Bomag 138ad Manual de Operador

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 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.
No warranty claims can be lodged in case of dam-

age resulting from
l operating errors,
l insufficient maintenance and
l 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.
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 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
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
4.2 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

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
6.2 Engine problems 83

1 Technical Data

Technical Data
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

Technical Data
* 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- % 40/30 40/30 40/30
bration (soil dependent)
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
Water sprinkler system

Type of sprinkling Pressure Pressure Pressure
Interval control Standard Standard Standard
Water tank capacity l 230 230 230
* The right for technical modifications remains reserved

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 (driver’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.

Technical Data
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

Technical Data
* 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
Water sprinkler system

Type of sprinkling Pressure
Interval control Standard
Water tank capacity l 230
Emulsion tank capacity l 20
* The right for technical modifications remains reserved

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 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 (driver’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.

Technical Data

2 Safety regulations

Safety regulations
General Notes Unintended use

This BOMAG machine has been built in ac- However, dangers may arise from this machine if
cordance with the latest technical standard it is operated by untrained personnel or if it is sub-
and complies with the applicable regulations ject of unintended use.
and technical rules. However, dangers for per- Do not work with vibration on hard concrete, cured
sons and property may arise from this ma- bitumen layers or extremely frozen ground.
chine, if: Starting and operation of the machine in explosive
l it is used for purposes other than the ones it is environments is prohibited.
intended for
l it is operated by untrained personnel Who has permission to operate the ma-
l it is changed or converted in an unprofessional
chine?
way Only trained and instructed persons of at least 18
years of age are permitted to drive and operate
l the safety instructions are not observed
this machine. For operation of the machine the re-
Each person involved in the operation, mainte- sponsibilities must be clearly specified and com-
nance and repair of the machine must there- plied with.
fore read and comply with these safety Persons under the influence of alcohol, medicine
regulations. If necessary, this must be con- or drugs are not allowed to operate, service or re-
firmed by obtaining the signature of the cus- pair the machine.
tomer.
Maintenance and repair work requires specific
Furthermore, the following instructions and regula- knowledge and must therefore only be performed
tions must obviously also be complied with: by trained specialists.
l applicable accident prevention instructions
l generally accepted safety and road traffic reg- Conversions and changes to the ma-
ulations chine
l country specific safety regulations. It is the Unauthorized alterations to the machine are pro-
duty of the operator to be acquainted with hibited for safety reasons.
these instructions and to apply these accord- Original parts and accessories have been special-
ingly. This applies also for local regulations ly designed for this machine. We wish to make ex-
concerning different types of handling work. plicitly clear that we have not tested or approved
Should the recommendations in these instruc- any parts or accessories not supplied by us. The
tions be different from the regulations valid in installation and/or use of such products may have
your country, you must comply with the safety an adverse effect on the active and/or passive
regulations valid in your country. driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use
Intended use of non-original parts or accessories.
This machine must only be used for:
Notes on safety in the operating and
l compaction of bituminous material, e.g. road
maintenance instructions:
surface layers. (Only AC and AD machines)
l medium to heavy compaction work in earth
construction (road sub-bases) Danger
!
Paragraphs marked like this highlight possible

l You should only operate the unit with fully
dangers for persons.
functional safety equipment.
l Have the machine inspected by an expert
Caution
!
once every year.
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.

