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Bomag BW138 AD Single Tandem Vibratory Roller Service Repair Manual

service repair manual

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Bomag BW138 AD Single Tandem Vibratory Roller Service Repair Manual

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  1. 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

  2. Foreword You should only operate the machine after you have been instructed and in compliance with these instructions. Strictly observe the safety regulations. Please observe also the guidelines of the Civil En- gineering Liability Association ”Safety Rules for the Operation of Road Rollers and Soil Compac- tors” and all relevant accident prevention regula- tions. Foreword BOMAG machines are products from the wide range of BOMAG compaction equipment. BOMAG’s vast experience in connection with state-of-the-art production and testing meth- ods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your ma- chine. This manual comprises: For your own personal safety you should only use original spare parts from BOMAG. Safety regulations l Operating instructions l In the course of technical development we re- serve the right for technical modifications without prior notification. These operating and maintenance instructions are also available in other languages. Furthermore, the spare parts catalogue is availa- ble from your BOMAG dealer against the serial number of your machine. Your BOMAG dealer will also supply you with in- formation about the correct use of our machines in soil and asphalt construction. The above notes do not constitute an extension of the warrantyand liabilityconditionsspecified inthe general terms of business of BOMAG. We wish you successful work with your BOMAG machine. BOMAG GmbH Printed in Germany Copyright by BOMAG Maintenance instructions l Trouble shooting l Using these instructions will help you to become familiar with the machine. l avoid malfunctions caused by unprofessional operation. l Compliance with the maintenance instructions will enhance the reliability of the machine on con- struction sites, l prolong the lifetime of the machine, l reduce repair costs and downtimes. l BOMAG will not assume liability for the function of the machine if it is handled in a way that does not comply with the usual modes of use, l if it is used for purposes other than the ones it is intended for, see safety regulations. l No warranty claims can be lodged in case of dam- age resulting from operating errors, l insufficient maintenance and l wrong fuels and lubricants. l 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 3 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 Supplement the above data together with the com- missioning protocol. Fig. 1 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 BW 125 ADH/ BW 135AD/138 AD/AC BOMAG

  4. Table of Contents Technical Data 7 Safety regulations 15 Indicators and Controls 23 3.1 General notes 3.2 Description of indicators and control elements 27 27 35 Operation 4.1 General notes 4.2 Inspections before starting operation 4.3 Starting the engine 4.4 Starting with jump wires 4.5 Driving the machine 4.6 Stopping the machine / applying the brake 4.7 Switching the vibration on and off 4.8 Switching the vibration on or off 4.9 Switching the pressure sprinkler system on or off 4.10 Stopping the engine/machine 4.11 Adjusting the driver's seat 4.12 Towing 4.13 Loading and transport 4.14 Foldable roll over protection structure (ROPS) 36 36 37 39 39 41 41 43 44 45 46 46 48 49 51 Maintenance 5.1 General notes on maintenance 5.2 Fuels and lubricants 5.3 Table of fuels and lubricants 5.4 Running-in instructions 5.5 Maintenance chart 5.6 Check the engine oil level 5.7 Checking the dry air filter 5.8 Checking the hydraulic oil level 5.9 Checking the hydraulic oil filter element 5.10 Checking the fuel level 5.11 Checking the water level 5.12 Checking the emulsion oil level 5.13 Lubricating the articulated joint 5.14 Cleaning cooling fins and engine oil cooler 5.15 Cleaning the hydraulic oil cooler 5.16 Adjusting the scrapers 5.17 Checking the battery condition, greasing the poles 5.18 Draining the slurry from the fuel tank 5.19 Changing the engine oil 5.20 Change the engine oil filter cartridge 52 53 55 56 57 59 59 60 60 61 61 62 62 63 64 64 65 66 67 68 BW 125 ADH/ BW 135AD/138 AD/AC 5 BOMAG

  5. Table of Contents 5.21 Check, adjust the valve clearance 5.22 Checking, tensioning, changing the V-belt 5.23 Changing the fuel pre-filter 5.24 Change the fuel filter cartridge 5.25 Changing the hydraulic oil 5.26 Changing the hydraulic oil filter element 5.27 Checking the injection valves 5.28 Replacing the toothed belt 5.29 Checking the tire pressure 5.30 Cleaning, changing the dry air filter 5.31 Cleaning the water tank 5.32 Water sprinkler system, maintenance in the event of frost 5.33 Engine conservation 5.34 Tightening torques for screws with metric unified thread 68 70 71 72 73 74 75 76 77 77 78 79 79 80 81 Trouble shooting 6.1 General notes 6.2 Engine problems 82 83 6 BW 125 ADH/ BW 135AD/138 AD/AC BOMAG

