 stages, only AD)*

l

Pull up locking lever 18 (Fig. 41) and shift throttle lever (17) to full load position "I" (55 Hz) or "II" (66 Hz).

Fig. 40 Fig. 42

Caution Destruction of hydraulic components! !

*

42

l

Actuate vibration push button 20 (Fig. 42) only after shifting travel lever (19) to the desired travel direction.

Optional equipment

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Operation

i

Note

When shifting the travel lever through position "III" to position "I" or "II", the vibration will be automatically switched off.

4.8

i

Switching the vibration off l

Press push button (20) again.

Switching the vibration on or off

Note

Only AC-machines.

Fig. 43 l

BW 125 ADH/ BW 135AD/138 AD/AC

Press the foot switch 23 (Fig. 43).

press

= on.

release

= off.

BOMAG

43

Operation

4.9

Switching the pressure sprinkler system on or off

Fig. 46

To switch the sprinkler system on move the ztravel lever out of braking position towards "0"-position (Fig. 46).

l

Fig. 44 l

Position "I"

= open

Position "II"

= closed

Fig. 45 l

Operate the rotary switch for the pressure sprinkler system 7 (Fig. 45). = sprinkler system "OFF"

Position "I"

= sprinkler system "ON"

Set the interval switch (8) to the desired flow interval.

Position "A" Position "B"..."F"

44

Note

The sprinkler system will only work when the travel lever is in direction "0"-position. This is also the testing position.

Fig. 47

Position "0"

l

i

Open the shut-off cock valve (Fig. 44).

To switch the sprinkler system off return the travel lever to the position "brake closed" (Fig. 47).

l

i

Note

The brake control light must light up.

= permanent sprinkling = sprinkling intervals of 32, 24, 16, 8 and 4 seconds, sprinkling time always 5 seconds.

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Operation

i

4.10 Stopping the engine/machine

Note

Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization.

Fig. 48

Fig. 50 l

Danger Danger of accident! !

Turn the ignition switch 28 (Fig. 50) to position "0" and pull the ignition key out.

On particularly steep inclinations place wheel chocks in front of or behind the drum (Fig. 48).

Fig. 49 l

If necessary press the push button 20 (Fig. 49) in order to switch the vibration off.

l

Move the travel lever (19) slowly to position "0". The brake closes.

l

Pull the locking lever (18) and shift the throttle lever (17) to position "0" (idle speed).

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

45

Operation

4.11 Adjusting the driver's seat

4.12 Towing !

Danger

Danger of accident!

Secure the machine against unintended rolling.

Releasing the brakes on front and rear drums mechanically (only AD-machines)

Fig. 51

Danger Danger of accident! !

Do not adjust the driver's seat while driving. l

Disengage the lever 1 (Fig. 51) and adjust the seat in longitudinal direction.

l

Pull the lever (2) up and adjust the backrest.

l

Use lever (3) to adjust to the weight of the operator.

Fig. 52 l

i

Note

Take the brake releasing device 1 (Fig. 52) out of the access steps.

In this adjustment the lever (3) is locked in upwards direction. If a lighter driver's weight is to be adjusted, the lever must first be pressed down to the stop in order to release the lock. Then adjust again in downward direction.

Fig. 53 l

46

BOMAG

Unscrew the protective plug 6 (Fig. 53).

BW 125 ADH/ BW 135AD/138 AD/AC

Operation

l

Place the brake releasing device (1) across the travel motor housing (2) and turn the screw (3) into the tapped bore (4), until it bottoms.

l

Turn the nut (5) down and tighten it approx. 1 to 2 turns.

Towing the machine

Releasing the brakes on drum and rubber wheels (only AC-machines)

Fig. 55

!

Caution

Generally use a draw bar (Fig. 55), max. towing speed 1 km/h, max. towing distance 500 m.

Fig. 54 l

Unscrew locking screw 1 (Fig. 54).

l

Operate the cock valve.

Position "I"

= brake released

Position "II"

= brake closed

l

Turn the steering wheel slowly approx. two turns in clockwise direction.

Fig. 56

Tow the machine by the front and rear towing hooks 1 (Fig. 56).

l

After towing !

Danger

Remove the brake releasing device and press the protective plug back in (only AD-machines).

Reset the cock valve to position "II", turn the locking screw back in and counter it with the hexagon nut (only AC-machines).

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

47

Operation

4.13 Loading and transport !

Danger

Mortal danger!

Use only strong and stable loading ramps with sufficient load bearing capacity. Make sure that persons are not endangered by the machine tipping or sliding off.

Always use shackles on the lashing points for loading, lashing or lifting the machine.

Tie the machine down, so that it is secured against rolling, sliding and turning over.

Fig. 58 l

Do not stand or step under loads being lifted.

Tie the machine down on the transport vehicle, use the lifting hooks 1 (Fig. 58) on front and rear frame for this purpose.

