Bomag BW 125 ADH BW 135 AD BW138 AD BW138 AC Single Tandem Vibratory Roller Service Repair Manual Instant Download

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Operating instructions Maintenance
instructions BW 125 ADH / BW 135 AD BW 138 AD /
BW 138 AC
S/N 101 650 12.... gt S/N 101 170 21....gt S/N 101
650 14 .... gt S/N 101 650 15 .... gt
Tandem Vibratory Roller Combination Roller
Catalogue number 008 138 01
04/2004
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(No Transcript)
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Foreword
BOMAG machines are products from the wide range
of BOMAG compaction equipment. BOMAGs vast
experience in connection with state-of-the-art
production and testing meth- ods, such as
lifetime tests of all important components and
highest quality demands guarantee maximum
reliability of your ma- chine.
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 En- gineering Liability Association
Safety Rules for the Operation of Road Rollers
and Soil Compac- tors and all relevant accident
prevention regula- tions. For your own personal
safety you should only use original spare parts
from BOMAG. In the course of technical
development we re- serve the right for technical
modifications without prior notification. These
operating and maintenance instructions are also
available in other languages. Furthermore, the
spare parts catalogue is availa- ble from your
BOMAG dealer against the serial number of your
machine. Your BOMAG dealer will also supply you
with in- formation about the correct use of our
machines 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

• This manual comprises
• Safety regulations
• Operating instructions
• Maintenance instructions
• Trouble shooting

• Using these instructions will
• help you to become familiar with the machine.
• avoid malfunctions caused by unprofessional
  operation.

• Compliance with the maintenance instructions will
• enhance the reliability of the machine on con-
  struction sites,
• prolong the lifetime of the machine,
• reduce repair costs and downtimes.

• BOMAG will not assume liability for the function
  of the machine
• if it is handled in a way that does not comply
  with the usual modes of use,
• if it is used for purposes other than the ones it
  is intended for, see safety regulations.

• No warranty claims can be lodged in case of dam-
  age resulting from
• operating errors,
• insufficient maintenance and
• wrong fuels and lubricants.
• Please note!
• This manual was written for operators and mainte-
  nance personnel on construction sites.
• Always keep this manual close at hand, e.g. in
  the tool compartment of the machine or in a
  specially provided container. These operating
  and mainte- nance instructions are part of the
  machine.

BOMAG
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BW 125 ADH/ BW 135AD/138 AD/AC
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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 com-
missioning protocol. During commissioning our
organisation will in- struct you in the
operation and maintenance of the machine. Please
observe strictly the safety regulations and all
notes on risks and dangers!
Fig. 2
Fig. 3
BOMAG
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Table of Contents

• Technical Data Safety regulations
• Indicators and Controls
• General notes
• Description of indicators and control elements
• Operation
• General notes
• Inspections before starting operation
• Starting the engine
• Starting with jump wires
• Driving the machine
• Stopping the machine / applying the brake
• Switching the vibration on and off
• Switching the vibration on or off
• Switching the pressure sprinkler system on or off
• Stopping the engine/machine
• Adjusting the driver's seat
• Towing
• Loading and transport
• Foldable roll over protection structure (ROPS)

