Bomag 138ad Manual de Operador
Bomag 138ad Manual de Operador
Bomag 138ad Manual de Operador
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 .... >
Catalogue number
008 138 01 04/2004
Foreword
BOMAG machines are products from the wide You should only operate the machine after you
F oreword
range of BOMAG compaction equipment. have been instructed and in compliance with these
instructions.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth- Strictly observe the safety regulations.
ods, such as lifetime tests of all important Please observe also the guidelines of the Civil En-
components and highest quality demands gineering Liability Association ”Safety Rules for
guarantee maximum reliability of your ma- the Operation of Road Rollers and Soil Compac-
chine. tors” and all relevant accident prevention regula-
tions.
This manual comprises:
For your own personal safety you should only
l Safety regulations use original spare parts from BOMAG.
l Operating instructions
In the course of technical development we re-
l Maintenance instructions serve the right for technical modifications
l Trouble shooting without prior notification.
These operating and maintenance instructions are
Using these instructions will also available in other languages.
l help you to become familiar with the machine. Furthermore, the spare parts catalogue is availa-
l avoid malfunctions caused by unprofessional ble from your BOMAG dealer against the serial
operation. number of your machine.
Your BOMAG dealer will also supply you with in-
Compliance with the maintenance instructions will formation about the correct use of our machines in
l enhance the reliability of the machine on con- soil and asphalt construction.
struction sites, The above notes do not constitute an extension of
l prolong the lifetime of the machine, the warranty and liability conditions specified in the
general terms of business of BOMAG.
l reduce repair costs and downtimes.
We wish you successful work with your BOMAG
BOMAG will not assume liability for the function of machine.
the machine BOMAG GmbH
l if it is handled in a way that does not comply Printed in Germany
with the usual modes of use,
Copyright by BOMAG
l if it is used for purposes other than the ones it
is intended for, see safety regulations.
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.
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
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
Fig. 4
Dimensions in A B C D H H2 K L O S W
mm
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 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 kg/cm 14 13,7 15,2
(CECE)
Dimensions
Oscillation angle +/-° 13 13 13
Inner track radius mm 3700 3650 3610
Drive
Engine manufacturer Deutz Deutz Deutz
Type F3L 2011 F3L 2011 F3L 2011
Cooling Air-oil Air-oil Air-oil
Number of cylinders 3 3 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 V 12 12 12
Drive system hydrost. hydrost. hydrost.
Driven axles front+rear front+rear front+rear
Brakes
Service brake hydrost. hydrost. hydrost.
Parking brake hydr.-mech. hydr.-mech. hydr.-mech.
Steering
Type of steering Oscill.-articul. Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost. hydrost.
Steering angle +/- Degree 25 25 25
Vibration system
Drive system hydrost. hydrost. hydrost.
Frequency Hz 50/60 50/60 46/52
Amplitude mm 0,45 0,40 0,50
Vibrating drum front+rear front+rear front+rear
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
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
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:
Fig. 5
Dimensions in A B C D H H2 K L O S W
mm
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
* BW 138 AC
Travel characteristics
Travel speed I km/h 0...5,0
Travel speed II km/h 0...10
Max. gradability/with vi- % 40/30
bration (soil dependent)
Drive
Engine manufacturer Deutz
Type F3L 2011
Cooling Air-oil
Number of cylinders 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 V 12
Drive system hydrostatic
Driven axles front+rear
Tires
Number of tires 4
Tire size 225/75 R16
Brakes
Service brake hydrost.
Parking brake hydr.-mech.
Steering
Type of steering Oscill.-articul.
Steering operation hydrost.
Steering angle +/- Degree 25
Vibration system
Drive system hydrost.
Frequency Hz 46/52
Amplitude mm 0,5
Vibrating drum front
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
BW 138 AC
LpA =81 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is
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:
l the seat is correctly adjusted not use the emergency stop switch as service
brake.
l mirrors (if present) are clean and correctly ad-
justed. Restart the machine only after the danger that
caused the actuation of the emergency stop switch
Do not start the machine with defective gauges,
has been eliminated.
control lights or control elements.
If the engine oil pressure control light lights up stop
Do not take any loose objects with you or fasten
the engine immediately.
them to the machine.
If the machine has contacted high-voltage power
On machines with roll over protection system you
lines:
must always wear your seat belt.
l Do not leave the operator's platform
Starting
l Warn others from coming close to or touching
Start and operate the machine only from the driv- the machine
er's seat.
l if possible drive the machine out of the danger
For starting set all control levers to 'neutral posi-
zone
tion'.
l Have the electric power switched off
Do not use any starting aids like start pilot or ether.
