Fayat Group Bomag BW 138 AD-5 Operating Instruction, Maintenance Instruction
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Fayat Group Bomag BW 138 AD-5 Operating Instruction, Maintenance Instruction

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Operating Instruction
Maintenance Instruction
Original Operating Instructions
BW 138 AD-5
S/N 101 650 37 1334>
Tandem vibratory roller
008 201 92 EN
© 10/2017

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Summary of Contents for Fayat Group Bomag BW 138 AD-5

  • Page 1 Operating Instruction Maintenance Instruction Original Operating Instructions BW 138 AD-5 S/N 101 650 37 1334> Tandem vibratory roller 008 201 92 EN © 10/2017...

  • Page 3: Table Of Contents

    Table of contents Table of contents Introduction..................11 1.1 Foreword..................12 1.2 Machine type plate and engine type plate......... 14 Technical data..................15 2.1 Noise and vibration data.............. 19 2.1.1 Noise data................... 19 2.1.2 Vibration data................20 Concerning your safety..............21 3.1 Basic prerequisites..............
  • Page 4 Table of contents 3.4.6 Safety regulations and environmental protection regulations for handling battery acid..............40 3.5 Loading / transporting the machine........... 42 3.6 Start-up procedure............... 44 3.6.1 Prior to starting up............... 44 3.6.2 Starting the engine..............45 3.6.3 Starting the engine with jump leads..........45 3.7 Driving the machine;...
  • Page 5 Table of contents 4.1.5 Rotary switch for hazard light system.......... 73 4.1.6 Rotary switch for flashing beacon..........73 4.1.7 Rotary switch for push button assignment on travel lever... 74 4.1.8 Rotary switch for drum pre-selection........... 74 4.1.9 Rotary switch for vibration pre-selection........75 4.1.10 Rotary switch for amplitude pre-selection.........
  • Page 6 Table of contents 5.9 Checking the water level, topping up......... 99 5.10 Checking, adjusting the scrapers........... 100 Operation.................... 101 6.1 Setting-up the work place............102 6.1.1 Adjust the driver’s seat.............. 102 6.1.2 Sliding the driver’s seat sideways..........103 6.2 Electronic immobilizer............... 104 6.3 Starting the engine..............
  • Page 7 Table of contents 6.11.2 Disconnecting the battery............134 6.11.3 Towing the machine..............134 6.11.4 After towing................138 Loading / transporting the machine..........141 7.1 Prepare for transport..............142 7.2 Loading the machine..............143 7.2.1 Fold down the foldable ROPS........... 144 7.2.2 Folding down the foldable ROPS with protective roof....
  • Page 8 Table of contents 8.7.6 Battery service................175 8.7.7 Check the parking brake............176 8.7.8 Checking the protective canopies..........176 8.8 Every 500 operating hours............177 8.8.1 Replacing the fuel filter.............. 177 8.8.2 Replacing the V-belt..............178 8.8.3 Checking the anti-freeze concentration and the condition of the coolant..................
  • Page 9 Table of contents 9.3.3 Central electrics................. 215 9.4 Engine faults................217 9.5 Trouble shooting ECONOMIZER..........220 10 Disposal....................223 10.1 Final shut-down of machine............ 224 BW 138 AD-5...
  • Page 10 Table of contents BW 138 AD-5...

  • Page 11: Introduction

    Introduction Introduction BW 138 AD-5...

  • Page 12: Foreword

    Introduction – Foreword Foreword BOMAG manufactures machines for earth, asphalt and refuse compaction, stabilizers/ recyclers as well as planers and pavers. BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all impor- tant components and highest quality demands guarantee maximum reliability of your machine.
  • Page 13 Introduction – Foreword A description of all necessary maintenance work, maintenance intervals as well as informa- tion on fuels and lubricants can be found in the Ä Chapter 8 „Mainte- chapter “Maintenance” nance“ on page 155. Do not service or repair your machine by your- self to avoid harming persons or damaging material or environment.

  • Page 14: Machine Type Plate And Engine Type Plate

    Introduction – Machine type plate and engine type plate Machine type plate and engine type plate Please enter here: Machine type (1): Serial number (2): Fig. 1: Machine type plate (example) Please enter here: Engine type (Fig. 1) Engine number (2): Fig.