7 15 23 27 27 35 36 36 37 39 39 41 41 43 44 45 46
46 48 49 51 52 53 55 56 57 59 59 60 60 61 61 62 62
63 64 64 65 66 67 68
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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 81
6.1 General notes 82
6.2 Engine problems 83
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1 Technical Data
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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
BW 125 ADH BW 125 ADH BW 135 AD BW 138 AD
Weights
Operating weight (CECE) kg 3360 3560 4200
Mean axle load (CECE) kg 1680 1780 2100
Mean static linear load (CECE) kg/cm 14 13,7 15,2
Dimensions
Oscillation angle /- 13 13 13
Inner track radius mm 3700 3650 3610
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Technical Data
BW 125 ADH BW 125 ADH BW 135 AD BW 138 AD
Travel characteristics
Travel speed I km/h 0...5,0 0...5,0 0...5,0
Travel speed II km/h 0...10 0...10 0...10
Max. gradability/with vi- bration (soil dependent) 40/30 40/30 40/30
Drive
Engine manufacturer Type Cooling Number of cylinders Deutz F3L 2011 Air-oil 3 Deutz F3L 2011 Air-oil 3 Deutz F3L 2011 Air-oil 3
Rated power ISO 9249 kW 34 34 34
Rated speed rpm 2800 2800 2800
Fixed engine speed 1 rpm 2200 2200 2500
Fixed engine speed 2 rpm 2700 2700 2800
Fuel tank capacity l 55 55 55
Electrical equipment Drive system Driven axles V 12 hydrost. frontrear 12 hydrost. frontrear 12 hydrost. frontrear
Brakes
Service brake Parking brake hydrost. hydr.-mech. hydrost. hydr.-mech. hydrost. hydr.-mech.
Steering
Type of steering Steering operation Steering angle /- Degree Oscill.-articul. hydrost. 25 Oscill.-articul. hydrost. 25 Oscill.-articul. hydrost. 25
Vibration system
Drive system hydrost. hydrost. hydrost.
Frequency Hz 50/60 50/60 46/52
Amplitude Vibrating drum mm 0,45 frontrear 0,40 frontrear 0,50 frontrear
Water sprinkler system
Type of sprinkling Interval control Water tank capacity l Pressure Standard 230 Pressure Standard 230 Pressure Standard 230
The right for technical modifications remains
reserved
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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 operators 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 (drivers seat) The weighted effective
acceleration value determined according to ISO
7096 is lt 0.5 m/sec2. Hand-arm vibration
values The weighted effective acceleration value
determined according to EN 500/ISO is lt 2.5
m/sec2.
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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
BW 138 AC
Weights
Operating weight (CECE) kg 4000
Axle load, drum (CECE) kg 2050
Axle load, wheels (CECE) kg 1950
Mean static linear load kg/cm 14,9
Dimensions
Oscillation angle /- 13
Inner track radius mm 3610
BOMAG
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Technical Data
BW 138 AC BW 138 AC
Travel characteristics
Travel speed I km/h 0...5,0
Travel speed II km/h 0...10
Max. gradability/with vi- bration (soil dependent) 40/30
Drive
Engine manufacturer Type Cooling Number of cylinders Deutz F3L 2011 Air-oil 3
Rated power ISO 9249 kW 34
Rated speed rpm 2800
Fixed engine speed 1 rpm 2250
Fixed engine speed 2 rpm 2800
Fuel tank capacity l 55
Electrical equipment Drive system Driven axles V 12 hydrostatic frontrear
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 /- Degree Oscill.-articul. hydrost. 25
Vibration system
Drive system hydrost.
Frequency Hz 46/52
Amplitude Vibrating drum mm 0,5 front
Water sprinkler system
Type of sprinkling Interval control Water tank capacity l Pressure Standard 230
Emulsion tank capacity l 20
The right for technical modifications remains
reserved
BOMAG
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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 operators 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 (drivers seat) The weighted
effective acceleration value determined according
to ISO 7096 is lt 0.5 m/sec2. Hand-arm vibration
values The weighted effective acceleration value
determined according to EN 500/ISO is lt 2.5
m/sec2.
BOMAG
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2 Safety regulations
BOMAG
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Safety regulations
Unintended use However, dangers may arise from
this machine if it is operated by untrained
personnel or if it is sub- ject of unintended
use. Do not work with vibration on hard concrete,
cured bitumen layers or extremely frozen
ground. Starting and operation of the machine in
explosive environments is prohibited.

• General Notes
• This BOMAG machine has been built in ac-
  cordance with the latest technical standard and
  complies with the applicable regulations and
  technical rules. However, dangers for per- sons
  and property may arise from this ma- chine, if
• it is used for purposes other than the ones it is
  intended for
• it is operated by untrained personnel
• it is changed or converted in an unprofessional
  way
• 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 regulations.
  If necessary, this must be con- firmed by
  obtaining the signature of the cus- tomer.
• Furthermore, the following instructions and
  regula- tions must obviously also be complied
  with

Who has permission to operate the ma-
chine? 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 re- sponsibilities must be clearly
specified and com- plied with. Persons under the
influence of alcohol, medicine or drugs are not
allowed to operate, service or re- pair the
machine. Maintenance and repair work requires
specific knowledge and must therefore only be
performed by trained specialists.

• applicable accident prevention instructions
• generally accepted safety and road traffic reg-
  ulations
• country specific safety regulations. It is the
  duty of the operator to be acquainted with these
  instructions and to apply these accord- ingly.
  This applies also for local regulations
  concerning different types of handling work.
  Should the recommendations in these instruc-
  tions be different from the regulations valid in
  your country, you must comply with the safety
  regulations valid in your country.

Conversions and changes to the ma-
chine Unauthorized alterations to the machine are
pro- hibited for safety reasons. Original parts
and accessories have been special- ly designed
for this machine. We wish to make ex- plicitly
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 ex-
cludes any liability for damage caused by the use
of non-original parts or accessories.

• Intended use
• This machine must only be used for
• compaction of bituminous material, e.g. road
  surface layers. (Only AC and AD machines)
• medium to heavy compaction work in earth
  construction (road sub-bases)
• You should only operate the unit with fully
  functional safety equipment.
• Have the machine inspected by an expert once
  every year.

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
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Safety regulations
Checking the roll over protection structure
(ROPS) The frame of the machine must not be
warped, bent or cracked in the area of the ROPS
fastening. The ROPS must not show any rust,
damage, hair- line 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 spec-
ifications 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 con-
sent of the distributor, since this will impair
the strength of the unit.
i
Note
Paragraphs marked like this contain technical in-
formation for the optimal economical use of the
machine.
Environment
Paragraphs marked like this point out practic-
es 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. Replace damaged and illegible
stickers/decals.
Starting the machine Before starting The machine
must only be operated from the driv- er's
seat. Use only machines which are serviced at
regular intervals. Become acquainted with the
equipment, the con- trol elements, the working
principle of the machine and the working
area. Wear your personal protective outfit (hard
hat, safety boots, etc.). Before climbing on the
machine check whether

• Loading the machine
• Use only strong and stable loading ramps of
  suffi- cient 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.
• Persons are highly endangered when
• they step or stand under loads being lifted
• they remain in the drive range of the machine
  during an instruction and during loading.
• The machine must not swing about when being lift-
  ed.
• Use only safe lifting gear of sufficient load
  bearing capacity.
• Fasten the lifting gear only at the specified
  lifting points.

