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
Foreword
F orew ord
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:
l Safety regulations l Operating instructions l Maintenance instructions l Trouble shooting
Using these instructions will
l help you to become familiar with the machine. l avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
l enhance the reliability of the machine on
con-struction sites,
l prolong the lifetime of the machine, l 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,
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-You should only operate the machine after you have been instructed and in compliance with these instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil En-gineering Liability Association ”Safety Rules for the Operation of Road Rollers and Soil Compac-tors” and all relevant accident prevention regula-tions.
For your own personal safety you should only use original spare parts from BOMAG.
In the course of technical development we re-serve the right for technical modifications without prior notification.
These operating and maintenance instructions are also available in other languages.
Furthermore, the spare parts catalogue is availa-ble from your BOMAG dealer against the serial number of your machine.
Your BOMAG dealer will also supply you with in-formation about the correct use of our machines in soil and asphalt construction.
The above notes do not constitute an extension of the warranty and liability conditions specified in the general terms of business of BOMAG.
We wish you successful work with your BOMAG machine.
BOMAG GmbH Printed in Germany Copyright by BOMAG
Foreword
Please fill in
. . . . Machine type (Fig. 1)
. . . . Serial-number (Fig. 1 and 2) . . . . Engine type (Fig. 3)
. . . . Engine number (Fig. 3)
i
NoteSupplement 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. 1
Fig. 2
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
Table of Contents
5.21 Check, adjust the valve clearance 68
5.22 Checking, tensioning, changing the V-belt 70
5.23 Changing the fuel pre-filter 71
5.24 Change the fuel filter cartridge 72
5.25 Changing the hydraulic oil 73
5.26 Changing the hydraulic oil filter element 74
5.27 Checking the injection valves 75
5.28 Replacing the toothed belt 76
5.29 Checking the tire pressure 77
5.30 Cleaning, changing the dry air filter 77
5.31 Cleaning the water tank 78
5.32 Water sprinkler system, maintenance in the event of frost 79
5.33 Engine conservation 79
5.34 Tightening torques for screws with metric unified thread 80
Trouble shooting 81
6.1 General notes 82
Technical Data
Fig. 4 Dimensions in mm A B C D H H2 K L O S W BW 125 ADH 1790 1280 650 800 1900 2700 320 2590 40 17,0 1200 BW 135 AD 1790 1380 650 800 1900 2700 320 2590 40 17,0 1300 BW 138 AD 1790 1460 650 810 1905 2705 325 2600 40 22 1380 * BW 125 ADH BW 135 AD BW 138 AD WeightsOperating weight (CECE) kg 3360 3560 4200
Mean axle load (CECE) kg 1680 1780 2100
Mean static linear load (CECE)
kg/cm 14 13,7 15,2
Dimensions
Technical Data
Travel characteristics
Travel speed I km/h 0...5,0 0...5,0 0...5,0
Travel speed II km/h 0...10 0...10 0...10
Max. gradability/with vi-bration (soil dependent)
% 40/30 40/30 40/30
Drive
Engine manufacturer 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
Technical Data
Fig. 5 Dimensions in mm A B C D H H2 K L O S W BW 138 AC 1790 1460 650 810 1905 2705 325 2580 40 22 1380 * BW 138 AC WeightsOperating 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
Technical Data
Travel characteristics
Travel speed I km/h 0...5,0
Travel speed II km/h 0...10
Max. gradability/with vi-bration (soil dependent)
% 40/30
Drive
Engine manufacturer 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
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
Safety regulations
General Notes
This BOMAG machine has been built in ac-cordance with the latest technical standard and complies with the applicable regulations and technical rules. However, dangers for per-sons and property may arise from this ma-chine, if:
l it is used for purposes other than the ones it is
intended for
l it is operated by untrained personnel
l it is changed or converted in an unprofessional
way
l the safety instructions are not observed
Each person involved in the operation, mainte-nance and repair of the machine must there-fore read and comply with these safety regulations. If necessary, this must be con-firmed by obtaining the signature of the cus-tomer.