Fig. 57 l

48

After driving the machine onto the transport vehicle swing the articulation lock 1 (Fig. 57) out of its receptacle and fasten it with the bolt (2) to the eye. Secure the bolt with the cotter pin.

Fig. 59 l

BOMAG

Use the four lifting eyes to lift the machine (Fig. 59).

BW 125 ADH/ BW 135AD/138 AD/AC

Operation

Loading weight: See technical data

After transport

4.14 Foldable roll over protection structure (ROPS) Split foldable roll over protection structure * (ROPS)

Fig. 60 l

Pull the bolt 2 (Fig. 60) out of the articulation lock and swash the locking rod (1) back into the bracket.

Fig. 61 l

Unscrew the bolts, fold the roll over protection structure down to transport position and fasten it again (Fig. 61).

l

The tools are stored in the engine compartment.

Danger Mortal danger! !

Operate the machine only with the ROPS folded up and the fastening screws tightened with the correct tightening torque.

*

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

Option

49

Operation

Fig. 62

Unscrew the bolts, fold the roll over protection structure up to operation position and fasten it again (Fig. 62).

l

Caution During assembly the screws must be tightened with the specified tighteneing toque! !

50

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

5 Maintenance

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

51

Maintenance

5.1

General notes on maintenance

l

Do not let the hose stir up the slurry at the bottom of the drum.

l

Do not draw off fuel from near the bottom of the drum.

l

The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.

When performing maintenance work always comply with the appropriate safety regulations.

Thorough maintenance of the machine guarantees higher functional safety of the unit and prolongs the lifetime of important components. The effort needed for this work is only little compared with the problems that may arise when not observing this rule.

The terms right/left correspond with travel direction forward.

Notes on the engine performance On diesel engines both combustion air quantity and fuel injection quantity are thoroughly adapted to each other and determine power, temperature level and exhaust gas quality of the engine.

l

Always clean machine and engine thoroughly before starting maintenance work.

If you engine has to work permanently in "thin air" (at higher altitudes) and under full load, you should consult the customer service of BOMAG or the customer service of the engine manufacturer.

l

For maintenance work stand the machine on level ground.

Notes on the hydraulic system

l

Perform maintenance work generally with the engine stopped.

l

Relieve hydraulic pressures before working on hydraulic lines.

l

Before working on electric parts of the machine disconnect the battery and cover it with insulation material.

l

When working in the area of the articulated joint attach the articulation lock (transport lock).

During maintenance work on the hydraulic system cleanliness is of major importance. Make sure that no dirt or other contaminating substances can enter into the system. Small particles can produce flutes in valves, cause pumps to seize, clog nozzles and pilot bores, thereby making expensive repairs inevitable. l

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.

l

Seal external leaks immediately. If necessary inform the responsible customer service.

l

Do not store drums with hydraulic oil outdoors, or at least under cover. Water can be drawn in through the bunghole when the weather changes.

l

Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.

Always use the filling and filtering unit (BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is fitted with a fine filter to clean the hydraulic oil, thereby prolonging the lifetime of the filter.

l

Drums with inside zinc lining are not suitable to store fuel.

Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.

l

Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.

Environment During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils and fuels environmentally.

Notes on the fuel system The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel. l

l

l

52

The fuel drum must rest for a longer period of time before drawing off fuel.

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Maintenance

5.2

fect the cold starting ability of the engine, but will not cause any engine damage.

Fuels and lubricants

Temperature related lubrication oil changes can be avoided by using multi-purpose oils. The following oil change intervals apply also when using multi-purpose oils.

Engine oil l

Use winter grade engine oil for winter operation!

In order to assure perfect cold starting it is import to chose the viscosity (SAE-class) of the engine oil according to the ambient temperature.

For winter operation below -10 째C the oil change intervals must be shortened.

Regular lubrication oil changes The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operating hours reached.

Oil quality You should preferably use oils of ACEA quality class E2-96, E3-96/E5-02, E4-99.

Oils of API-quality class CF/CF-4, CG-4/CH-4 may also be used.

Lubrication oil change intervals Oil change intervals with oil quality ACEA: E296, E3-96/ E5-02, E499 = 1000 operating hours API: CF/ CF-4, CG4/CH-4 = 1000 operating hours Caution These intervals apply only when using a diesel fuel with maximum 0.5 % sulphur by weight and for ambient temperatures higher than -10 째C. !

Fig. 63

Lubrication oil with a too high viscosity index causes starting difficulties. The temperature when starting the engine is therefore of highest importance when choosing the viscosity of engine oil for winter operation.

Oil viscosity Since lubrication 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 (SAEclass) (see diagram).

When using fuels with a sulphur content of more than 0.5% to 1% or under ambient temperatures below -10 째C the oil change intervals specified in the table must be halved. When using fuels with a sulphur content higher than 1% ... 1,5% the engine oil must have a TBN of approx. 12 x the S-content in % by weight if the service intervals are halved.