Safety regulations
i Note Checking the roll over protection

Paragraphs marked like this contain technical in- structure (ROPS)
formation for the optimal economical use of the The frame of the machine must not be warped,
machine. bent or cracked in the area of the ROPS fastening.
The ROPS must not show any rust, damage, hair-
Environment line cracks or open fractures.
Paragraphs marked like this point out practic- The ROPS must not rattle about when driving.
es for safe and environmental disposal of fuels This would indicate that it is not properly fastened.
and lubricants as well as replacement parts. All bolted connections must comply with the spec-
ifications and should be absolutely tight (observe
Observe environmental regulations.
the tightening torques). Screw and nuts must not
be damaged, bent or deformed.
Information and safety stickers/decals
No accessories may be welded or bolted on and
on the machine no additional holes must be drilled without the con-
Keep safety stickers in good and legible condition sent of the distributor, since this will impair the
(see parts manual) and comply with their meaning. 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 suffi- The machine must only be operated from the driv-
cient load bearing capacity. The ramp inclination er's seat.
must be less than the gradability of the machine.
Use only machines which are serviced at regular
Secure the machine against tipping or slipping off. intervals.
Secure the machine on the transport vehicle Become acquainted with the equipment, the con-
against rolling, slipping and turning over. trol elements, the working principle of the machine
Persons are highly endangered when and the working area.
l they step or stand under loads being lifted Wear your personal protective outfit (hard hat,
safety boots, etc.).
l they remain in the drive range of the machine
during an instruction and during loading. Before climbing on the machine check whether:
The machine must not swing about when being lift- l persons or obstructions are beside or under
ed. the machine
Use only safe lifting gear of sufficient load bearing l the machine is free of oily and combustible
capacity. material
Fasten the lifting gear only at the specified lifting l all grips, steps and platforms are free of
points. grease, oils, fuel, dirt, snow and ice
l the engine hood is closed and locked
Towing the machine
Use steps and grips to climb onto the machine.
You should generally use a tow bar.
Before starting the machine check whether:
Max. towing speed 1 km/h, max. towing distance
l the machine shows any obvious faults
500 m.
Before releasing the multi-disc brake secure the l all guards and safety elements are in place
machine against unintended rolling. l steering, brakes, control elements, light sys-
tem and warning horn work correctly

Safety regulations
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

Safety regulations
Behaviour in traffic Leaking fuel tanks can cause explosions. Ensure

Match the speeds to the working conditions. tight fit of the fuel tank cover, if necessary replace
immediately.
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 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.

Safety regulations
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.

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 manu-
facturer of the anti-sticking agent. Observe appli-
cable environmental regulations.
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.
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 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.

Safety regulations

3 Indicators and Controls

Indicators and Controls
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

3.1 General notes 3.2 Description of indicators

and control elements
Please read this section thoroughly before operat-
ing 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 de-
scriptions 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 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

goes out = with travel lever in positions "I",

"II" or "III".
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

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 "mid-
dle" = direction indicators off
Position "left" = direction indicator left,the con-
trol light in the rotary switch
lights up.
Position "right" = direction indicator right,the
control light in the rotary switch
lights up. Fig. 14
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

pull = the throttle lever can be moved

i Note
Standard design release = the throttle lever will engage in
position "I" and "II".
lights when the
machine is driv-
ing = when the driver’s seat is unoc-
cupied.
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),
and vibration, BW138 AD/AC.
Position "II" = Full load position (2700 rpm),
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
Foot switch for flow divider* (only AD)

press = flow divider switched on
Fig. 20
release = flow divider switched off
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
! Danger
Danger of accident!
Do not adjust the driver's seat while driving.

(2) 15A = (F12) working lights, right*

(3) 15A = (F08) direction indicators* and work-
ing 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 (on-
(2) 15A = (F06) sprinkler system (only AD **)
ly AC-machines)
(3) 10A = (F41) flashing beacon * / backup
Position "I" = Brake released
alarm *
(4) 10A = (F45) edge cutter *
i Note
(5) 15A = (F27) wiper/washer, front*
Release brake by turning the steering wheel in
clockwise direction. (6) 20A = (F141) hydraulic oil cooler
(7) 10A = (F03) vibration
Position "II" = Brake applied
(8) 15A = (F37) sprinkler pump
No. 27 = not used
!Danger
Danger of accident!
Always secure with locking screw.
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
(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.


4 Operation

Operation
4.1 General notes 4.2 Inspections before starting

operation
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
you are not yet fully familiar with the indicators and
control elements of the machine. Before the everyday use or before a longer work-
ing period the following tests and inspections must
All indicators and control elements are described
be performed.
in detail in this chapter.
Danger
!
Please observe strictly the safety regulations

in chapter 2 of these operating and mainte-
nance instructions.
l Park the machine on level ground.
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

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 driver’s seat.
Fig. 26
l Always start the engine from the driver’s seat Open

with seat contact switch (Fig. 26).
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).

Operation
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
l Check, whether the emergency stop switch

(Fig. 32) is unlocked.