• persons or obstructions are beside or under the
  machine
• the machine is free of oily and combustible
  material
• all grips, steps and platforms are free of
  grease, oils, fuel, dirt, snow and ice
• 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.

• Use steps and grips to climb onto the machine.
  Before starting the machine check whether
• the machine shows any obvious faults
• all guards and safety elements are in place
• steering, brakes, control elements, light sys-
  tem and warning horn work correctly

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Safety regulations

• the seat is correctly adjusted
• mirrors (if present) are clean and correctly ad-
  justed.
• Do not start the machine with defective gauges,
  control lights or control elements.
• Do not take any loose objects with you or fasten
  them to the machine.
• On machines with roll over protection system you
  must always wear your seat belt.
• Starting
• Start and operate the machine only from the driv-
  er's seat.
• For starting set all control levers to 'neutral
  posi- tion'.
• Do not use any starting aids like start pilot or
  ether. After starting check all gauges and
  control lights.
• Starting with jump wires
• 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 start the engine by shorting the electric
  ter- minals on the starter motor, because the
  machine may start to drive immediately.
• Starting in closed rooms
• Exhaust gases are highly dangerous! Always en-
  sure an adequate supply of fresh air when
  starting in closed rooms!

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. If the machine has contacted
high-voltage power lines

• Do not leave the operator's platform
• Warn others from coming close to or touching the
  machine
• if possible drive the machine out of the danger
  zone
• Have the electric power switched off

Operate the machine only from the operator's
stand. Keep the cabin doors closed. Do not adjust
the driver's seat while driving. Do not climb
onto or off the machine while the ma- chine is
driving. Change the travel direction only at
standstill. 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 ma- chine. Do
not work with vibration on hard concrete, cured
bitumen layers or extremely frozen ground. Always
keep a sufficient distance when passing through
subways, under bridges, tunnels, electric power
lines etc. Driving on inclinations and slopes Do
not drive on gradients exceeding the maximum
gradability of the machine. On slopes drive
extremely carefully and always di- rectly up or
down the slope. Change to a lower gear before
starting to drive. Wet and loose soils
considerably reduce the ground adhesion of the
machine on inclinations and slopes. Higher risk
of accident!
Driving the machine Persons in the danger
area 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. If necessary
give warning signals. Stop work im- mediately if
persons remain in the danger zone, despite the
warning. 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 ac- tuate the
emergency stop switch immediately. Do
BOMAG
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BW 125 ADH/ BW 135AD/138 AD/AC
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Safety regulations
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. Keep away from edges
and embankments. Check the effect of
vibration When compacting with vibration you must
always check the effect of the vibration on
nearby build- ings 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!
Leaking fuel tanks can cause explosions. Ensure
tight fit of the fuel tank cover, if necessary
replace immediately. Fire protection
measures Familiarise yourself with the location
and the oper- ation of fire fighting equipment.
Observe all fire re- porting and fire fighting
possibilities.
Maintenance work Comply with the maintenance work
described in the operating and maintenance
instructions, in- cluding the information
concerning the replace- ment 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 pro- vided or other
secure means. Do not use machine parts as access
steps. Keep unauthorized persons away from the
ma- chine. Do not perform maintenance work while
the ma- chine is driving or the engine is
running. Park the machine on horizontal, level
and firm ground. Pull the key out of the
ignition switch. Secure the articulated joint
with the articulation lock. Working on hydraulic
lines Relieve hydraulic pressures before working
on hy- draulic lines. Hydraulic oil escaping
under pres- sure 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. Drain
hydraulic oil at operating temperature - dan-
ger of scalding! Catch running out hydraulic oil
and dispose of en- vironmentally. Always catch
and dispose of biodegradable hy- draulic oils
separately.

• Parking the machine
• Park the machine on level and firm ground.
  Before leaving the machine
• return the control lever to neutral position
• apply the parking brake
• shut the engine down and pull the ignition key
  out
• lock the cabin door
• secure the machine against unintended use.
• Do not jump off the machine, but use access steps
  and grips.
• Mark machines, which could be in the way, with a
  clearly visible sign.
• 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 auxil- iary heater switched off. Do not
refuel in closed rooms. No open fire, do not
smoke. Do not spill any fuel. Catch running out
fuel, do not let it seep into the ground. Wipe
off spilled fuel. Keep dirt and water away from
the fuel.
BOMAG
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BW 125 ADH/ BW 135AD/138 AD/AC
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the link into your browser. The full manual is
available for immediate download. https//www.eb
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