Occasional falling short of the temperature limit (e.g. use of SAE 15W/40 down to -15 째C) may ef-

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

53

Maintenance

type HV according to ISO 6743/3. The viscosity index (VI) must be at least 150. (Observe the information of the manufacturer).

Example aspirating engine: Use in tropical climate, fuel 0.8% sulphur, lubrication oil change every 250 operating hours.

l

Bio-degradable hydraulic oil

Lubrication oil quality classes

On request the hydraulic system can also be filled with ester based biodegradable hydraulic oil (Panolin HLP Synth. 46).

The ACEA- and the API-classifications are used to classify the oil quality.

The biologically degradable hydraulic oil meets all demands of a mineral oil based hydraulic oil according to DIN 51524.

The oil manufacturer is solely responsible for assigning a product to a certain quality class.

i

In hydraulic systems filled with Panolin HLP Synth.

46 always use the same oil to top up.

Note

When changing to a higher alloyed oil quality after a longer period of operation, it is recommended to perform the first oil change of the higher quality oil already after 20 operating hours. The lubrication oil filter cartridge must be changed at the same time.

When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details.

Check the filter more frequently after this change.

Fuels

Lubrication grease

Quality

For lubrication use only EP-high pressure grease, lithium saponified (penetration 2).

You should only use commercially available brand diesel fuel with a sulphur content below 0.5% and ensure strict cleanliness when filling in. A higher sulphur content has a negative effect on the oil change intervals. Use only winter-grade diesel fuel under low ambient temperatures. The fuel level should always be topped up in due time so that the fuel tank is never run dry, as otherwise filter and injection lines need to be bled.

The following fuel specifications are permitted: DIN 51601; Nato Codes: F-54, F-75; BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-D; VV-F-800 a: DF-A, DF-1 and DF-2.

Winter fuel For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.

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. For topping up or for oil changes use only high-quality hydraulic oil, type HVLP according to DIN 51524, part 3, or hydraulic oils

54

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Maintenance

5.3

Table of fuels and lubricants

Assembly

Fuel or lubricant Summer

Winter

Quantity approx.

Attention Observe the level marks

Engine

Engine oil ACEA: E2-96, E3-96/E5-02, E4-99;

6.0 litres (1.6 USgal)

API: CF/CF-4, CG-4/CH-4 SAE 10W/40 (-20 °C to +30 °C) SAE 15W/40 (-10 °C to +40 °C) SAE 30

SAE 10W

(+5 °C to +30 °C)

(-5 °C to -30 °C)

SAE 40

SAE 20W/20

(+25 °C to +40 °C)

(+10 °C to -10 °C) Fuel

Diesel Hydraulic system

Winter diesel fuel (down to -12 °C)*

Hydraulic oil (ISO), HV46, kinem. viscosity

55 litres (17.2 USgal) 30 litres (7.9 USgal)

46 mm2/s at 40 °C or ester based biodegradable hydraulic oil Sprinkler system

Water

Sprinkling of tires Articulated joint

Anti-freeze mixture water 230 litres (60.8 USgal) Emulsion

High pressure grease (lithium saponified)

20 litres (5.3 USgal) as required

*For lower temperatures refer to the mixing table in chapter 5.2

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

55

Maintenance

5.4

Running-in instructions

The following maintenance work must be performed when running in new machines or overhauled engines: !

Caution Up to approx. 200 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 200 operating hours.

After 50 operating hours

56

l

Check the fuel pre-filter cartridge

l

Check the engine for leaks

l

Check the valve clearance, adjust if necessary

l

Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts.

l

Retighten the bolted connections on the machine.

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Maintenance

5.5

Maintenance chart

With all maintenance intervals perform also the work for shorter preceding service intervals.

No.

Designation

Note

Every 10 operating hours 5.6 5.7 5.8 5.9 5.10 5.11

Check the engine oil level Checking the dry air filter Check the hydraulic oil level Checking the hydraulic oil filter element Check the fuel level Checking the water level in the sprinkler system

Observe the dipstick marks Observe the dipstick marks

Winter: Anti-freeze mixture

Every 50 operating hours 5.12 5.13

Checking the emulsion level Grease the articulated joint

High pressure grease

Every 250 operating hours 5.14 5.15 5.16

Clean cooling fins and engine oil cooler Cleaning the hydraulic oil cooler Adjust the scrapers

Every 500 operating hours 5.17 5.18

Service the battery Drain the sludge from the fuel tank

distilled water, pole grease

Every 1000 operating hours 5.19 5.20 5.21 5.22 5.23 5.24

Changing the engine oil (at least 1x per year)** Change the engine oil filter cartridge Checking the valve clearance Check the V-belt tension Change the fuel pre-filter cartridge Change the fuel filter cartridge

Observe the dipstick marks

Every 2000 operating hours 5.25 5.26

Change the hydraulic oil*** screen filter (at least after Observe the dipstick marks 2 years) Change the hydraulic oil filter element****

Every 3000 operating hours 5.27

Check the injection valves

Every 5000 operating hours

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

57

Maintenance

No.