Furthermore, the following instructions and regula-tions must obviously also be complied with:
l applicable accident prevention instructions l 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 regulainstruc-tions valid in your country, you must comply with the safety regulations valid in your country.
Intended use
This machine must only be used for:
l 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)
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.
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.
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.
Notes on safety in the operating and
maintenance instructions:
! Danger
Safety regulations
i
NoteParagraphs 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.
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
l they step or stand under loads being lifted l they remain in the drive range of the machine
during an instruction and during loading. The machine must not swing about when being lift-ed.
Use only safe lifting gear of sufficient load bearing capacity.
Fasten the lifting gear only at the specified lifting points.
Towing the machine
You should generally use a tow bar.
Max. towing speed 1 km/h, max. towing distance 500 m.
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.
Starting the machine
Before starting
The machine must only be operated from the driv-er's seat.
Use only machines which are serviced at regular intervals.
Become acquainted with the equipment, the con-trol elements, the working principle of the machine and the working area.
Wear your personal protective outfit (hard hat, safety boots, etc.).
Before climbing on the machine check whether:
l persons or obstructions are beside or under
the machine
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
Use steps and grips to climb onto the machine. Before starting the machine check whether:
Safety regulations
l the seat is correctly adjusted
l mirrors (if present) are clean and correctly
ad-justed.
Do not start the machine with defective gauges, control lights or control elements.
Do not take any loose objects with you or fasten them to the machine.
On machines with roll over protection system you must always wear your seat belt.
Starting
Start and operate the machine only from the driv-er's seat.
For starting set all control levers to 'neutral posi-tion'.
Do not use any starting aids like start pilot or ether. After starting check all gauges and control lights.
Starting with jump wires
Connect plus with plus and minus with minus (ground cable) - always connect the ground strap last and disconnect it first! A wrong connection will cause severe damage in the electric system. Do not start the engine by shorting the electric ter-minals on the starter motor, because the machine may start to drive immediately.
Starting in closed rooms
Exhaust gases are highly dangerous! Always en-sure an adequate supply of fresh air when starting in closed rooms!
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
not use the emergency stop switch as service brake.
Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.
If the engine oil pressure control light lights up stop the engine immediately.
If the machine has contacted high-voltage power lines:
l Do not leave the operator's platform
l 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
Operate the machine only from the operator's stand.
Keep the cabin doors closed.
Do not adjust the driver's seat while driving. Do not climb onto or off the machine while the ma-chine is driving.
Change the travel direction only at standstill. Do not use the machine to transport persons. In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected.
Always keep a sufficient distance to excavation walls and embankments and do not use working methods that could impair the stability of the ma-chine.
Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground. Always keep a sufficient distance when passing through subways, under bridges, tunnels, electric power lines etc.
Driving on inclinations and slopes
Do not drive on gradients exceeding the maximum gradability of the machine.
On slopes drive extremely carefully and always di-rectly up or down the slope. Change to a lower
Safety regulations
Behaviour in traffic
Match the speeds to the working conditions. Always allow loaded transport vehicles to pass. Switch the lights on if the visibility is poor. Keep away from edges and embankments.
Check the effect of vibration
When compacting with vibration you must always check the effect of the vibration on nearby build-ings and underground supply lines (gas, water, sewage, electric power) and stop compaction work with vibration, if necessary.
Do not switch the vibration on when working on hard (frozen, concrete) ground. Danger of bearing damage!
Parking the machine
Park the machine on level and firm ground. Before leaving the machine:
l 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.
Do not jump off the machine, but use access steps and grips.
Mark machines, which could be in the way, with a clearly visible sign.
Parking on slopes and inclinations
Secure the machine against rolling, place metal chocks in front of and behind the drums.
Filling the fuel tank
Do not inhale any fuel fumes.Refuel only with the engine stopped and the auxil-iary heater switched off.
Do not refuel in closed rooms. No open fire, do not smoke.
Leaking fuel tanks can cause explosions. Ensure tight fit of the fuel tank cover, if necessary replace immediately.
Fire protection measures
Familiarise yourself with the location and the oper-ation of fire fighting equipment. Observe all fire re-porting and fire fighting possibilities.