Operate the machine only from the operator's
After starting check all gauges and control lights.
stand.
Starting with jump wires Keep the cabin doors closed.
Connect plus with plus and minus with minus Do not adjust the driver's seat while driving.
(ground cable) - always connect the ground strap
Do not climb onto or off the machine while the ma-
last and disconnect it first! A wrong connection will
chine is driving.
cause severe damage in the electric system.
Change the travel direction only at standstill.
Do not start the engine by shorting the electric ter-
minals on the starter motor, because the machine Do not use the machine to transport persons.
may start to drive immediately. In case of unusual noises and development of
smoke perform trouble shooting and have the fault
Starting in closed rooms
corrected.
Exhaust gases are highly dangerous! Always en-
Always keep a sufficient distance to excavation
sure an adequate supply of fresh air when starting
walls and embankments and do not use working
in closed rooms!
methods that could impair the stability of the ma-
chine.
Driving the machine
Do not work with vibration on hard concrete, cured
Persons in the danger area bitumen layers or extremely frozen ground.
Before taking up work, also after breaks, you Always keep a sufficient distance when passing
should always convince yourself that the danger through subways, under bridges, tunnels, electric
zone is free of persons or obstructions, especially power lines etc.
when driving in reverse.
Driving on inclinations and slopes
If necessary give warning signals. Stop work im-
Do not drive on gradients exceeding the maximum
mediately if persons remain in the danger zone,
gradability of the machine.
despite the warning.
On slopes drive extremely carefully and always di-
Do not step or stand in the articulation area of the
rectly up or down the slope. Change to a lower
machine when the engine is running. Danger of
gear before starting to drive.
squashing!
Wet and loose soils considerably reduce the
Driving ground adhesion of the machine on inclinations
In events of emergency and in case of danger ac- and slopes. Higher risk of accident!
tuate the emergency stop switch immediately. Do
Keep away from edges and embankments. Familiarise yourself with the location and the oper-
ation of fire fighting equipment. Observe all fire re-
Check the effect of vibration porting and fire fighting possibilities.
When compacting with vibration you must always
check the effect of the vibration on nearby build- Maintenance work
ings and underground supply lines (gas, water, Comply with the maintenance work described in
sewage, electric power) and stop compaction work the operating and maintenance instructions, in-
with vibration, if necessary. cluding the information concerning the replace-
Do not switch the vibration on when working on ment of parts.
hard (frozen, concrete) ground. Danger of bearing Maintenance work must only be performed by
damage! qualified and authorized persons.
For overhead maintenance and assembly work
Parking the machine use the access steps and working platforms pro-
Park the machine on level and firm ground. vided or other secure means. Do not use machine
Before leaving the machine: parts as access steps.
Keep unauthorized persons away from the ma-
l return the control lever to neutral position
chine.
l apply the parking brake
Do not perform maintenance work while the ma-
l shut the engine down and pull the ignition key chine is driving or the engine is running.
out
Park the machine on horizontal, level and firm
l lock the cabin door ground.
l secure the machine against unintended use. Pull the key out of the ignition switch.
Do not jump off the machine, but use access steps Secure the articulated joint with the articulation
and grips. lock.
Mark machines, which could be in the way, with a Working on hydraulic lines
clearly visible sign.
Relieve hydraulic pressures before working on hy-
Parking on slopes and inclinations draulic lines. Hydraulic oil escaping under pres-
sure can penetrate the skin and cause severe
Secure the machine against rolling, place metal
injury. When being injured by hydraulic oil consult
chocks in front of and behind the drums.
a medical doctor immediately, as otherwise this
may cause severe infections.
Filling the fuel tank
Do not step in front of or behind the drums/rubber
Do not inhale any fuel fumes. wheels when performing adjustment work in the
Refuel only with the engine stopped and the auxil- hydraulic system.
iary heater switched off. Do not change the setting of pressure relief valves.
Do not refuel in closed rooms. Drain hydraulic oil at operating temperature - dan-
No open fire, do not smoke. ger of scalding!
Do not spill any fuel. Catch running out fuel, do not Catch running out hydraulic oil and dispose of en-
let it seep into the ground. vironmentally.