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 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
l Once the engine is running switch on a power-

ful consumer (working light, etc.). i Note
Seat contact control light (Fig. 35):
! Caution goes out = when the driver’s seat is occu-
If no powerful consumer is switched on volt- pied.
age peaks may occur when separating the con- lights up when
necting cables between the batteries, which the machine is at
could damage electrical components. rest = when the driver’s seat is unoc-
l After starting disconnect the negative poles cupied. Drive operation is not
(ground cable) first and the positive poles af- possible. (The brake is
ter. closed).
l Switch off the consumer.

i Note
Standard design

Operation
lights when the

machine is driv-
ing = when the driver’s seat is unoc-
cupied.
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
l Pull locking lever 18 (Fig. 36) and shift throttle

lever (17) to full load position "I" or "II".
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.

Operation
4.6 Stopping the machine / ap- 4.7 Switching the vibration on

plying the brake and off
! 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
!
Danger of bearing damage!

Do not activate the vibration on hard (frozen,
Fig. 38
concrete) ground.
l Move the travel lever 19 (Fig. 38) slowly to po-
sition "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:
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.

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 up-
ward = Vibration of rear drum only
Position horizon-
tal = Vibration of both drums
Position down-
ward = Vibration of front drum only
Switch the vibration on
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.

Operation
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.
Switching the vibration off i Note

Only AC-machines.
l Press push button (20) again.
Fig. 43
l Press the foot switch 23 (Fig. 43).

press = on.
release = off.

Operation
4.9 Switching the pressure

sprinkler system on or off
Fig. 46
l To switch the sprinkler system on move the

ztravel lever out of braking position towards
"0"-position (Fig. 46).
Fig. 44
l Open the shut-off cock valve (Fig. 44). i Note

The sprinkler system will only work when the travel
Position "I" = open
lever is in direction "0"-position. This is also the
Position "II" = closed testing position.
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.
Position "A" = permanent sprinkling

Position
"B"..."F" = sprinkling intervals of 32, 24,
16, 8 and 4 seconds, sprinkling
time always 5 seconds.

Operation
4.10 Stopping the engine/ma- i Note

Do not shut the engine down all of the sudden from
chine full speed, but let it idle for a while for temperature
equalization.
Fig. 48
Fig. 50
l Turn the ignition switch 28 (Fig. 50) to position

Danger
!
"0" and pull the ignition key out.
Danger of accident!
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).

Operation
4.11 Adjusting the driver's seat 4.12 Towing
! Danger
Danger of accident!
Secure the machine against unintended roll-
ing.
Releasing the brakes on front and rear

drums mechanically (only AD-ma-
chines)
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 Unscrew the protective plug 6 (Fig. 53).

Operation
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.
Releasing the brakes on drum and rub-

ber 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
l Tow the machine by the front and rear towing

hooks 1 (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).

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 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.

Operation
Loading weight: See technical data

4.14 Foldable roll over protec-
After transport tion 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 compart-
ment.
Danger
!
Mortal danger!
Operate the machine only with the ROPS fold-
ed up and the fastening screws tightened with
the correct tightening torque.
* Option

Operation
Fig. 62
l Unscrew the bolts, fold the roll over protection

structure up to operation position and fasten it
again (Fig. 62).
Caution
!
During assembly the screws must be tightened

with the specified tighteneing toque!