Maintenance work
Comply with the maintenance work described in the operating and maintenance instructions, in-cluding the information concerning the replace-ment of parts.
Maintenance work must only be performed by qualified and authorized persons.
For overhead maintenance and assembly work use the access steps and working platforms pro-vided or other secure means. Do not use machine parts as access steps.
Keep unauthorized persons away from the ma-chine.
Do not perform maintenance work while the ma-chine is driving or the engine is running.
Park the machine on horizontal, level and firm ground.
Pull the key out of the ignition switch.
Secure the articulated joint with the articulation lock.
Working on hydraulic lines
Relieve hydraulic pressures before working on hy-draulic lines. Hyhy-draulic 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!
Safety regulations
Do not start the engine after draining the hydraulic oil.
Once all work is completed (with the system still depressurized!) check all connections and fittings for leaks.
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at reg-ular intervals.
Hydraulic hoses must be immediately replaced if:
l the outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
l the outer layer is brittle (formation of cracks in
the hose material)
l the hose shows deformations in pressurized
and depressurized condition, which do not comply with the genuine shape of the hydrau-lic hose
l the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, forma-tion of blisters
l leakages.
l incorrect installation.
l the hydraulic hose has separated from the
fit-ting
l mixing up of hoses by mistake.
l the fitting shows corrosion that impairs both
function and strength.
l fittings are damaged or deformed, whereby
the function and strength of the hose/hose connection is impaired.
Only genuine BOMAG replacement hydraulic hos-es ensure that the correct hose type (prhos-essure range) is used at the right location.
Working on the engine
Shut the engine down before opening the engine hood.
Drain the engine oil at operating temperature -danger of scalding!
Wipe off spilled oil, catch running out oil and
dis-Do not leave any tools or other objects, that could cause damage, in the engine compartment.
Working on electric components
Before starting to work on electric parts of the ma-chine disconnect the battery and cover it with insu-lating material.
Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fire haz-ard!
Before starting welding work on the machine dis-connect the battery.
Working on the battery
When working on the battery do not smoke, do not use open
Do not let acid come in contact with hands or clothes! When injured by acid flush off with clear water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must not come in contact with the battery poles - danger of short circuit and burning!
When recharging serviceable batteries remove all plugs, to avoid the accumulation of explosive gas-es.
Observe the applicable instructions when starting with an auxiliary battery.
Dispose of old batteries in accordance with valid regulations.
Switch off the charging current before removing the charging clamps.
Ensure sufficient ventilation, especially if the bat-tery is to be charged in a closed room.
Working on the fuel system
Do not inhale any fuel fumes.
No open fire, do not smoke, do not spill any fuel. Catch running out fuel, do not let it seep into the ground and dispose of environmentally.
Working on wheels and tires
Explosion-like bursting of tires or parts of tires and rims can cause most severe or even deadly
inju-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.
Indicators and Controls
Indicators and Controls
Indicators and Controls
1 Hydraulic oil temperature control light 2 Oil pressure control light
3 Oil temperature control light 4 Charge control light
5 Emergency stop push button 6 Brake control light
7 Rotary switch for pressure sprinkler system 8 Interval switch for pressure sprinkler system 9 Rotary switch for lighting (STVZO)*
10 Rotary switch for indicator light, with control light *
11 Rotary switch for hazard light system, with control light *
12 Push button for warning horn 13 Rotary switch for working light 14 Rotary switch for flashing beacon*
15 Momentary contact switch for edge cutter* 16 Seat contact control light
17 Throttle lever
18 Locking lever for throttle lever 19 Travel lever / brake
20 Push button for vibration 21 Ball valve, vibration (only AD)
22 Lever for transverse sliding seat adjustment 23 Foot switch for rubber tire sprinkling system (only BW 138 AC) or foot switch for flow divider on AD-machines*
24 Ball valve, brake releasing device (only AC) 25 Fuse box B, bottom
26 Fuse box A, top 27 not used 28 Ignition switch
29 Operating hour meter, in engine compartment
Indicators and Controls
3.1
General notes
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.
