Operating instructions Maintenance instructions BW 125 ADH / BW 135 AD BW 138 AD / BW 138 AC S/N 101 650 12.... > S/N 101 170 21....> S/N 101 650 14 .... > S/N 101 650 15 .... >
Tandem Vibratory Roller Combination Roller
Catalogue number
008 138 01
04/2004
Foreword
BOMAG machines are products from the wide range of BOMAG compaction equipment. F oreword
BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your machine.
You should only operate the machine after you have been instructed and in compliance with these instructions. Strictly observe the safety regulations. Please observe also the guidelines of the Civil Engineering Liability Association ”Safety Rules for the Operation of Road Rollers and Soil Compactors” and all relevant accident prevention regulations.
This manual comprises: l
Safety regulations
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Operating instructions
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Maintenance instructions
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Trouble shooting
For your own personal safety you should only use original spare parts from BOMAG. In the course of technical development we reserve the right for technical modifications without prior notification. These operating and maintenance instructions are also available in other languages.
Using these instructions will l
help you to become familiar with the machine.
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avoid malfunctions caused by unprofessional operation.
Compliance with the maintenance instructions will l
enhance the reliability of the machine on construction sites,
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prolong the lifetime of the machine,
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reduce repair costs and downtimes.
BOMAG will not assume liability for the function of the machine l
if it is handled in a way that does not comply with the usual modes of use,
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if it is used for purposes other than the ones it is intended for, see safety regulations.
Furthermore, the spare parts catalogue is available from your BOMAG dealer against the serial number of your machine. Your BOMAG dealer will also supply you with information about the correct use of our machines in soil and asphalt construction. The above notes do not constitute an extension of the warranty and liability conditions specified in the general terms of business of BOMAG. We wish you successful work with your BOMAG machine. BOMAG GmbH Printed in Germany Copyright by BOMAG
No warranty claims can be lodged in case of damage resulting from l
operating errors,
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insufficient maintenance and
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wrong fuels and lubricants.
Please note! This manual was written for operators and maintenance personnel on construction sites. Always keep this manual close at hand, e.g. in the tool compartment of the machine or in a specially provided container. These operating and maintenance instructions are part of the machine.
BW 125 ADH/ BW 135AD/138 AD/AC
BOMAG
3
Foreword
Please fill in ............................ Machine type (Fig. 1) ............................ Serial-number (Fig. 1 and 2) ............................ Engine type (Fig. 3) ............................ Engine number (Fig. 3)
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Note
Fig. 1
Supplement the above data together with the commissioning protocol. During commissioning our organisation will instruct you in the operation and maintenance of the machine. Please observe strictly the safety regulations and all notes on risks and dangers!
Fig. 2
Fig. 3
4
BOMAG
BW 125 ADH/ BW 135AD/138 AD/AC
Table of Contents
Technical Data
7
Safety regulations
15
Indicators and Controls
23
3.1 General notes
27
3.2 Description of indicators and control elements
27
Operation
35 4.1 General notes
36
4.2 Inspections before starting operation
36
4.3 Starting the engine
37
4.4 Starting with jump wires
39
4.5 Driving the machine