  6. 1 Technical Data BW 125 ADH/ BW 135AD/138 AD/AC 7 BOMAG

  7. Technical Data Fig. 4 Dimensions in mm BW 125 ADH BW 135 AD BW 138 AD A B C D H H2 K L O S W 1790 1790 1790 1280 1380 1460 650 650 650 800 800 810 1900 1900 1905 2700 2700 2705 320 320 325 2590 2590 2600 40 40 40 17,0 17,0 22 1200 1300 1380 * BW 125 ADH BW 135 AD BW 138 AD Weights Operating weight (CECE) Mean axle load (CECE) Mean static linear load (CECE) kg kg 3360 1680 14 3560 1780 13,7 4200 2100 15,2 kg/cm Dimensions Oscillation angle Inner track radius +/-° mm 13 13 13 3700 3650 3610 8 BW 125 ADH/ BW 135AD/138 AD/AC BOMAG

  8. Technical Data * BW 125 ADH BW 135 AD BW 138 AD Travel characteristics Travel speed I Travel speed II Max. gradability/with vi- bration (soil dependent) km/h km/h 0...5,0 0...10 40/30 0...5,0 0...10 40/30 0...5,0 0...10 40/30 % 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 Deutz Deutz Deutz F3L 2011 Air-oil F3L 2011 Air-oil F3L 2011 Air-oil 3 3 3 kW rpm rpm rpm 34 34 34 2800 2200 2700 2800 2200 2700 2800 2500 2800 l 55 12 55 12 55 12 V hydrost. front+rear hydrost. front+rear hydrost. front+rear Brakes Service brake Parking brake hydrost. hydr.-mech. hydrost. hydr.-mech. hydrost. hydr.-mech. Steering Type of steering Steering operation Steering angle +/- Oscill.-articul. hydrost. Oscill.-articul. hydrost. Oscill.-articul. hydrost. Degree 25 25 25 Vibration system Drive system Frequency Amplitude Vibrating drum hydrost. 50/60 0,45 front+rear hydrost. 50/60 0,40 front+rear hydrost. 46/52 0,50 front+rear Hz mm Water sprinkler system Type of sprinkling Interval control Water tank capacity Pressure Standard Pressure Standard Pressure Standard l 230 230 230 * The right for technical modifications remains reserved BW 125 ADH/ BW 135AD/138 AD/AC 9 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 speedand 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. 10 BW 125 ADH/ BW 135AD/138 AD/AC BOMAG

  10. Technical Data Fig. 5 Dimensions in mm BW 138 AC A B C D H H2 K L O S W 1790 1460 650 810 1905 2705 325 2580 40 22 1380 * BW 138 AC Weights Operating weight (CECE) Axle load, drum (CECE) Axle load, wheels (CECE) Mean static linear load kg kg kg 4000 2050 1950 14,9 kg/cm Dimensions Oscillation angle Inner track radius +/-° mm 13 3610 BW 125 ADH/ BW 135AD/138 AD/AC 11 BOMAG

  11. Technical Data * BW 138 AC Travel characteristics Travel speed I Travel speed II Max. gradability/with vi- bration (soil dependent) km/h km/h 0...5,0 0...10 40/30 % 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 Deutz F3L 2011 Air-oil 3 kW rpm rpm rpm 34 2800 2250 2800 55 12 l V hydrostatic front+rear 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 +/- Oscill.-articul. hydrost. Degree 25 Vibration system Drive system Frequency Amplitude Vibrating drum hydrost. 46/52 Hz mm 0,5 front Water sprinkler system Type of sprinkling Interval control Water tank capacity Emulsion tank capacity Pressure Standard l l 230 20 * The right for technical modifications remains reserved 12 BW 125 ADH/ BW 135AD/138 AD/AC BOMAG

  12. Technical Data The following noise and vibration values according to the EC-directive for machines, edition (98/37/ EEC) and the noise emission regulation2000/14/EC were measured at nominalengine 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. BW 125 ADH/ BW 135AD/138 AD/AC 13 BOMAG