5 Maintenance

Maintenance
l Do not let the hose stir up the slurry at the bot-

5.1 General notes on mainte- tom of the drum.
nance l Do not draw off fuel from near the bottom of
the drum.
l The rest in the drum is not suitable for the en-
When performing maintenance work always com- gine and should only be used for cleaning pur-
ply with the appropriate safety regulations. poses.
Thorough maintenance of the machine guaran-
tees higher functional safety of the unit and pro- Notes on the engine performance
longs the lifetime of important components. The On diesel engines both combustion air quantity
effort needed for this work is only little compared and fuel injection quantity are thoroughly adapted
with the problems that may arise when not observ- to each other and determine power, temperature
ing this rule. level and exhaust gas quality of the engine.
The terms right/left correspond with travel direc- If you engine has to work permanently in "thin air"
tion forward. (at higher altitudes) and under full load, you should
l Always clean machine and engine thoroughly consult the customer service of BOMAG or the
before starting maintenance work. 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 During maintenance work on the hydraulic system
engine stopped. cleanliness is of major importance. Make sure that
no dirt or other contaminating substances can en-
l Relieve hydraulic pressures before working on ter into the system. Small particles can produce
hydraulic lines. flutes in valves, cause pumps to seize, clog noz-
l Before working on electric parts of the ma- zles and pilot bores, thereby making expensive re-
chine disconnect the battery and cover it with pairs inevitable.
insulation material. l If, during the daily inspection of the oil level,
l When working in the area of the articulated the hydraulic oil level is found to have
joint attach the articulation lock (transport dropped, check all lines, hoses and compo-
lock). nents for leaks.
l Seal external leaks immediately. If necessary
Environment inform the responsible customer service.
During maintenance work catch all oils and fu- l Do not store drums with hydraulic oil outdoors,
els and do not let them seep into the ground or or at least under cover. Water can be drawn in
into the sewage system. Dispose of oils and fu- through the bunghole when the weather
els environmentally. changes.
l Always use the filling and filtering unit
Notes on the fuel system (BOMAG part-no. 007 610 01) to fill the hy-
The lifetime of the diesel engine depends to a draulic system. This unit is fitted with a fine fil-
great extent on the cleanliness of the fuel. ter to clean the hydraulic oil, thereby
prolonging the lifetime of the filter.
l Keep fuel free of contaminants and water,
since this will damage the injection elements l Clean fittings, filler covers and the area around
of the engine. such parts before disassembly to avoid enter-
ing of dirt.
l Drums with inside zinc lining are not suitable to
store fuel. l Do not leave the tank opening unnecessarily
open, but cover it so that nothing can fall in.
l The fuel drum must rest for a longer period of
time before drawing off fuel.

Maintenance
fect the cold starting ability of the engine, but will

5.2 Fuels and lubricants not cause any engine damage.
Temperature related lubrication oil changes can
be avoided by using multi-purpose oils. The follow-
Engine oil ing oil change intervals apply also when using mul-
l Use winter grade engine oil for winter opera- ti-purpose oils.
tion!
In order to assure perfect cold starting it is import Regular lubrication oil changes
to chose the viscosity (SAE-class) of the engine oil The longest permissible time a lubrication oil
according to the ambient temperature. should remain in an engine is 1 year. If the follow-
For winter operation below -10 °C the oil change ing oil change intervals are not reached over a pe-
intervals must be shortened. riod 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: E2-
96, E3-96/
E5-02, E4-
99 = 1000 operating hours
API: CF/
CF-4, CG-
4/CH-4 = 1000 operating hours
!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-

Maintenance
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.
Fuels Lubrication grease

For lubrication use only EP-high pressure grease,
Quality
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 in-
jection 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 separa-
tion 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 chang-
es use only high-quality hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils

Maintenance
5.3 Table of fuels and lubri-

cants
Assembly Fuel or lubricant Quantity approx.
Summer Winter 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 Winter diesel fuel (down 55 litres (17.2 USgal)

to -12 °C)*
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity 30 litres (7.9 USgal)
46 mm2/s at 40 °C
or
ester based biodegradable hydraulic oil
Sprinkler system Water Anti-freeze mixture water 230 litres (60.8 USgal)
Sprinkling of tires Emulsion 20 litres (5.3 USgal)
Articulated joint High pressure grease (lithium saponified) as required
*For lower temperatures refer to the mixing table in

chapter 5.2

Maintenance
5.4 Running-in instructions
The following maintenance work must be per-

formed 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

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 ma-
chine.