39
4.6 Stopping the machine / applying the brake
41
4.7 Switching the vibration on and off
41
4.8 Switching the vibration on or off
43
4.9 Switching the pressure sprinkler system on or off
44
4.10 Stopping the engine/machine
45
4.11 Adjusting the driver's seat
46
4.12 Towing
46
4.13 Loading and transport
48
4.14 Foldable roll over protection structure (ROPS)
49
Maintenance
51 5.1 General notes on maintenance
52
5.2 Fuels and lubricants
53
5.3 Table of fuels and lubricants
55
5.4 Running-in instructions
56
5.5 Maintenance chart
57
5.6 Check the engine oil level
59
5.7 Checking the dry air filter
59
5.8 Checking the hydraulic oil level
60
5.9 Checking the hydraulic oil filter element
60
5.10 Checking the fuel level
61
5.11 Checking the water level
61
5.12 Checking the emulsion oil level
62
5.13 Lubricating the articulated joint
62
5.14 Cleaning cooling fins and engine oil cooler
63
5.15 Cleaning the hydraulic oil cooler
64
5.16 Adjusting the scrapers
64
5.17 Checking the battery condition, greasing the poles
65
5.18 Draining the slurry from the fuel tank
66
5.19 Changing the engine oil
67
5.20 Change the engine oil filter cartridge
68
BW 125 ADH/ BW 135AD/138 AD/AC
BOMAG
5
Table of Contents
5.21 Check, adjust the valve clearance
68
5.22 Checking, tensioning, changing the V-belt
70
5.23 Changing the fuel pre-filter
71
5.24 Change the fuel filter cartridge
72
5.25 Changing the hydraulic oil
73
5.26 Changing the hydraulic oil filter element
74
5.27 Checking the injection valves
75
5.28 Replacing the toothed belt
76
5.29 Checking the tire pressure
77
5.30 Cleaning, changing the dry air filter
77
5.31 Cleaning the water tank
78
5.32 Water sprinkler system, maintenance in the event of frost
79
5.33 Engine conservation
79
5.34 Tightening torques for screws with metric unified thread
80
Trouble shooting
6
81 6.1 General notes
82
6.2 Engine problems
83
BOMAG
BW 125 ADH/ BW 135AD/138 AD/AC
1 Technical Data
BW 125 ADH/ BW 135AD/138 AD/AC
BOMAG
7
Technical Data
Fig. 4
Dimensions in mm
A
B
C
D
H
H2
K
L
O
S
W
BW 125 ADH
1790
1280
650
800
1900
2700
320
2590
40
17,0
1200
BW 135 AD
1790
1380
650
800
1900
2700
320
2590
40
17,0
1300
BW 138 AD
1790
1460
650
810
1905
2705
325
2600
40
22
1380
*
Weights Operating weight (CECE) Mean axle load (CECE) Mean static linear load (CECE) Dimensions Oscillation angle Inner track radius
8
BW 125 ADH
BW 135 AD
BW 138 AD
kg kg kg/cm
3360 1680 14
3560 1780 13,7
4200 2100 15,2
+/-° mm
13 3700
13 3650
13 3610
BOMAG
BW 125 ADH/ BW 135AD/138 AD/AC
Technical Data
*
Travel characteristics Travel speed I Travel speed II Max. gradability/with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Fixed engine speed 1 Fixed engine speed 2 Fuel tank capacity Electrical equipment Drive system Driven axles
Vibration system Drive system Frequency Amplitude Vibrating drum Water sprinkler system Type of sprinkling Interval control Water tank capacity *
BW 135 AD
BW 138 AD
0...5,0 0...10 40/30
0...5,0 0...10 40/30
0...5,0 0...10 40/30
Deutz F3L 2011 Air-oil 3 34 2800 2200 2700 55 12 hydrost. front+rear
Deutz F3L 2011 Air-oil 3 34 2800 2200 2700 55 12 hydrost. front+rear
Deutz F3L 2011 Air-oil 3 34 2800 2500 2800 55 12 hydrost. front+rear
hydrost. hydr.-mech.
hydrost. hydr.-mech.
hydrost. hydr.-mech.
Oscill.-articul. hydrost. 25
Oscill.-articul. hydrost. 25
Oscill.-articul. hydrost. 25
hydrost. 50/60 0,45 front+rear
hydrost. 50/60 0,40 front+rear
hydrost. 46/52 0,50 front+rear
Pressure Standard 230
Pressure Standard 230
Pressure Standard 230
km/h km/h %
kW rpm rpm rpm l V
Brakes Service brake Parking brake Steering Type of steering Steering operation Steering angle +/-
BW 125 ADH
Degree
Hz mm
l
The right for technical modifications remains reserved
BW 125 ADH/ BW 135AD/138 AD/AC
BOMAG
9
Technical Data
The following noise and vibration values according to the EC-directive for machines, edition (98/37/ EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with the vibration switched on. The machine was standing on an elastic base. During operation these values may vary because of the existing operating conditions.
Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level on the operator’s stand: BW 125 ADH LpA =79 dB(A) BW 135 AD LpA =83,5 dB(A) BW 138 AD LpA =86 dB(A) The nose emission value for the machine according to the noise emission regulation 2000/14/EG is guaranteed sound capacity level of the machine: BW 125 ADH LWA = 107 dB(A) BW 135 AD LWA = 107 dB(A) BW 138 AD LWA = 104 dB(A) These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO 11204 for sound pressure level (LpA) at the place of the operator.
Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire boy (driverâ&#x20AC;&#x2122;s seat) The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2. Hand-arm vibration values The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2.
10
BOMAG
BW 125 ADH/ BW 135AD/138 AD/AC
Technical Data
Fig. 5
Dimensions in mm
A
B
C
D
H
H2
K
L
O
S
W
BW 138 AC
1790
1460
650
810
1905
2705
325
2580
40
22
1380
*
Weights Operating weight (CECE) Axle load, drum (CECE) Axle load, wheels (CECE) Mean static linear load Dimensions Oscillation angle Inner track radius
BW 125 ADH/ BW 135AD/138 AD/AC
BW 138 AC
kg kg kg kg/cm
4000 2050 1950 14,9
+/-° mm
13 3610
BOMAG
11
Technical Data
*
BW 138 AC
Travel characteristics Travel speed I Travel speed II Max. gradability/with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Fixed engine speed 1 Fixed engine speed 2 Fuel tank capacity Electrical equipment Drive system Driven axles
km/h km/h %
0...5,0 0...10 40/30
Deutz F3L 2011 Air-oil 3 34 2800 2250 2800 55 12 hydrostatic front+rear
kW rpm rpm rpm l V
Tires Number of tires Tire size
4 225/75 R16
Brakes Service brake Parking brake
hydrost. hydr.-mech.
Steering Type of steering Steering operation Steering angle +/Vibration system Drive system Frequency Amplitude Vibrating drum Water sprinkler system Type of sprinkling Interval control Water tank capacity Emulsion tank capacity *
12
Oscill.-articul. hydrost. 25
Degree
hydrost. 46/52 0,5 front
Hz mm
Pressure Standard 230 20
l l
The right for technical modifications remains reserved
BOMAG
BW 125 ADH/ BW 135AD/138 AD/AC
Technical Data
The following noise and vibration values according to the EC-directive for machines, edition (98/37/ EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with the vibration switched on. The machine was standing on an elastic base. During operation these values may vary because of the existing operating conditions.
Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level on the operatorâ&#x20AC;&#x2122;s stand: BW 138 AC LpA =81 dB(A) The nose emission value for the machine according to the noise emission regulation 2000/14/EG is guaranteed sound capacity level of the machine: BW 138 AC LWA = 102 dB(A) These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO 11204 for sound pressure level (LpA) at the place of the operator.
Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire boy (driverâ&#x20AC;&#x2122;s seat) The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2. Hand-arm vibration values The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2.
BW 125 ADH/ BW 135AD/138 AD/AC
BOMAG
13
2 Safety regulations
BW 125 ADH/ BW 135AD/138 AD/AC
BOMAG
15
Safety regulations
General Notes
Unintended use
This BOMAG machine has been built in accordance with the latest technical standard and complies with the applicable regulations and technical rules. However, dangers for persons and property may arise from this machine, if:
However, dangers may arise from this machine if it is operated by untrained personnel or if it is subject of unintended use.
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it is used for purposes other than the ones it is intended for
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it is operated by untrained personnel
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it is changed or converted in an unprofessional way
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Each person involved in the operation, maintenance and repair of the machine must therefore read and comply with these safety regulations. If necessary, this must be confirmed by obtaining the signature of the customer. Furthermore, the following instructions and regulations must obviously also be complied with: l
applicable accident prevention instructions
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generally accepted safety and road traffic regulations
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country specific safety regulations. It is the duty of the operator to be acquainted with these instructions and to apply these accordingly. This applies also for local regulations concerning different types of handling work. Should the recommendations in these instructions be different from the regulations valid in your country, you must comply with the safety regulations valid in your country.