Wipe off spilled fuel. Keep dirt and water away Always catch and dispose of biodegradable hy-
from the fuel. draulic oils separately.
Do not start the engine after draining the hydraulic Do not leave any tools or other objects, that could
oil. cause damage, in the engine compartment.
Once all work is completed (with the system still Working on electric components
depressurized!) check all connections and fittings
for leaks. Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
Changing hydraulic hoses lating material.
Hydraulic hoses must be visually inspected at reg- Do not use fuses with higher ampere ratings and
ular intervals. do not repair fuses with a piece of wire. Fire haz-
Hydraulic hoses must be immediately replaced if: ard!
Before starting welding work on the machine dis-
l the outer layer is damaged down to the inlay
connect the battery.
(e.g. chafing, cuts, cracks)
l the outer layer is brittle (formation of cracks in Working on the battery
the hose material) When working on the battery do not smoke, do not
l the hose shows deformations in pressurized use open
and depressurized condition, which do not Do not let acid come in contact with hands or
comply with the genuine shape of the hydrau- clothes! When injured by acid flush off with clear
lic hose water and seek medical advice.
l the hose shows deformations in bends, e.g. Metal objects (e.g. tools, rings, watch straps) must
squeezing, buckling, layer separation, forma- not come in contact with the battery poles - danger
tion of blisters of short circuit and burning!
l leakages. When recharging serviceable batteries remove all
plugs, to avoid the accumulation of explosive gas-
l incorrect installation.
es.
l the hydraulic hose has separated from the fit-
Observe the applicable instructions when starting
ting
with an auxiliary battery.
l mixing up of hoses by mistake. Dispose of old batteries in accordance with valid
l the fitting shows corrosion that impairs both regulations.
function and strength. Switch off the charging current before removing
l fittings are damaged or deformed, whereby the charging clamps.
the function and strength of the hose/hose Ensure sufficient ventilation, especially if the bat-
connection is impaired. tery is to be charged in a closed room.
Only genuine BOMAG replacement hydraulic hos-
Working on the fuel system
es ensure that the correct hose type (pressure
range) is used at the right location. Do not inhale any fuel fumes.
No open fire, do not smoke, do not spill any fuel.
Working on the engine
Catch running out fuel, do not let it seep into the
Shut the engine down before opening the engine
ground and dispose of environmentally.
hood.
Drain the engine oil at operating temperature - Working on wheels and tires
danger of scalding! Explosion-like bursting of tires or parts of tires and
Wipe off spilled oil, catch running out oil and dis- rims can cause most severe or even deadly inju-
pose of environmentally. ries.
Store used filters and other oil contaminated ma- Assembly of tires must only be performed with ap-
terials in a separate, specially marked container propriate experience and tools. If necessary have
and dispose of environmentally. tires assembled in a qualified workshop.
Cleaning work
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other inflammable sub-
stances 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.
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 instruc-
tions for this work.
Exhaust gases are highly dangerous! Always en-
sure 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.
Fig. 6
Fig. 7
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
* 23 Foot switch for rubber tire sprinkling system
9 Rotary switch for lighting (STVZO)
(only BW 138 AC) or foot switch for flow divider
10 Rotary switch for indicator light, with control
on AD-machines*
light *
24 Ball valve, brake releasing device (only AC)
11 Rotary switch for hazard light system, with
control light * 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
29 Operating hour meter, in engine compartment
* Optional equipment
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 pres-
sure 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
lights up = when switching the ignition
on, in case of charge failures
during operation, perform trou-
ble shooting.
goes out = after starting the engine
Fig. 9
No. 5 = Emergency stop push button
Fig. 11
!Danger No. 7 = Rotary switch for pressure sprinkler
Danger of accident! system
Use only in events of emergency during oper- Position "left" = Sprinkling "OFF"
ation. Position "right" = Sprinkling "ON"
Do not use as parking brake. No. 8 = Interval switch for pressure sprinkler
system
Restart the machine only after the danger that
caused the actuation of the emergency stop turn clockwise
switch has been eliminated. Position "left" = permanent sprinkling
The machine is braked immediately, the engine further posi-
is shut down. tions = various sprinkling intervals
actuate = press the button completely from 4...32 seconds, activation
down, it automatically locks in time always 5 seconds.
fully pressed position.
switch off/un-
lock = Turn button clockwise. Re-
start the engine.