Maintenance
5.5 Maintenance chart
With all maintenance intervals perform also

the work for shorter preceding service inter-
vals.
No. Designation Note
Every 10 operating hours

5.6 Check the engine oil level Observe the dipstick marks
5.7 Checking the dry air filter
5.8 Check the hydraulic oil level Observe the dipstick marks
5.9 Checking the hydraulic oil filter element
5.10 Check the fuel level
5.11 Checking the water level in the sprinkler system Winter: Anti-freeze mixture
5.12 Checking the emulsion level
5.13 Grease the articulated joint High pressure grease
5.14 Clean cooling fins and engine oil cooler
5.15 Cleaning the hydraulic oil cooler
5.16 Adjust the scrapers
5.17 Service the battery distilled water, pole grease
5.18 Drain the sludge from the fuel tank
5.19 Changing the engine oil (at least 1x per year)** Observe the dipstick marks
5.20 Change the engine oil filter cartridge
5.21 Checking the valve clearance
5.22 Check the V-belt tension
5.23 Change the fuel pre-filter cartridge
5.24 Change the fuel filter cartridge
5.25 Change the hydraulic oil*** screen filter (at least after Observe the dipstick marks
2 years)
5.26 Change the hydraulic oil filter element****
5.27 Check the injection valves

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 Checking the tire pressure
5.30 Clean, change the dry air filter cartridge*
5.31 Clean the water tank
5.32 Maintenance in case of frost
5.33 Engine conservation
5.34 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

Every 10 operating hou rs
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
l If the red indicator 1 (Fig. 65) is visible with the

engine shut down, clean the filter cartridge, re-
fer to the section " maintenance as required".
l Press the reset button (2), the red indicator
will disappear.
Fig. 64
l Pull the dipstick out, wipe it off with a lint-free,

clean cloth and reinsert it until it bottoms. ! Caution
If the red indicator appears again after starting
l Pull the dipstick back out again.
the engine, you must change the filter car-
l The oil level should reach the "MAX"-mark tridge and, if necessary, also the safety car-
(Fig. 64). tridge*.
l If the oil level is too low top up oil immediately.
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
l Open the filler cap and check the water level.

l Fill in water, as far as this is necessary (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.
l If necessary top up with fuel (diesel or winter

diesel), see table of fuels and lubricants.
! Caution
Fill in fuel through a screen filter.

Every 50 oper ating hours
5.12 Checking the emulsion oil 5.13 Lubricating the articulated

level joint
i Note
Only AC-machines.
Fig. 71
l Lubricate each grease nipple (Fig. 71) (2 per

drum) with approx. 5 shots of high pressure
Fig. 70
grease from the grease gun.
l Clean the area around the filler opening.

l Open the filler cap and check the emulsion lev-
i Note
For quality of grease refer to the table of "fuels, lu-
el, top up if necessary (Fig. 70).
bricants and filling capacities".

If necessary repeat this procedure.

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
l Remove the cooling air duct cover.

l Blow the cooler out with compressed air, start-
ing 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 envi-
ronmentally.
l Clean the engine off with a water or steam jet
(do not aim at sensitive engine components).

5.15 Cleaning the hydraulic oil 5.16 Adjusting the scrapers

cooler
i Note
! Danger If the scrapers (2 per drum) are worn, they must be
adjusted or replaced.
Danger of injury!
Perform cleaning work only with engine
stopped and cooled down.
Fig. 74
l Open the flap 1 (Fig. 74).

Fig. 73 l Loosen the hexagon screws (2).
l Remove dried on dirt from the hydraulic oil l Adjust the scraper (3) so that it touches the
cooler using a suitable brush. drum lightly (slight bending of plastic insert).
l Blow the cooling passages out with com- l Tighten the hexagon screws.
pressed air, starting from the air discharge
side (Fig. 73).
Fig. 75
l Turn the screws 1 (Fig. 75) to adjust the scrap-

er, that it has a uniform distance of approx. 2
mm to the rubber tires (only AC-machines).

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
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.

5.18 Draining the slurry from the

fuel tank
! Danger
Fire hazard!
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.

5.19 Changing the engine oil
! Danger
Danger of scalding!
Danger of scalding when draining off hot en-
gine oil!
! Caution
Catch old oil and dispose of environmentally. Fig. 79
l Fill in new engine oil (Fig. 79) through the oil

i Note filler neck.
Drain the engine oil only when the engine is warm. l Screw the cap back on again.
The oil change after 500 operating hours refers to
a fuel sulphur content < / - of 0.5%. i Note
For other fuels the oil change intervals must be For quality and quantity of oil refer to the ”table of
shortened accordingly. (See section 5.2, lubrica- fuels, lubricants and filling capacities”.
tion oil change intervals).
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 run- l Check the oil level on the dipstick (Fig. 80).
ning out oil. The oil level must reach the "MAX"-mark, top
l Turn the oil drain plug back in with a new seal up oil if necessary.
ring.