This machine must only be used for: l
compaction of bituminous material, e.g. road surface layers. (Only AC and AD machines)
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medium to heavy compaction work in earth construction (road sub-bases)
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You should only operate the unit with fully functional safety equipment.
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Have the machine inspected by an expert once every year.
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Starting and operation of the machine in explosive environments is prohibited.
Who has permission to operate the machine?
the safety instructions are not observed
Intended use
Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground.
Only trained and instructed persons of at least 18 years of age are permitted to drive and operate this machine. For operation of the machine the responsibilities must be clearly specified and complied with. Persons under the influence of alcohol, medicine or drugs are not allowed to operate, service or repair the machine. Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists.
Conversions and changes to the machine Unauthorized alterations to the machine are prohibited for safety reasons. Original parts and accessories have been specially designed for this machine. We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive driving safety. The manufacturer explicitly excludes any liability for damage caused by the use of non-original parts or accessories.
Notes on safety in the operating and maintenance instructions: Danger Paragraphs marked like this highlight possible dangers for persons. !
Caution Paragraphs marked like this highlight possible dangers for machines or parts of the machine. !
BOMAG
BW 125 ADH/ BW 135AD/138 AD/AC
Safety regulations
i
Checking the roll over protection structure (ROPS)
Note
Paragraphs marked like this contain technical information for the optimal economical use of the machine.
The frame of the machine must not be warped, bent or cracked in the area of the ROPS fastening.
Environment Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts. Observe environmental regulations.
Information and safety stickers/decals on the machine Keep safety stickers in good and legible condition (see parts manual) and comply with their meaning.
The ROPS must not show any rust, damage, hairline cracks or open fractures. The ROPS must not rattle about when driving. This would indicate that it is not properly fastened. All bolted connections must comply with the specifications and should be absolutely tight (observe the tightening torques). Screw and nuts must not be damaged, bent or deformed. No accessories may be welded or bolted on and no additional holes must be drilled without the consent of the distributor, since this will impair the strength of the unit.
Replace damaged and illegible stickers/decals.
Starting the machine Loading the machine
Before starting
Use only strong and stable loading ramps of sufficient load bearing capacity. The ramp inclination must be less than the gradability of the machine. Secure the machine against tipping or slipping off. Secure the machine on the transport vehicle against rolling, slipping and turning over.
The machine must only be operated from the driver's seat. Use only machines which are serviced at regular intervals. Become acquainted with the equipment, the control elements, the working principle of the machine and the working area.
Persons are highly endangered when l
they step or stand under loads being lifted
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they remain in the drive range of the machine during an instruction and during loading.
Wear your personal protective outfit (hard hat, safety boots, etc.). Before climbing on the machine check whether:
The machine must not swing about when being lifted.
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persons or obstructions are beside or under the machine
Use only safe lifting gear of sufficient load bearing capacity.
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the machine is free of oily and combustible material
Fasten the lifting gear only at the specified lifting points.
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all grips, steps and platforms are free of grease, oils, fuel, dirt, snow and ice
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the engine hood is closed and locked
Towing the machine You should generally use a tow bar. Max. towing speed 1 km/h, max. towing distance 500 m. Before releasing the multi-disc brake secure the machine against unintended rolling.
BW 125 ADH/ BW 135AD/138 AD/AC
Use steps and grips to climb onto the machine. Before starting the machine check whether: l
the machine shows any obvious faults
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all guards and safety elements are in place
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steering, brakes, control elements, light system and warning horn work correctly
BOMAG
17
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Safety regulations
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the seat is correctly adjusted
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mirrors (if present) are clean and correctly adjusted.
Do not start the machine with defective gauges, control lights or control elements.
not use the emergency stop switch as service brake. Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated. If the engine oil pressure control light lights up stop the engine immediately.
Do not take any loose objects with you or fasten them to the machine.
If the machine has contacted high-voltage power lines:
On machines with roll over protection system you must always wear your seat belt.