Designation

Note

5.28

Replace toothed belts, timing belt and toothed belt for at the latest after 5 years hydraulic pump

As required 5.29 5.30 5.31 5.32 5.33 5.34

Checking the tire pressure Clean, change the dry air filter cartridge* Clean the water tank Maintenance in case of frost Engine conservation Observe the tightening torques

*At the latest after 1 years **With more than 1% sulphur in the fuel every 250 operating hours ***Also in case of repairs in the hydraulic system. ****At the latest after 2 years

58

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Every 10 operating hours

Every 10 operating hou rs

5.6

i

Check the engine oil level

5.7

Checking the dry air filter

Note

The machine must be in horizontal position.

Run the engine 2 minutes with idle speed and shut it down.

Fig. 65 l

If the red indicator 1 (Fig. 65) is visible with the engine shut down, clean the filter cartridge, refer to the section " maintenance as required".

l

Press the reset button (2), the red indicator will disappear.

Fig. 64

Pull the dipstick out, wipe it off with a lint-free, clean cloth and reinsert it until it bottoms.

l

l

Pull the dipstick back out again.

l

The oil level should reach the "MAX"-mark (Fig. 64).

l

If the oil level is too low top up oil immediately.

i

Caution If the red indicator appears again after starting the engine, you must change the filter cartridge and, if necessary, also the safety cartridge*. !

Note

For quality and quantity of oil refer to the â&#x20AC;?table of fuels, lubricants and filling capacitiesâ&#x20AC;?. l

Check the oil level again after running the engine for approx. 1 minute.

*

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

Option

59

Every 10 operating hours

5.8

Checking the hydraulic oil level

Fig. 66 l

Clean the area around the filler opening.

l

Remove the filler cap.

l

Check the hydraulic oil level on the oil dipstick.

The oil level must be between the "MIN" and "MAX" marks (Fig. 66).

If the oil is below this level top up hydraulic oil immediately.

l

i

5.9

Checking the hydraulic oil filter element

Fig. 67 l

Check the service indicator 1 (Fig. 67) at operating temperature and with the engine running at maximum speed.

l

If necessary press the pin in.

Pin remains depressed = hydraulic oil filter element ok.

Pin pops up

= replace the hydraulic oil filter element

Note

For quality and quantity of oil refer to the table of "fuels, lubricants and filling capacities".

In hydraulic systems filled with Panolin HLP Synth.

46 always use the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer.

i

Note

If the hydraulic oil is very cold the pin may pop up, you should therefore only check the filter and press the pin in at operating temperature.

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.

60

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Every 10 operating hours

5.10 Checking the fuel level !

5.11 Checking the water level

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke.

Do not refuel in closed rooms.

Fig. 69 l

Open the filler cap and check the water level.

l

Fill in water, as far as this is necessary (Fig. 69).

i

In the event of frost observe the special service instructions under "maintenance in the event of frost".

Fig. 68 l

Clean the area around the filler opening.

l

Open the fuel filler cap (Fig. 68) and check the fuel level visually.

l

Note

l

Close the filler cap.

If necessary top up with fuel (diesel or winter diesel), see table of fuels and lubricants.

!

Caution Fill in fuel through a screen filter.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

61

Every 50 operating hours

Every 50 oper ating hours

5.12 Checking the emulsion oil level

i

5.13 Lubricating the articulated joint

Note

Only AC-machines.

Fig. 71

Lubricate each grease nipple (Fig. 71) (2 per drum) with approx. 5 shots of high pressure grease from the grease gun.

l

Fig. 70 l

Clean the area around the filler opening.

l

Open the filler cap and check the emulsion level, top up if necessary (Fig. 70).

62

i

Note

For quality of grease refer to the table of "fuels, lubricants and filling capacities".

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Every 250 operating hours

l

If necessary repeat this procedure.

l

Reassemble the cooling air duct cover, run the engine warm for a while to avoid corrosion.

Every 250 oper ating hours

5.14 Cleaning cooling fins and engine oil cooler !

Danger

Danger of injury!

Perform cleaning work only with engine stopped and cooled down!

i

Note

Dirty operating conditions, particularly lubrication oil and fuel deposits on the cooling fins of the engine and the engine oil cooler have an adverse effect on the cooling of the engine. You should therefore immediately seal any oil or fuel leaks near cooling fan, cylinder or engine oil cooler and subsequently clean the cooling fins.

Fig. 72 l

Remove the cooling air duct cover.

l

Blow the cooler out with compressed air, starting from the air discharge side. Remove all dirt that has been blown into the air duct (Fig. 72).

l

In case of oily dirt spray the engine with a cold cleansing agent and let it soak in for about 10 minutes.

Caution Environmental damage! !

Catch running off fluids and dispose of environmentally. l

Clean the engine off with a water or steam jet (do not aim at sensitive engine components).

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

63

Every 250 operating hours

5.15 Cleaning the hydraulic oil cooler

5.16 Adjusting the scrapers

i !