3.2
Description of indicators
and control elements
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.
Indicators and Controls
Fig. 9
No. 5 = Emergency stop push button
! Danger
Danger of accident!
Use only in events of emergency during oper-ation.
Do not use as parking brake.
Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.
The machine is braked immediately, the engine is shut down.
actuate = press the button completely down, it automatically locks in fully pressed position.
switch
off/un-lock = Turn button clockwise. Re-start the engine.
goes out = with travel lever in positions "I", "II" or "III".
Fig. 11
No. 7 = Rotary switch for pressure sprinkler system
Position "left" = Sprinkling "OFF" Position "right" = Sprinkling "ON"
No. 8 = Interval switch for pressure sprinkler system
turn clockwise
Position "left" = permanent sprinkling further
posi-tions = various sprinkling intervals from 4...32 seconds, activation time always 5 seconds.
Fig. 12
Indicators and Controls
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.
No. 11 = Rotary switch for hazard light with control light**
Position "left" = hazard light switched off Position "right" = hazard light switched on, the
control lights in the rotary switches (10) and (11) light up.
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 switch 28 in position "I".
Fig. 14
No. 14 = Rotary switch for flashing beacon***
Position "left" = Flashing beacon off Position "right" = Flashing beacon on
No. 15 = Rotary key switch for edge cutter****
POsition
"mid-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. 15
No. 16 = Seat contact control light*
goes out = when the driver’s seat is occu-pied.
lights up when the machine is at
Indicators and Controls
i
NoteStandard design
lights when the machine is
driv-ing = when the driver’s seat is unoc-cupied.
i
NoteDesign 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. 16
No. 17 = Throttle lever
Position "0" = Idle speed position, engine start.
Position "I" = Full load position (2200 rpm), operating position for driving and vibration, BW125ADH and BW135AD.
= Full load position (2500 rpm), operating position for driving and vibration, BW138 AD/AC. Position "II" = Full load position (2700 rpm),
operating position for driving and vibration, BW125ADH and
pull = the throttle lever can be moved release = the throttle lever will engage in
position "I" and "II".
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
Indicators and Controls
Fig. 19
Ball valve for 3-stage vibration*
Position
up-ward = Vibration of rear drum only Position
horizon-tal = Vibration of both drums Position
down-ward = Vibration of front drum only
Fig. 20
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
Fig. 21
No. 23 = Foot switch for tire sprinkler system (only AC)
press = sprinkling on. release = sprinkling off.
Fig. 22
Foot switch for flow divider* (only AD)
press = flow divider switched on release = flow divider switched off
Indicators and Controls
Fig. 23
No. 24 = Ball valve, brake releasing device (on-ly AC-machines)
Position "I" = Brake released
i
NoteRelease brake by turning the steering wheel in clockwise direction.
Position "II" = Brake applied
! Danger
Danger of accident!
Always secure with locking screw.
Fig. 24
! Danger
(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
(1) 40A = (F01) Main fuse
(2) 15A = (F06) sprinkler system (only AD**) (3) 10A = (F41) flashing beacon * / backup
alarm *
(4) 10A = (F45) edge cutter * (5) 15A = (F27) wiper/washer, front* (6) 20A = (F141) hydraulic oil cooler (7) 10A = (F03) vibration
(8) 15A = (F37) sprinkler pump
No. 27 = not used
Fig. 25
No. 28 = Ignition switch
Position "0"/"P" = ignition off, key can be pulled out.
Position "I" = ignition on, oil pressure control light (2) and charge control
Indicators and Controls
i
NoteFor 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
NoteThe 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 operataccord-ing hours.
Operation
4.1
General notes
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.
All indicators and control elements are described in detail in this chapter.
4.2
Inspections before starting
operation
Before the everyday use or before a longer work-ing period the followwork-ing tests and inspections must be performed.
! 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
NoteThe 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
Operation
4.3
Starting the engine
! 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. 26
l Always start the engine from the driver’s seat
with seat contact switch (Fig. 26).
! Danger
Danger of accident!
Always wear your seat belt.
Fig. 27
Fasten your seat belt (Fig. 27).