Fig. 12
No. 9 = Rotary switch for lighting (STVZO)*
Position "left" = Light off
Position "mid-
Fig. 10
dle" = Parking light on
No. 6 = Brake control lamp
lights up = with travel lever in position "0". * Optional equipment
No. 11 = Rotary switch for hazard light with No. 14 = Rotary switch for flashing beacon***
control light ** Position "left" = Flashing beacon off
Position "left" = hazard light switched off Position "right" = Flashing beacon on
Position "right" = hazard light switched on, the No. 15 = Rotary key switch for edge cutter****
control lights in the rotary POsition "mid-
switches (10) and (11) light up. dle" = 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 Fig. 15
switch 28 in position "I". No. 16 = Seat contact control light*
goes out = when the driver’s seat is occu-
pied.
lights up when
the machine is at
rest = when the driver’s seat is unoc-
cupied. Drive operation is not
possible. (The brake is
closed).
* Option *** Optional equipment
** Option **** Option
i Note
Design with seat contact for engine shut-down
lights when the
machine is driv-
ing* = when the driver’s seat is unoc-
cupied. 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 vibra-
tion, brake is released.
Position "II" = Backward travel without vibra-
tion, brake is released.
Position "III" = max. forward/reverse travel
with vibration, brake is re-
leased.
No. 20 = Push button for vibration
Fig. 16 press = 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
Fig. 18
BW135AD.
No. 21 = Cock valve for vibration (only AD)
= Full load position (2850 rpm),
operating position for driving Position "I" = vibration of both drums
and vibration, BW138 AD/AC. Position "II" = vibration of front drum only
No. 18 = Locking lever for throttlelever
Fig. 19 Fig. 21
No. 23 = Foot switch for tire sprinkler system
Ball valve for 3-stage vibration*
(only AC)
Position up-
press = sprinkling on.
ward = Vibration of rear drum only
Position horizon- release = sprinkling off.
tal = Vibration of both drums
Position down-
ward = Vibration of front drum only
Fig. 22
! Danger
Danger of accident!
Do not adjust the driver's seat while driving.
* Optional equipment
Fig. 25
No. 28 = Ignition switch
Position "0"/"P" = ignition off, key can be pulled
Fig. 24
out.
Position "I" = ignition on, oil pressure control
! Danger light (2) and charge control
Fire hazard! 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
* Optional equipment
(1) 15A = (F07) hazard light* ** Optional equipment
i Note
For starting the driver's seat must be occupied and
the emergency stop switch must be unlocked.
Position "II" = turn further against spring
pressure, start the engine. Re-
lease the ignition key, the con-
trol lights go out.
i Note
The ignition switch is designed with a lock to pre-
vent repetitive starting. For a new starting attempt
the ignition key must first be turned back to posi-
tion "0".
No. 29 = Operating hour meter, in engine com-
partment
counts the operating hours while the engine is run-
ning
All maintenance work must be performed accord-
ing to the indicated operating hours.
Danger
!
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'.
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
! 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 driver’s seat.
Fig. 26
Danger
!
Danger of accident!
Always wear your seat belt.
Fig. 29
Fig. 27
* Optional equipment
Fig. 30 Fig. 33
l Shift travel lever 19 (Fig. 30) to position '0'. The l Turn ignition key 28 (Fig. 33) to position "I".
brake is closed. Charge control light (4) and oil pressure warn-
ing light (2) light up.
i Note
If the vibration starts to run in ignition switch posi-
tion "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 igni-
tion key back to position "I", charge control
light and oil pressure control light go out.
Fig. 31
i Note
l Pull the locking lever 18 (Fig. 31) and shift the Run the engine warm for a short while before start-
throttle lever (17) to position '0', idle speed. ing work.
Fig. 32
! Danger
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclina-
tions and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive on gradients exceeding the maxi-
mum 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 ma-
chine.
l When jump starting with an external battery
connect both plus poles first.
l Then connect the ground cable first to the mi-
nus 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'. Fig. 35
i Note
Design with seat contact for engine shut-down*
lights when the
machine is driv-
ing* = when the driver’s seat is unoc-
cupied. 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 vi-
bration
Position "II" = max. backward travel without
vibration
Position "III" = Max. forward/backward travel
with vibration.
Fig. 36
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.
* Optional equipment
! Danger
Risk of damage
When compacting with vibration you must
check the effect of nearby buildings and un-
derground supply lines (gas, water, sewage,
electric power), if necessary stop compaction
with vibration.
Caution
!