Danger

Danger of injury!

Note

If the scrapers (2 per drum) are worn, they must be adjusted or replaced.

Perform cleaning work only with engine stopped and cooled down.

Fig. 74

Fig. 73

l

Open the flap 1 (Fig. 74).

l

Loosen the hexagon screws (2).

l

Remove dried on dirt from the hydraulic oil cooler using a suitable brush.

l

Adjust the scraper (3) so that it touches the drum lightly (slight bending of plastic insert).

l

Blow the cooling passages out with compressed air, starting from the air discharge side (Fig. 73).

l

Tighten the hexagon screws.

Fig. 75 l

64

BOMAG

Turn the screws 1 (Fig. 75) to adjust the scraper, that it has a uniform distance of approx. 2 mm to the rubber tires (only AC-machines).

BW 125 ADH/ BW 135AD/138 AD/AC

Every 500 operating hours

Every 500 oper ating hours

5.17 Checking the battery condition, greasing the poles

Caution Top up missing fluid with distilled water. !

Unscrew the plugs and check the acid level, if necessary top up with distilled water.

l

!

Danger

With control inserts

Danger of explosion, causticization!

When working on the battery do not use open fire, do not smoke!

Do not let acid come in contact with hands or clothes!

The acid level must reach the bottom of the control inserts.

Without control inserts The acid level must reach 10 to 15 mm above the upper edge of the lead plates.

Wear safety goggles.

Do not lay any tools on the battery!

i

For recharging remove the plugs from the battery to avoid an accumulation of highly explosive gases.

Caution Dispose of used batteries environmentally. !

Note

Measure the acid level with a clean wooden stick.

With transparent battery housing The acid level must reach the mark on the housing. l

Clean battery poles and pole clamps and grease them with pole grease (Vaseline).

l

Retighten the terminal clamps.

l

Check the fastening of the battery.

Fig. 76

Maintenance free batteries: l

Clean battery and battery compartment (Fig. 76).

l

Clean battery poles and pole clamps and grease them with pole grease (Vaseline).

l

Retighten the terminal clamps.

l

Check the fastening of the battery.

Serviceable batteries: l

Clean battery and battery compartment.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

65

Every 500 operating hours

5.18 Draining the slurry from the fuel tank !

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke.

Do not spill any fuel.

Catch running out fuel, do not let it seep into the ground.

i

Note

When performing this work the fuel tank shall only hold max. 1.5 litres of fuel, pump off if necessary.

Fig. 77 l

Unscrew the drain plug 1 (Fig. 77) from under the fuel tank and let the fuel run out.

l

Once all fuel has run out screw the oil drain plug back in with a new seal ring.

66

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Every 1000 operating hours

Every 1000 operating hours

5.19 Changing the engine oil !

Danger

Danger of scalding!

Danger of scalding when draining off hot engine oil! !

Caution

Environmental damage!

Catch old oil and dispose of environmentally.

i

Fig. 79 l

Fill in new engine oil (Fig. 79) through the oil filler neck.

l

Screw the cap back on again.

Note

Drain the engine oil only when the engine is warm.

The oil change after 500 operating hours refers to a fuel sulphur content < / - of 0.5%.

For other fuels the oil change intervals must be shortened accordingly. (See section 5.2, lubrication oil change intervals).

i

Note

For quality and quantity of oil refer to the â&#x20AC;?table of fuels, lubricants and filling capacitiesâ&#x20AC;?. l

Run the engine 2 minutes with idle speed and shut it down.

Fig. 78 l

Unscrew the oil filler cap (Fig. 79).

Fig. 80

l

Unscrew drain plug 1 (Fig. 78) and catch running out oil.

l

l

Turn the oil drain plug back in with a new seal ring.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

Check the oil level on the dipstick (Fig. 80).

The oil level must reach the "MAX"-mark, top up oil if necessary.

67

Every 1000 operating hours

5.20 Change the engine oil filter cartridge !

5.21 Check, adjust the valve clearance

Danger

!

Danger of scalding!

Caution

Perform inspection and adjustment work only when the engine is cold.

Danger of scalding by hot oil when unscrewing the engine oil filter.

Valve clearance: Intake valve 0.3 mm

Caution Environmental damage! !

Exhaust valve 0.5 mm

Catch the oil and dispose of environmentally together with the engine oil filter cartridge.

Fig. 82 l

Remove valve cover 1 (Fig. 82).

Fig. 81 l

Loosen and unscrew the engine oil filter cartridge (Fig. 81) using an appropriate filter wrench.

l

Wipe the sealing face on the engine clean.

l

Cover the rubber seal of the new filter cartridge slightly with clean oil.

l

Spin the new fuel filter cartridge on and tighten it hand tight.

l

Perform a short test run and inspect the engine for leaks and check the oil level, if necessary top up oil.