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
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 car-

tridge (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 car-
tridge 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 en-
gine for leaks and check the oil level, if neces-
sary top up oil. Fig. 83
l Crank the engine by the front crankshaft end

(Fig. 83) in direction of arrow,

Adjusting the valve clearance
Fig. 84
l until both valves on cylinder 1 are "overlap-

Fig. 86
ping" (i.e. the exhaust valve is not yet closed,
the inlet valve starts to open). l Loosen counter nut 2 (Fig. 86) for 2 to .3 turns.
l Check and, if necessary, adjust the valves Adjust the setscrew (1) with a screwdriver, un-
marked black (Fig. 84). til the feeler gauge can be inserted and pulled
out with little resistance after retightening the
counter nut.
i Note
E = Intake valve
i Note
A = Exhaust valve As a control measure mark each adjusted valve
with chalk.
Checking the valve clearance
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
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 be-
tween the V-belt pulleys, retighten if necessary
(Fig. 88).
Tensioning the V-belt
Fig. 89
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.

Changing the V-belt

5.23 Changing the fuel pre-filter
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. ! Danger
Fire hazard!
l Install the new V-belt and tension it as de-
scribed above. When working on the fuel system do not use
i Note Do not spill any fuel.
Tension the new V-belt after a running time of ap-
prox. 30 minutes. ! Caution
Catch running out fuel, do not let it seep into
the ground.
Fig. 90
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).

5.24 Change the fuel filter car-

tridge
! Danger
Fire hazard!
Caution
!
Catch running out fuel and dispose of environ-
mentally 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 car-
tridge.
l Spin on the new fuel filter cartridge and tighten
it hand tight.
i Note
The fuel system is self-bleeding.

pump the oil from the tank into a clean vessel

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.
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.
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), re-

move the cover from the hydraulic oil tank and

l Run the engine for about 3 minutes with low

5.26 Changing the hydraulic oil speed, this will bleed the hydraulic system.
filter element 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
!
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
l Loosen the knurled nut 4 (Fig. 94) on the filter

housing.
l Take the filter bowl (3) off with the filter ele-
ment.
l Take the old filter element (2) out, clean the fil-
ter bowl.
l Clean the thread on the filter bowl.
l Assemble the filter bowl with a new filter ele-
ment, check the condition of the seal rings (1).

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.

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

specialist workshop.

As required
As r equired
5.29 Checking the tire pressure 5.30 Cleaning, changing the dry
air filter
i Note
Only AC-machines.
Fig. 97
l Dry air filter service is necessary if the mes-

Fig. 96 sage appears in the inspection glass 2 (Fig.
l Check the tire pressure with a pressure gauge 97) of the vacuum gauge (1), however, at the
on the tire inflation valve (Fig. 96). latest after one year.
Nominal value: 2,2 bar (32 psi)

! Caution
Do not use gasoline or hot fluids to clean the
i Note filter element.
Ensure equal pressure in all tires.
After cleaning the filter element must be in-
spected with a torch for damage.
Dry air filter elements with damaged filter ele-
ment 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 af-
ter 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.

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 ele-
Fig. 99
ment (3) out and clean it.
l Install the filter cartridge. l Unscrew the cover 1 (Fig. 99).
l Flush the water tank out with a strong water
l Reset the service indicator by pressing the re-
jet.
set button (4).
l Let all water with dirt run out.
Dry cleaning: l Screw the cover back in.
l Blow the filter cartridge out from inside to out- l Fill the water tank with clean water.
side with dry compressed air (max. 5 bar).
l Pull the rubber caps off the sprinkler tubes.
Wet cleaning: l Activate the sprinkler system for a short while

so that all coarse dirt is flushed out of the lines.
l Clean the filter cartridge by moving it to and fro
l Press the rubber caps back on.
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.