Fasten/release your seat belt
*.
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.
Open
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
Operation
Fig. 30
l Shift travel lever 19 (Fig. 30) to position '0'. The
brake is closed.
Fig. 31
l Pull the locking lever 18 (Fig. 31) and shift the
throttle lever (17) to position '0', idle speed.
Fig. 33
l Turn ignition key 28 (Fig. 33) to position "I".
Charge control light (4) and oil pressure warn-ing light (2) light up.
i
NoteIf the vibration starts to run in ignition switch posi-tion "II", press the vibraposi-tion 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 posiigni-tion "I", charge control light and oil pressure control light go out.
i
NoteRun the engine warm for a short while before start-ing work.
Operation
4.4
Starting with jump wires
Fig. 34
! 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'. l Once the engine is running switch on a
power-ful consumer (working light, etc.).
! Caution
If no powerful consumer is switched on volt-age peaks may occur when separating the con-necting cables between the batteries, which could damage electrical components.
l After starting disconnect the negative poles
(ground cable) first and the positive poles af-ter.
Switch off the consumer.
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.
Always give way to loaded transport vehicles!
Fig. 35
i
NoteSeat contact control light (Fig. 35):
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).
Operation
lights when the machine is
driv-ing = when the driver’s seat is unoc-cupied.
i
NoteDesign 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. 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
NoteDuring operation the throttle lever always remains locked in one of the full load positions.
Control the travel speed with the travel lever.
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.
Operation
4.6
Stopping the machine /
ap-plying the brake
Fig. 38
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.
4.7
Switching the vibration on
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, concrete) ground.
i
NoteActivate 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
Operation
Pre-selecting vibration (only AD)
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
Pre-selecting vibration (3 stages, only
AD)
*Fig. 40
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. 41
l Pull up locking lever 18 (Fig. 41) and shift
throttle lever (17) to full load position "I" (55 Hz) or "II" (66 Hz).
Operation
i
NoteWhen shifting the travel lever through position "III" to position "I" or "II", the vibration will be automati-cally switched off.
Switching the vibration off
l Press push button (20) again.
4.8
Switching the vibration on
or off
i
NoteOnly AC-machines.
Fig. 43
l Press the foot switch 23 (Fig. 43).
press = on.
Operation
4.9
Switching the pressure
sprinkler system on or off
Fig. 44
l Open the shut-off cock valve (Fig. 44).
Position "I" = open Position "II" = closed
Fig. 45
l Operate the rotary switch for the pressure
sprinkler system 7 (Fig. 45).
Position "0" = sprinkler system "OFF" Position "I" = sprinkler system "ON"
l Set the interval switch (8) to the desired flow
interval.
Position "A" = permanent sprinkling
Fig. 46
l To switch the sprinkler system on move the
ztravel lever out of braking position towards "0"-position (Fig. 46).
i
NoteThe sprinkler system will only work when the travel lever is in direction "0"-position. This is also the testing position.
Fig. 47
l To switch the sprinkler system off return the
travel lever to the position "brake closed" (Fig. 47).
i
NoteOperation
4.10 Stopping the
engine/ma-chine
Fig. 48
! Danger
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
i
NoteDo not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization.
Fig. 50
l Turn the ignition switch 28 (Fig. 50) to position
Operation
4.11 Adjusting the driver's seat
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-erator.
i
NoteIn 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.
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. 52
l Take the brake releasing device 1 (Fig. 52) out
of the access steps.
Operation
l Place the brake releasing device (1) across
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. 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.
Towing the machine
Fig. 55
! Caution
Generally use a draw bar (Fig. 55), max. towing speed 1 km/h, max. towing distance 500 m.
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).
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 against rolling, sliding and turning over. Do not stand or step under loads being lifted.
Fig. 57
l After driving the machine onto the transport
vehicle swing the articulation lock 1 (Fig. 57) out of its receptacle and fasten it with the bolt (2) to the eye. Secure the bolt with the cotter pin.
Fig. 58
l Tie the machine down on the transport vehicle,
use the lifting hooks 1 (Fig. 58) on front and rear frame for this purpose.