Fig. 83 l

68

BOMAG

Crank the engine by the front crankshaft end (Fig. 83) in direction of arrow,

BW 125 ADH/ BW 135AD/138 AD/AC

Every 1000 operating hours

Adjusting the valve clearance

Fig. 84

until both valves on cylinder 1 are "overlapping" (i.e. the exhaust valve is not yet closed, the inlet valve starts to open).

l

Fig. 86

Loosen counter nut 2 (Fig. 86) for 2 to .3 turns.

Adjust the setscrew (1) with a screwdriver, until the feeler gauge can be inserted and pulled out with little resistance after retightening the counter nut.

l

Check and, if necessary, adjust the valves marked black (Fig. 84).

l

i

Note

E = Intake valve

i

A = Exhaust valve

Note

As a control measure mark each adjusted valve with chalk.

Checking the valve clearance

Fig. 87 Fig. 85 l

l

l

A feeler gauge of appropriate thickness 2 (Fig. 85) must fit with little resistance between rocker arm (1) and valve (3).

Turn the crankshaft another revolution (360 Grad) further (for this purpose mark the flywheel or V-belt pulley with chalk).

l

If the gap is too narrow or too wide for the feeler gauge, the valve must be adjusted.

Check and, if necessary, adjust the valves marked black (Fig. 87).

l

Assemble the cylinder head cover with a new gasket.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

69

Every 1000 operating hours

i

Note

After a short test run check the engine for leaks.

5.22 Checking, tensioning, changing the V-belt Checking the V-belt

Fig. 88 l

Check the entire circumference of the V-belt for damage and cracks. Replace damaged or cracked V-belts.

l

Check with thumb pressure whether the V-belt can be depressed more than 10...0,15 mm between the V-belt pulleys, retighten if necessary (Fig. 88).

Tensioning the V-belt

Fig. 89

70

l

Slacken the hexagon screws 1 (Fig. 89).

l

Press the idling pulley (2) in direction "I", until the correct V-belt tension is achieved.

l

Tighten the hexagon screws again.

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Every 1000 operating hours

Changing the V-belt l

Slacken the hexagon screws 1 (Fig. 89).

l

Swivel the idling pulley (2) in direction "II".

l

Take the old V-belt off the V-belt pulley.

5.23 Changing the fuel pre-filter !

Install the new V-belt and tension it as described above.

l

i

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke.

Do not spill any fuel.

Note

Tension the new V-belt after a running time of approx. 30 minutes.

!

Caution Environmental damage!

Catch running out fuel, do not let it seep into the ground.

Fig. 90

BW 125 ADH/ BW 135AD/138 AD/AC

l

Loosen the hose clamps (Fig. 90).

l

Pull the fuel filter out of the hoses.

l

Install the new fuel filter by observing the flow direction (arrow).

BOMAG

71

Every 1000 operating hours

5.24 Change the fuel filter cartridge !

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke.

Caution Environmental damage! !

Catch running out fuel and dispose of environmentally together with the fuel filter!

Fig. 91 l

Loosen and unscrew fuel filter cartridge 1 (Fig. 91) using an appropriate filter wrench.

l

Clean the sealing face on the filter bowl.

l

Slightly oil the rubber seal on the new filter cartridge.

l

Spin on the new fuel filter cartridge and tighten it hand tight.

i

Note

The fuel system is self-bleeding.

72

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Every 2000 operating hours

pump the oil from the tank into a clean vessel or oil bag using the filling and filtering unit.

Every 2000 operating hours

5.25 Changing the hydraulic oil !

!

Danger

Catch the hydraulic oil and dispose of environmentally!

Danger of scalding!

Thoroughly clean the inside of the hydraulic oil tank.

l

!

Caution

Caution

Environmental damage!

Catch old oil and dispose of environmentally.

Do not start the engine after draining the hydraulic oil. Do not run the pumps without oil.

When changing from mineral oil based hydraulic oil to an ester based biodegradable oil, you should consult the lubrication oil service of the oil manufacturer for details.

i

Note

Apart from the normal oil change intervals, the hydraulic oil must also be changed after major repairs in the hydraulic system.

Fig. 93

The hydraulic oil filter element must be changed with every hydraulic oil change (see next chapter).

See also chapter 5.1 "Notes on the hydraulic system".

i

Note

We recommend to use a filtering unit with fine filter to fill in hydraulic oil.

l

Drive the machine, until the hydraulic oil has reached operating temperature.

l

Clean the area around the filler opening.

l

Fill in new engine oil (Fig. 93).

l

Open the filler cap (Fig. 93).

l

Screw the filler cap back on.

l

Check the hydraulic oil level on the oil dipstick.

The oil level must be between the "MIN" and "MAX" marks.

l

Perform a test run and check the system for leaks.

For quality and quantity of oil refer to the table of "fuels, lubricants and filling capacities".

Bleeding the hydraulic system l

Run the engine for about 3 minutes with low speed, this will bleed the hydraulic system.