As required
5.32 Water sprinkler system, 5.33 Engine conservation

maintenance in the event of
If the engine is to be shut down for a longer period
frost of time (e.g. over winter), we recommend the fol-
lowing engine conservation measures to avoid
corrosion:
! Caution
l Clean engine and cooling system: With cold
If there is a risk of frost the water sprinkler sys- cleansing agent and water jet or, even better,
tem must be emptied or filled with an anti- with steam cleaning equipment.
freeze mixture.
l Run the engine warm and shut it down.
l Clean the water tank.
l Drain the still warm engine oil and fill in anti-
corrosion engine oil.
l Drain the fuel from the fuel tank, mix it well with
10% anti-corrosion oil and fill it back in. In-
stead 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
Fig. 100 cover off, spray the rocker chambers with a
mixture of diesel fuel and 10% anti-corrosion
l Open drain tap 1 (Fig. 100) and drain off all oil. Then fasten the cover again.
water.
l Crank the engine several times without ignition
Position "0" = Drain tap closed in order to spray all combustion chambers.
Position "I" = Drain tap open.
l Take the V-belt off and spray the grooves of
l Switch the sprinkler system on and drain all the V-belt pulley with anti-corrosion oil. Re-
water from the piping. move the anti-corrosion oil before taking the
l Fill the water tank with approx. 5 l of an anti- machine back into service.
freeze mixture (water and anti-freeze agent, l Close air intake on air filter and exhaust open-
e.g. glysantene). ing tightly.
l Switch the sprinkler system on, until anti-
freeze mixture comes running out of the sprin- i Note
kler tubes. Depending on weather conditions these conserva-
tion 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.

As required
Anti-corrosion oils are all oils complying with

the specification MIL-L-21260 B or TL 9150- 5.34 Tightening torques for
037/2 or Nato Code C640/642. screws with metric unified
thread
! Caution
A machine with conserved engine must be
clearly marked by attaching a clear warning la-
bel.
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.

6 Trouble shooting

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 mainte-
nance instructions.
Malfunctions are frequently caused by incorrect
operation of the machine or insufficient mainte-
nance. Whenever a fault occurs you should there-
fore 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 deal-
ers.
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.

Trouble shooting
6.2 Engine problems
Faults Possible cause Remedy
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.
Neutral start switch on travel lever defec- change, position correctly

tive or no contact between switch and
travel lever.
Battery not charged or not connected Terminal clamps on battery tighten,

check line connections
Poor starting of Battery power to low Have battery checked

engine or en-
gine works irreg- Battery pole clamps loose or oxidized, Clean the pole clamps, tighten and cover
ularly with poor causing the starter to turn too slow them with acid-free grease
power Especially during winter: use of too vis- Use an engine oil complying with the am-
cous engine oil bient temperatures
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
Valve clearance not as specified Adjust the valve clearance
Injection valves or plug-type injection Have inspected by a specialist

pump defective
Dry air filter cartridge dirty clean, replace if necessary
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
Injection valves defective Have inspected by a specialist

Trouble shooting
Faults Possible cause Remedy
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
V-belt loose or torn Tighten or replace the V-belt
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

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Operating instructions

Tandem Vibratory Roller

No warranty claims can be lodged in case of dam-

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 3

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

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 5

5.21 Check, adjust the valve clearance 68

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

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 7

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

* BW 125 ADH BW 135 AD BW 138 AD

Water sprinkler system

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 9

sound pressure level on the operator’s stand:

guaranteed sound capacity level of the machine:

Vibration of the entire boy (driver’s seat)

Hand-arm vibration values

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

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 11

Water sprinkler system

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

sound pressure level on the operator’s stand:

guaranteed sound capacity level of the machine:

Vibration of the entire boy (driver’s seat)

Hand-arm vibration values

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 13

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

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 15

General Notes Unintended use

Paragraphs marked like this highlight possible

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

i Note Checking the roll over protection

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 17

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

Behaviour in traffic Leaking fuel tanks can cause explosions. Ensure

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 19

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

Always ensure the correct tire pressure and do not

After maintenance work

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 21

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

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 23

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

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 25

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

3.1 General notes 3.2 Description of indicators

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 27

goes out = with travel lever in positions "I",

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

Position "right" = Travel light and parking light

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 29

pull = the throttle lever can be moved

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

Foot switch for flow divider* (only AD)

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 31

(2) 15A = (F12) working lights, right*

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

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 33

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

BW 125 ADH/ BW 135AD/138 AD/AC BOMAG 35