Fig. 59
l Use the four lifting eyes to lift the machine (Fig.
Operation
Loading weight: See technical data
After transport
Fig. 60
l Pull the bolt 2 (Fig. 60) out of the articulation
lock and swash the locking rod (1) back into the bracket.
4.14 Foldable roll over
protec-tion structure (ROPS)
Split foldable roll over protection
structure
*(ROPS)
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 tightenfold-ed with the correct tightening torque.
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!
Maintenance
5.1
General notes on
mainte-nance
When performing maintenance work always com-ply with the appropriate safety regulations. Thorough maintenance of the machine guaran-tees higher functional safety of the unit and pro-longs the lifetime of important components. The effort needed for this work is only little compared with the problems that may arise when not observ-ing this rule.
The terms right/left correspond with travel direc-tion forward.
l Always clean machine and engine thoroughly
before starting maintenance work.
l For maintenance work stand the machine on
level ground.
l Perform maintenance work generally with the
engine stopped.
l Relieve hydraulic pressures before working on
hydraulic lines.
l Before working on electric parts of the
ma-chine disconnect the battery and cover it with insulation material.
l When working in the area of the articulated
joint attach the articulation lock (transport lock).
Environment
During maintenance work catch all oils and fu-els and do not let them seep into the ground or into the sewage system. Dispose of oils and fu-els environmentally.
Notes on the fuel system
The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel.
l Keep fuel free of contaminants and water,
since this will damage the injection elements
l Do not let the hose stir up the slurry at the
bot-tom of the drum.
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-gine and should only be used for cleaning pur-poses.
Notes on the engine performance
On diesel engines both combustion air quantity and fuel injection quantity are thoroughly adapted to each other and determine power, temperature level and exhaust gas quality of the engine. If you engine has to work permanently in "thin air" (at higher altitudes) and under full load, you should consult the customer service of BOMAG or the customer service of the engine manufacturer.Notes on the hydraulic system
During maintenance work on the hydraulic system cleanliness is of major importance. Make sure that no dirt or other contaminating substances can en-ter into the system. Small particles can produce flutes in valves, cause pumps to seize, clog noz-zles and pilot bores, thereby making expensive re-pairs inevitable.
l If, during the daily inspection of the oil level,
the hydraulic oil level is found to have dropped, check all lines, hoses and compo-nents for leaks.
l Seal external leaks immediately. If necessary
inform the responsible customer service.
l Do not store drums with hydraulic oil outdoors,
or at least under cover. Water can be drawn in through the bunghole when the weather changes.
l Always use the filling and filtering unit
(BOMAG part-no. 007 610 01) to fill the hy-draulic system. This unit is fitted with a fine fil-ter to clean the hydraulic oil, thereby
prolonging the lifetime of the filter.
Maintenance
5.2
Fuels and lubricants
Engine oil
l Use winter grade engine oil for winter
opera-tion!
In order to assure perfect cold starting it is import to chose the viscosity (SAE-class) of the engine oil according to the ambient temperature.
For winter operation below -10 °C the oil change intervals must be shortened.
Fig. 63
Lubrication oil with a too high viscosity index caus-es starting difficulticaus-es. The temperature when starting the engine is therefore of highest impor-tance when choosing the viscosity of engine oil for winter operation.
Oil viscosity
Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the
oper-fect the cold starting ability of the engine, but will not cause any engine damage.
Temperature related lubrication oil changes can be avoided by using multi-purpose oils. The follow-ing oil change intervals apply also when usfollow-ing mul-ti-purpose oils.
Regular lubrication oil changes
The longest permissible time a lubrication oil should remain in an engine is 1 year. If the follow-ing oil change intervals are not reached over a pe-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
These intervals apply only when using a diesel fuel with maximum 0.5 % sulphur by weight and for ambient temperatures higher than -10 °C.
When using fuels with a sulphur content of more than 0.5% to 1% or under ambient tem-peratures below -10 °C the oil change intervals specified in the table must be halved. When us-ing fuels with a sulphur content higher than 1% ... 1,5% the engine oil must have a TBN of
ap-Maintenance
Example aspirating engine:
l Use in tropical climate, fuel 0.8% sulphur,
lu-brication oil change every 250 operating hours.