  • Page 15: Technical Data

    Technical data Technical data BW 138 AD-5...
  • Page 16 Technical data Dimensions Fig. 3 1900 1470 1900 2700 (74.8) (57.9) (27.6) (35.4) (74.8) (106.3) Dimensions in millimetres (Dimensions in inch) 2840 1380 (13.4) (111.8) (1.7) (0.7) (54.3) Dimensions in millimetres (Dimensions in inch) BW 138 AD-5...
  • Page 17 Technical data Length with chip spreader (optional equipment) 3687 (145.2) (in) Height with protective roof and flashing beacon 3040 (optional equipment) (119.7) (in) Weights Max. operating weight 4700 (10362) (lbs) Operating weight with ROPS (CECE) 4300 (9480) (lbs) Average static linear load (CECE) 15.6 kg/cm (87)
  • Page 18 Technical data Drive Fixed engine speed (1) 2300 Fixed engine speed (2) 2600 Electric system Voltage Brakes Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Oscill.-articul. Steering operation hydrostatic Steering angle +/- 32 ° Oscillation angle +/- 10 °...

  • Page 19: Noise And Vibration Data

    Technical data – Noise and vibration data Filling capacities Fuel (diesel) (14.5) (gal us) Water (82) (gal us) Noise and vibration data The following noise and vibration data were determined in accordance with the following guidelines under equipment specific conditions and by using harmonized standards: EU Machine Directive edition 2006/42/EU Noise Emission Directive 2000/14/EU, Noise...

  • Page 20: Vibration Data

    Technical data – Noise and vibration data 2.1.2 Vibration data Vibration of the entire The weighted effective acceleration value body (driver’s seat) determined according to ISO 7096 is ≤ 0.5 Hand-arm vibration The weighted effective acceleration value determined according to EN 500/ISO 5349 is ≤ 2.5 m/s BW 138 AD-5...

  • Page 21: Concerning Your Safety

    Concerning your safety Concerning your safety BW 138 AD-5...

  • Page 22: Basic Prerequisites

    Concerning your safety – Basic prerequisites Basic prerequisites 3.1.1 General This BOMAG machine has been built in compli- ance 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: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel,...

  • Page 23: Explanation Of Signal Words Used

    Concerning your safety – Basic prerequisites 3.1.2 Explanation of signal words used: DANGER! Danger to life if failing to comply! Sections marked accordingly indi- cate an extremely dangerous situa- tion that could lead to fatal or severe injuries, if this warning is dis- regarded.

  • Page 24: Personal Protective Equipment

    Concerning your safety – Basic prerequisites Sections marked accordingly indi- cate technical information or notes on using the machine or its compo- nents. ENVIRONMENT! Environmental damage if failing to comply! Paragraphs marked accordingly indicate practices for safe and envi- ronment-friendly disposal of fuels and lubricants as well as replace- ment parts.

  • Page 25: Intended Use

    Concerning your safety – Basic prerequisites Face protection To protect the face against airborne par- ticles and squirting fluids. Hard hat To protect the head against falling parts and to protect against injuries. Hearing protection To protect hearing against excessive noise.
  • Page 26 Concerning your safety – Basic prerequisites Any danger caused by improper use is the sole responsibility of the operating company or driver/operator, the manufacturer cannot be made liable. Examples for improper use are: work with vibration on hard concrete, cured bitumen layers or extremely frozen ground cleaning the drums while driving or changing nozzles during travel...

  • Page 27: Definition Of Responsible Persons

    Concerning your safety – Definition of responsible persons Definition of responsible persons 3.2.1 Operating company The operating company is the natural or jurid- ical person who uses the machine or in who's name the machine is used. The operating company must make sure that the machine is only used for the purpose it is intended for and in strict compliance with the safety regulations mentioned in these operating...

  • Page 28: Driver / Operator

    Concerning your safety – Definition of responsible persons This person is acquainted with the applicable governmental industrial safety regulations, accident prevention instructions, guidelines and generally acknowledged technical rules and regulations (standards, directives, technical rules of other member states of the European Union or other contractual states concerning the agreement about the European Economic Area) in as far as is necessary to be able to...

  • Page 29: Fundamentals For Safe Operation

    Concerning your safety – Fundamentals for safe operation Fundamentals for safe operation 3.3.1 Remaining dangers, remaining risks Despite careful work and compliance with standards and regulations it cannot be ruled out that further dangers may arise when working with and handling the machine. Both the machine as well as all other system components comply with the currently valid safety regulations.

  • Page 30: Damage, Defects, Misuse Of Safety Devices

    Concerning your safety – Fundamentals for safe operation We wish to make explicitly clear that we have not tested or approved any parts or accesso- ries not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive safety.

  • Page 31: Handling Fuels And Lubricants

    Concerning your safety – Handling fuels and lubricants Handling fuels and lubricants 3.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the indi- vidual fuels and lubricants. Safety data sheets provide valuable informa- tion about the following characteristics: name of substance...