Fig. 92 l

Unscrew the fastening screws (Fig. 92), remove the cover from the hydraulic oil tank and

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

73

Every 2000 operating hours

5.26 Changing the hydraulic oil filter element !

l

Run the engine for about 3 minutes with low speed, this will bleed the hydraulic system.

l

After a short test run check for leaks and press the rubber cap (5).

Danger

Danger of scalding!

Danger of scalding by hot oil when unscrewing the oil filter element.

Caution Environmental damage! !

Catch running out oil and dispose of environmentally.

Do not use the oil in the filter bowl again.

i

Note

Apart from the normal oil change intervals, the hydraulic oil must also be changed after major repairs in the hydraulic system.

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.

Fig. 94 l

Loosen the knurled nut 4 (Fig. 94) on the filter housing.

l

Take the filter bowl (3) off with the filter element.

l

Take the old filter element (2) out, clean the filter bowl.

l

Clean the thread on the filter bowl.

l

Assemble the filter bowl with a new filter element, check the condition of the seal rings (1).

74

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Every 3000 operating hours

Every 3000 operating hours

5.27 Checking the injection valves

i

Note

This work must only be performed by authorized service personnel.

The injection valves must be replaced every 12000 operating hours.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

75

Every 5000 operating hours

Every 5000 operating hour s

5.28 Replacing the toothed belt !

Caution The toothed belt must only be changed by a specialist workshop or by the After Sales Service of BOMAG.

Do not retension toothed belts, replace them together with the idler pulley.

Replace a toothed belt at the latest after 5 years, even if the number of operating hours has not yet been reached.

Fig. 95 l

76

Have the toothed belt (Fig. 95) replaced by a specialist workshop.

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

As required

As r equired

5.29 Checking the tire pressure

i

5.30 Cleaning, changing the dry air filter

Note

Only AC-machines.

Fig. 97

Dry air filter service is necessary if the message appears in the inspection glass 2 (Fig. 97) of the vacuum gauge (1), however, at the latest after one year.

l

Fig. 96

Check the tire pressure with a pressure gauge on the tire inflation valve (Fig. 96).

l

Nominal value: 2,2 bar (32 psi)

i

Note

Ensure equal pressure in all tires.

Caution Do not use gasoline or hot fluids to clean the filter element. !

After cleaning the filter element must be inspected with a torch for damage.

Dry air filter elements with damaged filter element or seal ring must be replaced in any case.

It is therefore recommended to keep at least one filter element in stock.

The dry air filter element must be changed after 5 times cleaning, but at the latest after 1 year. Each cleaning interval must be marked with a cross on the cover of the filter element.

Cleaning is useless if the air filter element is covered with a sooty deposit. Use a new filter cartridge.

Incorrectly handled inserts may be ineffective because of damage (e.g. cracks) and cause damage to the engine.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

77

As required

5.31 Cleaning the water tank

Fig. 98 l

Fold both clamps 1 (Fig. 98) back.

l

Take the filter cover (2) off, pull the filter element (3) out and clean it.

Fig. 99

l

Install the filter cartridge.

l

Unscrew the cover 1 (Fig. 99).

Reset the service indicator by pressing the reset button (4).

l

l

Flush the water tank out with a strong water jet.

l

Let all water with dirt run out.

l

Screw the cover back in.

l

Fill the water tank with clean water.

l

Pull the rubber caps off the sprinkler tubes.

l

Activate the sprinkler system for a short while so that all coarse dirt is flushed out of the lines.

l

Press the rubber caps back on.

Dry cleaning: l

Blow the filter cartridge out from inside to outside with dry compressed air (max. 5 bar).

Wet cleaning: l

78

Clean the filter cartridge by moving it to and fro in luke-warm water containing a commercial fine detergent. Then rinse it well in clear water, shake all water off and let it dry properly.

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

As required

5.32 Water sprinkler system, maintenance in the event of frost

5.33 Engine conservation If the engine is to be shut down for a longer period of time (e.g. over winter), we recommend the following engine conservation measures to avoid corrosion:

Caution If there is a risk of frost the water sprinkler system must be emptied or filled with an antifreeze mixture. !

l

l

Clean engine and cooling system: With cold cleansing agent and water jet or, even better, with steam cleaning equipment.

l

Run the engine warm and shut it down.

l

Drain the still warm engine oil and fill in anticorrosion engine oil.

l

Drain the fuel from the fuel tank, mix it well with 10% anti-corrosion oil and fill it back in. Instead of mixing the fuel with anti-corrosion oil you may also fill the tank with injection pump testing oil with anti-corrosive properties (e.g.

Calibration fluid B).

l

Then run the engine for 10 minutes, so that lines, filter, pump and nozzles are filled with the conserving mixture and the new engine oil is distributed to all parts.

l

After running the engine take the cylinder head cover off, spray the rocker chambers with a mixture of diesel fuel and 10% anti-corrosion oil. Then fasten the cover again.

l

Crank the engine several times without ignition in order to spray all combustion chambers.

l

Take the V-belt off and spray the grooves of the V-belt pulley with anti-corrosion oil. Remove the anti-corrosion oil before taking the machine back into service.

l

Close air intake on air filter and exhaust opening tightly.