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Do not leave the operator's platform
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Warn others from coming close to or touching the machine
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if possible drive the machine out of the danger zone
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Have the electric power switched off
Starting Start and operate the machine only from the driver's seat. For starting set all control levers to 'neutral position'. Do not use any starting aids like start pilot or ether. After starting check all gauges and control lights.
Operate the machine only from the operator's stand.
Starting with jump wires
Keep the cabin doors closed.
Connect plus with plus and minus with minus (ground cable) - always connect the ground strap last and disconnect it first! A wrong connection will cause severe damage in the electric system.
Do not adjust the driver's seat while driving. Do not climb onto or off the machine while the machine is driving.
Do not start the engine by shorting the electric terminals on the starter motor, because the machine may start to drive immediately. Starting in closed rooms Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!
Do not use the machine to transport persons. In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected. Always keep a sufficient distance to excavation walls and embankments and do not use working methods that could impair the stability of the machine.
Driving the machine
Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground.
Persons in the danger area
Always keep a sufficient distance when passing through subways, under bridges, tunnels, electric power lines etc.
Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions, especially when driving in reverse.
Driving on inclinations and slopes
If necessary give warning signals. Stop work immediately if persons remain in the danger zone, despite the warning.
Do not drive on gradients exceeding the maximum gradability of the machine. On slopes drive extremely carefully and always directly up or down the slope. Change to a lower gear before starting to drive.
Do not step or stand in the articulation area of the machine when the engine is running. Danger of squashing! Driving In events of emergency and in case of danger actuate the emergency stop switch immediately. Do
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Change the travel direction only at standstill.
Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes. Higher risk of accident!
BOMAG
BW 125 ADH/ BW 135AD/138 AD/AC
Safety regulations
Leaking fuel tanks can cause explosions. Ensure tight fit of the fuel tank cover, if necessary replace immediately.
Behaviour in traffic Match the speeds to the working conditions. Always allow loaded transport vehicles to pass. Switch the lights on if the visibility is poor.
Fire protection measures
Keep away from edges and embankments.
Familiarise yourself with the location and the operation of fire fighting equipment. Observe all fire reporting and fire fighting possibilities.
Check the effect of vibration When compacting with vibration you must always check the effect of the vibration on nearby buildings and underground supply lines (gas, water, sewage, electric power) and stop compaction work with vibration, if necessary. Do not switch the vibration on when working on hard (frozen, concrete) ground. Danger of bearing damage!
Maintenance work Comply with the maintenance work described in the operating and maintenance instructions, including the information concerning the replacement of parts. Maintenance work must only be performed by qualified and authorized persons. For overhead maintenance and assembly work use the access steps and working platforms provided or other secure means. Do not use machine parts as access steps.
Parking the machine Park the machine on level and firm ground. Before leaving the machine:
Keep unauthorized persons away from the machine.
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return the control lever to neutral position
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apply the parking brake
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shut the engine down and pull the ignition key out
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lock the cabin door
Park the machine on horizontal, level and firm ground.
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secure the machine against unintended use.
Pull the key out of the ignition switch.
Do not perform maintenance work while the machine is driving or the engine is running.
Do not jump off the machine, but use access steps and grips.
Secure the articulated joint with the articulation lock.
Mark machines, which could be in the way, with a clearly visible sign.
Working on hydraulic lines
Parking on slopes and inclinations Secure the machine against rolling, place metal chocks in front of and behind the drums.
Filling the fuel tank Do not inhale any fuel fumes. Refuel only with the engine stopped and the auxiliary heater switched off. Do not refuel in closed rooms.
Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. When being injured by hydraulic oil consult a medical doctor immediately, as otherwise this may cause severe infections. Do not step in front of or behind the drums/rubber wheels when performing adjustment work in the hydraulic system. Do not change the setting of pressure relief valves.
No open fire, do not smoke.
Drain hydraulic oil at operating temperature - danger of scalding!
Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.
Catch running out hydraulic oil and dispose of environmentally.
Wipe off spilled fuel. Keep dirt and water away from the fuel.
Always catch and dispose of biodegradable hydraulic oils separately.
BW 125 ADH/ BW 135AD/138 AD/AC
BOMAG
19