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 up-
ward = Vibration of rear drum only
Position horizon-
tal = Vibration of both drums
Position down-
ward = Vibration of front drum only
Fig. 39
! Caution
Destruction of hydraulic components!
Switch over only with the vibration switched
off.
l Pre-select the desired drum or drums with ball
valve 21 (Fig. 39).
Position "I" = Vibration of both drums
Position "II" = Vibration of front drum only
Fig. 41
Pre-selecting vibration (3 stages, only l Pull up locking lever 18 (Fig. 41) and shift
AD)* throttle lever (17) to full load position "I" (55
Hz) or "II" (66 Hz).
Fig. 40
Fig. 42
Caution
! l Actuate vibration push button 20 (Fig. 42) only
Destruction of hydraulic components! after shifting travel lever (19) to the desired
travel direction.
* Optional equipment
i Note
4.8 Switching the vibration on
When shifting the travel lever through position "III"
to position "I" or "II", the vibration will be automati- or off
cally switched off.
Fig. 43
Fig. 46
Fig. 45 Fig. 47
l Operate the rotary switch for the pressure l To switch the sprinkler system off return the
sprinkler system 7 (Fig. 45). travel lever to the position "brake closed" (Fig.
Position "0" = sprinkler system "OFF" 47).
Position "I" = sprinkler system "ON"
l Set the interval switch (8) to the desired flow
i Note
interval. The brake control light must light up.
Fig. 48
Fig. 50
Fig. 49
! Danger
Danger of accident!
Secure the machine against unintended roll-
ing.
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 op-
Fig. 52
erator.
l Take the brake releasing device 1 (Fig. 52) out
of the access steps.
i Note
In this adjustment the lever (3) is locked in up-
wards 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 Place the brake releasing device (1) across Towing the machine
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.
Fig. 55
! Caution
Generally use a draw bar (Fig. 55), max. towing
speed 1 km/h, max. towing distance 500 m.
Fig. 54
Fig. 56
After towing
! Danger
Remove the brake releasing device and press
the protective plug back in (only AD-ma-
chines).
Reset the cock valve to position "II", turn the
locking screw back in and counter it with the
hexagon nut (only AC-machines).
! Danger
Mortal danger!
Use only strong and stable loading ramps with
sufficient load bearing capacity. Make sure
that persons are not endangered by the ma-
chine 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 Fig. 58
against rolling, sliding and turning over. l Tie the machine down on the transport vehicle,
Do not stand or step under loads being lifted. use the lifting hooks 1 (Fig. 58) on front and
rear frame for this purpose.
Fig. 57
Fig. 59
l After driving the machine onto the transport
vehicle swing the articulation lock 1 (Fig. 57) l Use the four lifting eyes to lift the machine (Fig.
out of its receptacle and fasten it with the bolt 59).
(2) to the eye. Secure the bolt with the cotter
pin.
Fig. 60
Danger
!
Mortal danger!
Operate the machine only with the ROPS fold-
ed up and the fastening screws tightened with
the correct tightening torque.
* Option
Fig. 62
Caution
!
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.
!Caution
Fig. 63 These intervals apply only when using a diesel
Lubrication oil with a too high viscosity index caus- fuel with maximum 0.5 % sulphur by weight
es starting difficulties. The temperature when and for ambient temperatures higher than
starting the engine is therefore of highest impor- -10 °C.
tance when choosing the viscosity of engine oil for When using fuels with a sulphur content of
winter operation. more than 0.5% to 1% or under ambient tem-
peratures below -10 °C the oil change intervals
Oil viscosity specified in the table must be halved. When us-
ing fuels with a sulphur content higher than 1%
Since lubrication oil changes its viscosity with the
... 1,5% the engine oil must have a TBN of ap-
temperature, the ambient temperature at the oper-
prox. 12 x the S-content in % by weight if the
ating location of the engine is of utmost impor-
service intervals are halved.
tance when choosing the viscosity class (SAE-
class) (see diagram).
Occasional falling short of the temperature limit
(e.g. use of SAE 15W/40 down to -15 °C) may ef-
Example aspirating engine: type HV according to ISO 6743/3. The viscosity in-
dex (VI) must be at least 150. (Observe the infor-
l Use in tropical climate, fuel 0.8% sulphur, lu-
mation of the manufacturer).
brication oil change every 250 operating
hours.
Bio-degradable hydraulic oil
Lubrication oil quality classes On request the hydraulic system can also be filled
with ester based biodegradable hydraulic oil (Pan-
The ACEA- and the API-classifications are used to
olin HLP Synth. 46).
classify the oil quality.