  13. 2 Safety regulations BW 125 ADH/ BW 135AD/138 AD/AC 15 BOMAG

  14. Safety regulations General Notes Unintended use However, dangers may arise from this machine if it is operated by untrained personnel or if it is sub- ject of unintended use. Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground. Starting and operation of the machine in explosive environments is prohibited. This BOMAG machine has been built in ac- cordance with the latest technical standard and complies with the applicable regulations and technical rules. However, dangers for per- sons and property may arise from this ma- chine, if: it is used for purposes other than the ones it is intended for l Who has permission to operate the ma- chine? Only trained and instructed persons of at least 18 years of age are permitted to drive and operate this machine. For operation of the machine the re- sponsibilities must be clearly specified and com- plied with. Persons under the influence of alcohol, medicine or drugs are not allowed to operate, service or re- pair the machine. Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists. it is operated by untrained personnel l it is changed or converted in an unprofessional way l the safety instructions are not observed l Each person involved in the operation, mainte- nance and repair of the machine must there- fore read and comply with these safety regulations. If necessary, this must be con- firmed by obtaining the signature of the cus- tomer. Furthermore, the following instructions and regula- tions must obviously also be complied with: applicable accident prevention instructions l Conversions and changes to the ma- chine Unauthorized alterations to the machine are pro- hibited for safety reasons. Original parts and accessories have been special- ly designed for this machine. We wish to make ex- plicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive driving safety. The manufacturer explicitly ex- cludes any liability for damage caused by the use of non-original parts or accessories. generally accepted safety and road traffic reg- ulations l country specific safety regulations. It is the duty of the operator to be acquainted with these instructions and to apply these accord- ingly. This applies also for local regulations concerning different types of handling work. Should the recommendations in these instruc- tions be different from the regulations valid in your country, you must comply with the safety regulations valid in your country. l Intended use This machine must only be used for: Notes on safety in the operating and maintenance instructions: compaction of bituminous material, e.g. road surface layers. (Only AC and AD machines) l medium to heavy compaction work in earth construction (road sub-bases) l Danger ! Paragraphs marked like this highlight possible dangers for persons. You should only operate the unit with fully functional safety equipment. l Have the machine inspected by an expert once every year. l Caution ! Paragraphs marked like this highlight possible dangers for machines or parts of the machine. 16 BW 125 ADH/ BW 135AD/138 AD/AC BOMAG

  15. Safety regulations Checking the roll over protection structure (ROPS) The frame of the machine must not be warped, bent or cracked in the area of the ROPS fastening. The ROPS must not show any rust, damage, hair- line cracks or open fractures. The ROPS must not rattle about when driving. This would indicate that it is not properly fastened. All bolted connections must comply with the spec- ifications and should be absolutely tight (observe the tightening torques). Screw and nuts must not be damaged, bent or deformed. No accessories may be welded or bolted on and no additional holes must be drilled without the con- sent of the distributor, since this will impair the strength of the unit. i Note Paragraphs marked like this contain technical in- formation for the optimal economical use of the machine. Environment Paragraphs marked like this point out practic- es for safe and environmental disposal of fuels and lubricants as well as replacement parts. Observe environmental regulations. Information and safety stickers/decals on the machine Keep safety stickers in good and legible condition (see parts manual) and comply with their meaning. Replace damaged and illegible stickers/decals. Starting the machine Loading the machine Use only strong and stable loading ramps of suffi- cient load bearing capacity. The ramp inclination must be less than the gradability of the machine. Secure the machine against tipping or slipping off. Secure the machine on the transport vehicle against rolling, slipping and turning over. Persons are highly endangered when Before starting The machine must only be operated from the driv- er's seat. Use only machines which are serviced at regular intervals. Become acquainted with the equipment, the con- trol elements, the working principle of the machine and the working area. Wear your personal protective outfit (hard hat, safety boots, etc.). Before climbing on the machine check whether: they step or stand under loads being lifted l they remain in the drive range of the machine during an instruction and during loading. l persons or obstructions are beside or under the machine The machine must not swing about when being lift- ed. Use only safe lifting gear of sufficient load bearing capacity. Fasten the lifting gear only at the specified lifting points. l the machine is free of oily and combustible material l all grips, steps and platforms are free of grease, oils, fuel, dirt, snow and ice l the engine hood is closed and locked l Towing the machine You should generally use a tow bar. Max. towing speed 1 km/h, max. towing distance 500 m. Before releasing the multi-disc brake secure the machine against unintended rolling. Use steps and grips to climb onto the machine. Before starting the machine check whether: the machine shows any obvious faults l all guards and safety elements are in place l steering, brakes, control elements, light sys- tem and warning horn work correctly l BW 125 ADH/ BW 135AD/138 AD/AC 17 BOMAG