Lubrication oil quality classes
The ACEA- and the API-classifications are used to classify the oil quality.
The oil manufacturer is solely responsible for as-signing a product to a certain quality class.
i
NoteWhen changing to a higher alloyed oil quality after a longer period of operation, it is recommended to perform the first oil change of the higher quality oil already after 20 operating hours. The lubrication oil filter cartridge must be changed at the same time.
Fuels
Quality
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.
type HV according to ISO 6743/3. The viscosity in-dex (VI) must be at least 150. (Observe the infor-mation of the manufacturer).
Bio-degradable hydraulic oil
On request the hydraulic system can also be filled with ester based biodegradable hydraulic oil (Pan-olin HLP Synth. 46).
The biologically degradable hydraulic oil meets all demands of a mineral oil based hydraulic oil ac-cording to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth. 46 always use the same oil to top up.
When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details.
Check the filter more frequently after this change.
Lubrication grease
For lubrication use only EP-high pressure grease, lithium saponified (penetration 2).
Maintenance
5.3
Table of fuels and
lubri-cants
*For lower temperatures refer to the mixing table in chapter 5.2
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;
API: CF/CF-4, CG-4/CH-4 6.0 litres (1.6 USgal) 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 to -12 °C)*
55 litres (17.2 USgal)
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)
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
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
Every 50 operating hours
5.12 Checking the emulsion level
5.13 Grease the articulated joint High pressure grease
Every 250 operating hours
5.14 Clean cooling fins and engine oil cooler 5.15 Cleaning the hydraulic oil cooler 5.16 Adjust the scrapers
Every 500 operating hours
5.17 Service the battery distilled water, pole grease 5.18 Drain the sludge from the fuel tank
Every 1000 operating hours
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
Every 2000 operating hours
5.25 Change the hydraulic oil*** screen filter (at least after 2 years)
Observe the dipstick marks
Maintenance
*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
5.28 Replace toothed belts, timing belt and toothed belt for hydraulic pump
at the latest after 5 years
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
Every 10 operating hours
Every 10 operati ng hou rs
5.6
Check the engine oil level
i
NoteThe machine must be in horizontal position. Run the engine 2 minutes with idle speed and shut it down.
Fig. 64
l Pull the dipstick out, wipe it off with a lint-free,
clean cloth and reinsert it until it bottoms.
l Pull the dipstick back out again.
l The oil level should reach the "MAX"-mark
(Fig. 64).
l If the oil level is too low top up oil immediately.
i
NoteFor 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.
5.7
Checking the dry air filter
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.
! Caution
If the red indicator appears again after starting the engine, you must change the filter tridge and, if necessary, also the safety car-tridge*.
Every 10 operating hours
5.8
Checking the hydraulic oil
level
Fig. 66
l Clean the area around the filler opening. l Remove the filler cap.
l Check the hydraulic oil level on the oil dipstick.
The oil level must be between the "MIN" and "MAX" marks (Fig. 66).
l If the oil is below this level top up hydraulic oil
immediately.
i
NoteFor quality and quantity of oil refer to the table of "fuels, lubricants and filling capacities".
In hydraulic systems filled with Panolin HLP Synth. 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.
5.9
Checking the hydraulic oil
filter element
Fig. 67
l Check the service indicator 1 (Fig. 67) at
oper-ating temperature and with the engine running at maximum speed.
l If necessary press the pin in.
Pin remains
de-pressed = hydraulic oil filter element ok. Pin pops up = replace the hydraulic oil filter
element
i
NoteIf the hydraulic oil is very cold the pin may pop up, you should therefore only check the filter and press the pin in at operating temperature.
Every 10 operating hours
5.10 Checking the fuel 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. 68
l Clean the area around the filler opening. l Open the fuel filler cap (Fig. 68) and check the
fuel level visually.
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.
5.11 Checking the water level
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
NoteIn the event of frost observe the special service in-structions under "maintenance in the event of frost".