The biologically degradable hydraulic oil meets all
The oil manufacturer is solely responsible for as-
demands of a mineral oil based hydraulic oil ac-
signing a product to a certain quality class.
cording to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.
i Note
46 always use the same oil to top up.
When changing to a higher alloyed oil quality after
When changing from mineral oil based hydraulic
a longer period of operation, it is recommended to
oil to an ester based biologically degradable oil,
perform the first oil change of the higher quality oil
you should consult the lubrication oil service of the
already after 20 operating hours. The lubrication
oil manufacturer for details.
oil filter cartridge must be changed at the same
time. Check the filter more frequently after this change.
Winter fuel
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At
very low temperatures disturbing paraffin separa-
tion can also be expected when using winter diesel
fuel.
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
SAE 15W/40
Fuel
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity 30 litres (7.9 USgal)
46 mm2/s at 40 °C
or
Sprinkler system Water Anti-freeze mixture water 230 litres (60.8 USgal)
! 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.
5.6 Check the engine oil level 5.7 Checking the dry air filter
i Note
The machine must be in horizontal position.
Run the engine 2 minutes with idle speed and shut
it down.
Fig. 65
i Note
For quality and quantity of oil refer to the ”table of
fuels, lubricants and filling capacities”.
l Check the oil level again after running the en-
gine for approx. 1 minute.
* Option
5.8 Checking the hydraulic oil 5.9 Checking the hydraulic oil
level filter element
Fig. 66 Fig. 67
l Clean the area around the filler opening. l Check the service indicator 1 (Fig. 67) at oper-
ating temperature and with the engine running
l Remove the filler cap.
at maximum speed.
l Check the hydraulic oil level on the oil dipstick.
l If necessary press the pin in.
The oil level must be between the "MIN" and
"MAX" marks (Fig. 66). Pin remains de-
pressed = hydraulic oil filter element ok.
l If the oil is below this level top up hydraulic oil
immediately. Pin pops up = replace the hydraulic oil filter
element
i Note
For quality and quantity of oil refer to the table of i Note
"fuels, lubricants and filling capacities". If the hydraulic oil is very cold the pin may pop up,
you should therefore only check the filter and
In hydraulic systems filled with Panolin HLP Synth. press the pin in at operating temperature.
46 always use the same oil to top up. With other
ester based oils consult the lubrication oil service
of the respective oil manufacturer.
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.
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
i Note
Fig. 68 In the event of frost observe the special service in-
structions under "maintenance in the event of
l Clean the area around the filler opening.
frost".
l Open the fuel filler cap (Fig. 68) and check the
fuel level visually. l Close the filler cap.
! Caution
Fill in fuel through a screen filter.
i Note
Only AC-machines.
Fig. 71
l
5.14 Cleaning cooling fins and
l Reassemble the cooling air duct cover, run the
engine oil cooler engine warm for a while to avoid corrosion.
! 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 en-
gine and the engine oil cooler have an adverse ef-
fect 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
Caution
!
Environmental damage!
Catch running off fluids and dispose of envi-
ronmentally.
l Clean the engine off with a water or steam jet
(do not aim at sensitive engine components).
Fig. 74
Fig. 75
Caution
!
5.17 Checking the battery condi-
Top up missing fluid with distilled water.
tion, greasing the poles
l Unscrew the plugs and check the acid level, if
necessary top up with distilled water.
! Danger With control inserts
Danger of explosion, causticization! The acid level must reach the bottom of the control
When working on the battery do not use open inserts.
fire, do not smoke!
Without control inserts
Do not let acid come in contact with hands or
The acid level must reach 10 to 15 mm above the
clothes!
upper edge of the lead plates.
Wear safety goggles.
Do not lay any tools on the battery!
i Note
For recharging remove the plugs from the bat- Measure the acid level with a clean wooden stick.
tery to avoid an accumulation of highly explo-
sive gases. With transparent battery housing
The acid level must reach the mark on the hous-
Caution
!
ing.
Dispose of used batteries environmentally. 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
Serviceable batteries:
l Clean battery and battery compartment.
! 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
! Danger
Danger of scalding!
Danger of scalding when draining off hot en-
gine oil!
! Caution
Environmental damage!