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  17. Safety regulations the seat is correctly adjusted 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. Ifthe engine oil pressure controllight lights up stop the engine immediately. If the machine has contacted high-voltage power lines: l mirrors (if present) are clean and correctly ad- justed. l Do not start the machine with defective gauges, control lights or control elements. Do not take any loose objects with you or fasten them to the machine. On machines with roll over protection system you must always wear your seat belt. Do not leave the operator's platform l Starting Start and operate the machine only from the driv- er's seat. For starting set all control levers to 'neutral posi- tion'. Do not use any starting aids like start pilot or ether. After starting check all gauges and control lights. Warn others from coming close to or touching the machine l if possible drive the machine out of the danger zone l Have the electric power switched off l Operate the machine only from the operator's stand. Keep the cabin doors closed. Do not adjust the driver's seat while driving. Do not climb onto or off the machine while the ma- chine is driving. Change the travel direction only at standstill. Do not use the machine to transport persons. In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected. Always keep a sufficient distance to excavation walls and embankments and do not use working methods that could impair the stability of the ma- chine. Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground. Always keep a sufficient distance when passing through subways, under bridges, tunnels, electric power lines etc. Starting with jump wires Connect plus with plus and minus with minus (ground cable) - always connect the ground strap last and disconnect it first! A wrong connection will cause severe damage in the electric system. Do not start the engine by shorting the electric ter- minals on the starter motor, because the machine may start to drive immediately. Starting in closed rooms Exhaust gases are highly dangerous! Always en- sure an adequate supply of fresh air when starting in closed rooms! Driving the machine Persons in the danger area Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions, especially when driving in reverse. If necessary give warning signals. Stop work im- mediately if persons remain in the danger zone, despite the warning. Do not step or stand in the articulation area of the machine when the engine is running. Danger of squashing! Driving on inclinations and slopes Do not drive on gradients exceeding the maximum gradability of the machine. On slopes drive extremely carefully and always di- rectly up or down the slope. Change to a lower gear before starting to drive. Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes. Higher risk of accident! Driving In events of emergency and in case of danger ac- tuate the emergency stop switch immediately. Do 18 BW 125 ADH/ BW 135AD/138 AD/AC BOMAG

  18. 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. Keep away from edges and embankments. Fire protection measures Familiarise yourself with the location and the oper- ation of fire fighting equipment. Observe all fire re- porting and fire fighting possibilities. Check the effect of vibration When compacting with vibration you must always check the effect of the vibration on nearby build- ings and underground supply lines (gas, water, sewage,electricpower)and stop compactionwork 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, in- cluding the information concerning the replace- ment of parts. Maintenance work must only be performed by qualified and authorized persons. For overhead maintenance and assembly work use the access steps and working platforms pro- vided or other secure means. Do not use machine parts as access steps. Keep unauthorized persons away from the ma- chine. Do not perform maintenance work while the ma- chine is driving or the engine is running. Park the machine on horizontal, level and firm ground. Pull the key out of the ignition switch. Secure the articulated joint with the articulation lock. Parking the machine Park the machine on level and firm ground. Before leaving the machine: return the control lever to neutral position l apply the parking brake l shut the engine down and pull the ignition key out l lock the cabin door l secure the machine against unintended use. l Do not jump off the machine, but use access steps and grips. Mark machines, which could be in the way, with a clearly visible sign. Working on hydraulic lines Relieve hydraulic pressures before working on hy- draulic lines. Hydraulic oil escaping under pres- sure can penetrate the skin and cause severe injury. When being injured by hydraulic oil consult a medical doctor immediately, as otherwise this may cause severe infections. Do not step in front of or behind the drums/rubber wheels when performing adjustment work in the hydraulic system. Do not change the setting of pressure relief valves. Drain hydraulic oil at operating temperature - dan- ger of scalding! Catch running out hydraulic oil and dispose of en- vironmentally. Always catch and dispose of biodegradable hy- draulic oils separately. Parking on slopes and inclinations Secure the machine against rolling, place metal chocks in front of and behind the drums. Filling the fuel tank Do not inhale any fuel fumes. Refuel only with the engine stopped and the auxil- iary heater switched off. Do not refuel in closed rooms. No open fire, do not smoke. Do not spill any fuel. Catch running out fuel, do not let it seep into the ground. Wipe off spilled fuel. Keep dirt and water away from the fuel. BW 125 ADH/ BW 135AD/138 AD/AC 19 BOMAG

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