Clean the water tank.

Fig. 100 l

Open drain tap 1 (Fig. 100) and drain off all water.

Position "0"

= Drain tap closed

Position "I"

= Drain tap open.

l

Switch the sprinkler system on and drain all water from the piping.

l

Fill the water tank with approx. 5 l of an antifreeze mixture (water and anti-freeze agent, e.g. glysantene).

l

Switch the sprinkler system on, until antifreeze mixture comes running out of the sprinkler tubes.

i

Note

Depending on weather conditions these conservation measures will protect the machine for approx.

6 to 12 months.

Before taking the machine back into service you must drain off the conservation oil and replace it with engine oil (see table of fuels and lubricants) according to API-(MIL-) classification.

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

79

As required

Anti-corrosion oils are all oils complying with the specification MIL-L-21260 B or TL 9150037/2 or Nato Code C640/642. !

5.34 Tightening torques for screws with metric unified thread

Caution

A machine with conserved engine must be clearly marked by attaching a clear warning label.

Fig. 101

* Strength classes for screws with untreated, nonlubricated surface. Screw quality designations are stamped on the screw heads.

8.8 = 8G 10.9 = 10K 12.9 = 12K The values result in a 90% utilization of the screw's yield point at a coefficient of friction Âľ total = 0,14.

Compliance with the tightening torque is checked with torque wrenches.

The specified tightening torques do not apply when using MoS2 lubricants.

i

Note

Self-locking nuts must always be replaced once they have been unscrewed.

80

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

6 Trouble shooting

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

81

Trouble shooting

6.1

General notes

The following work must only be carried out by qualified and trained personnel or by the BOMAG sales service.

Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions.

Malfunctions are frequently caused by incorrect operation of the machine or insufficient maintenance. Whenever a fault occurs you should therefore thoroughly read these instruction on correct operation and maintenance. If you cannot locate the cause of a fault or rectify it yourself by following the trouble shooting chart, you should contact the service departments at our branch offices or dealers.

On the following pages you will find a selection of fault remedies. It goes without saying that not all possible reasons for faults could be listed. !

Danger

Danger of injury!

Do not touch rotating parts of the engine.

82

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC

Trouble shooting

6.2

Engine problems

Faults

Possible cause

Remedy

Engine does not start

Fuel tank empty

Fill the fuel tank

Fuel filter clogged, in winter due to paraffin separation

Change the filter, use winter fuel

Fuel lines leaking

Check the line connections for leaks and tighten the fittings.

Neutral start switch on travel lever defective or no contact between switch and travel lever.

change, position correctly

Battery not charged or not connected

Terminal clamps on battery tighten, check line connections

Battery power to low

Have battery checked

Battery pole clamps loose or oxidized, causing the starter to turn too slow

Clean the pole clamps, tighten and cover them with acid-free grease

Especially during winter: use of too viscous engine oil

Use an engine oil complying with the ambient temperatures

Fuel supply restricted, Clogging of fuels system by paraffin separation during winter

Change the engine oil filter cartridge.

Check the line connections for leaks and tighten the fittings. Use winter fuel under cold conditions

Valve clearance not as specified

Adjust the valve clearance

Injection valves or plug-type injection pump defective

Have inspected by a specialist

Dry air filter cartridge dirty

clean, replace if necessary

Excessive play in throttle cable

Adjust the throttle cable, replace if necessary

Engine oil level too high

Drain the engine oil down to the top dipstick mark

Dry air filter cartridge dirty

clean, replace if necessary

Poor compression due to burned or broken compression rings or incorrect valve clearance

Have compression rings and pistons examined by a specialist, adjust the valve clearance

Injection valves defective

Have inspected by a specialist

Poor starting of engine or engine works irregularly with poor power

Excessive exhaust smoke

BW 125 ADH/ BW 135AD/138 AD/AC

BOMAG

83

Trouble shooting

Faults

Possible cause

Remedy

Engine overheating, engine must be shut down immediately!

Cooling fins or engine oil cooler excessively soiled

Clean cooling fins and cooling air intake

Injection valves defective

Have inspected by a specialist

Capacity of plug-type injection pumps not correctly adjusted

Have corrected by a specialist

Lack of cooling air flow at the cooling blower

Clear the air duct

Dry air filter cartridge dirty

clean, replace if necessary

V-belt loose or torn

Tighten or replace the V-belt

Engine has too low oil pressure, engine must be immediately shut down!

Leaks in the lubrication system, oil level too low

Check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten all fittings

Wrong SAE-class of engine oil

Change the engine oil.

The charge control light lights up during operation

Generator speed too low

Check the V-belt tension, tighten if necessary.

The generator does not charge the battery, because of a defect on generator or regular

Have inspected by a specialist

84

BOMAG

BW 125 ADH/ BW 135AD/138 AD/AC