Catch old oil and dispose of environmentally. Fig. 79
Fig. 78
5.20 Change the engine oil filter 5.21 Check, adjust the valve
cartridge clearance
! Danger ! Caution
Danger of scalding! 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
!
Exhaust valve 0.5 mm
Environmental damage!
Catch the oil and dispose of environmentally
together with the engine oil filter cartridge.
Fig. 82
Fig. 81
Fig. 84
Fig. 87
Fig. 85 l Turn the crankshaft another revolution (360
l A feeler gauge of appropriate thickness 2 (Fig. Grad) further (for this purpose mark the fly-
85) must fit with little resistance between rock- wheel or V-belt pulley with chalk).
er arm (1) and valve (3). l Check and, if necessary, adjust the valves
l If the gap is too narrow or too wide for the feel- marked black (Fig. 87).
er gauge, the valve must be adjusted. l Assemble the cylinder head cover with a new
gasket.
i Note
5.22 Checking, tensioning,
After a short test run check the engine for leaks.
changing the V-belt
Fig. 88
Fig. 89
Fig. 90
! 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 environ-
mentally together with the fuel filter!
Fig. 91
i Note
The fuel system is self-bleeding.
5.25 Changing the hydraulic oil or oil bag using the filling and filtering unit.
! Caution
! Danger
Catch the hydraulic oil and dispose of environ-
Danger of scalding!
mentally!
l Thoroughly clean the inside of the hydraulic oil
! Caution tank.
Environmental damage!
Catch old oil and dispose of environmentally.
Do not start the engine after draining the hy-
draulic oil. Do not run the pumps without oil.
When changing from mineral oil based hydrau-
lic 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 hy-
draulic oil must also be changed after major re-
pairs in the hydraulic system. Fig. 93
The hydraulic oil filter element must be changed
with every hydraulic oil change (see next chapter).
i Note
See also chapter 5.1 "Notes on the hydraulic sys- We recommend to use a filtering unit with fine filter
tem". to fill in hydraulic oil.
l Drive the machine, until the hydraulic oil has For quality and quantity of oil refer to the table of
reached operating temperature. "fuels, lubricants and filling capacities".
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.
Fig. 92
! 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 environ-
mentally.
Do not use the oil in the filter bowl again.
i Note
Apart from the normal oil change intervals, the hy-
draulic oil must also be changed after major re-
pairs in the hydraulic system.
If the filter has to be changed together with the hy-
draulic oil, the filter must only be changed after the
oil change and after the test run.
Fig. 94
i Note
This work must only be performed by authorized
service personnel.
The injection valves must be replaced every
12000 operating hours.
! Caution
The toothed belt must only be changed by a
specialist workshop or by the After Sales Serv-
ice 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
As r equired
5.29 Checking the tire pressure 5.30 Cleaning, changing the dry
air filter
i Note
Only AC-machines.
Fig. 97
Fig. 98
Fig. 101
* Strength classes for screws with untreated, non-
lubricated 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 µ 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.
! Danger
Danger of injury!
Do not touch rotating parts of the engine.
Engine does not Fuel tank empty Fill the fuel tank
start
Fuel filter clogged, in winter due to paraf- Change the filter, use winter fuel
fin separation
Fuel lines leaking Check the line connections for leaks and
tighten the fittings.
Fuel supply restricted, Clogging of fuels Change the engine oil filter cartridge.
system by paraffin separation during win- Check the line connections for leaks and
ter tighten the fittings. Use winter fuel under
cold conditions
Excessive play in throttle cable Adjust the throttle cable, replace if neces-
sary
Excessive ex- Engine oil level too high Drain the engine oil down to the top dip-
haust smoke stick mark
Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance
Engine over- Cooling fins or engine oil cooler exces- Clean cooling fins and cooling air intake
heating, engine sively soiled
must be shut
down immedi- Injection valves defective Have inspected by a specialist
ately! Capacity of plug-type injection pumps not Have corrected by a specialist
correctly adjusted
Lack of cooling air flow at the cooling Clear the air duct
blower
Engine has too Leaks in the lubrication system, oil level Check fittings on oil lines, lubrication oil fil-
low oil pressure, too low ter and oil cooler for leaks, if necessary
engine must be tighten all fittings
immediately
shut down! Wrong SAE-class of engine oil Change the engine oil.
The charge con- Generator speed too low Check the V-belt tension, tighten if neces-
trol light lights up sary.
during operation
The generator does not charge the bat- Have inspected by a specialist
tery, because of a defect on generator or
regular