  • Page 32: Safety Regulations And Environmental Protection Regulations For Handling Diesel Fuel

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.2 tions for handling diesel fuel WARNING! Danger of burning by ignited diesel fuel! – Do not allow diesel fuel to come into contact with hot compo- nents.
  • Page 33 Concerning your safety – Handling fuels and lubricants ENVIRONMENT! Diesel fuel is an environmentally hazardous substance! – Always keep diesel fuel in proper containers. – Immediately bind spilled diesel fuel with an oil-binding agent and dispose of properly. – Dispose of diesel fuel and fuel fil- ters according to regulations.

  • Page 34: Safety Regulations And Environmental Protection Regulations For Handling Oil

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.3 tions for handling oil WARNING! Danger of burning by ignited oil! – Do not allow oil to come into con- tact with hot components. – Smoking and open fire is pro- hibited! –...
  • Page 35 Concerning your safety – Handling fuels and lubricants – Immediately bind spilled oil with an oil-binding agent. – Dispose of oil and oil filter according to regulations. BW 138 AD-5...

  • Page 36: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic Oil

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.4 tions for handling hydraulic oil WARNING! Danger of injury caused by escaping pressure fluid! – Always depressurize the hydraulic system before starting work in the hydraulic system. –...
  • Page 37 Concerning your safety – Handling fuels and lubricants CAUTION! Health hazard caused by contact with hydraulic oil! – Wear your personal protective equipment (protective gloves, protective clothing). – Do not inhale any oil vapours. – Avoid contact. CAUTION! Danger of slipping on spilled oil! –...

  • Page 38: Safety Regulations And Environmental Protection Regulations For Handling Coolants

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.5 tions for handling coolants WARNING! Danger of scalding by hot fluid! – Open the compensation tank only when the engine is cold. – Wear your personal protective equipment (protective gloves, protective clothing, goggles).
  • Page 39 Concerning your safety – Handling fuels and lubricants – Immediately bind spilled coolant with an oil-binding agent and dis- pose of it according to regula- tions. – Dispose of coolant according to regulations. BW 138 AD-5...

  • Page 40: Safety Regulations And Environmental Protection Regulations For Handling Battery Acid

    Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.6 tions for handling battery acid WARNING! Danger of cauterization with acid! – Wear your personal protective equipment (protective gloves, protective clothing, goggles). – Do not allow clothes, skin or eyes to come into contact with acid.
  • Page 41 Concerning your safety – Handling fuels and lubricants ENVIRONMENT! Battery acid is an environmen- tally hazardous substance! – Dispose of battery and battery acid according to regulations. BW 138 AD-5...

  • Page 42: Loading / Transporting The Machine

    Concerning your safety – Loading / transporting the machine Loading / transporting the machine Before loading you should empty the chip spreader and centre it if it is laterally extended. Use only stable loading ramps of sufficient load bearing capacity. Loading ramps and transport vehicle must be free of grease, oil, snow and ice.
  • Page 43 Concerning your safety – Loading / transporting the machine When lifting the machine, avoid uncontrolled movements of the load. If necessary, hold the load with guide ropes. After the transport loosen the articulation lock again, as otherwise the machine would not be steerable.

  • Page 44: Start-Up Procedure

    Concerning your safety – Start-up procedure Start-up procedure 3.6.1 Prior to starting up Use only machines which are serviced at reg- ular intervals. Become acquainted with the equipment, the indicators and control elements, the working principle of the machine and the working area. Use your personal protective equipment (hard hat, safety boots, if necessary also goggles and ear protection).

  • Page 45: Starting The Engine

    Concerning your safety – Start-up procedure 3.6.2 Starting the engine The machine must only be started and oper- ated from the driver’s seat. Before starting and moving the machine, make sure that there is nobody in the danger zone. To start, set all control levers to “neutral posi- tion”.

  • Page 46: Driving The Machine; Working Operation

    Concerning your safety – Driving the machine; working operation Driving the machine; working operation 3.7.1 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.

  • Page 47: Driving Up And Down Slopes

    Concerning your safety – Driving the machine; working operation Match the speed to the working conditions. Do not make extreme steering movements when driving with high speed, danger of tipping over! Always give way to loaded transport vehicles. Switch the lights on if the visibility is poor. Always keep a safe distance to excavation pit borders, embankments and edges.

  • Page 48: Cross Slope

    Concerning your safety – Driving the machine; working operation 3.7.4 Cross slope The tipping angle was measured statically on level, hard ground with the machine stopped and without steering. The max. permissible inclination of the machine may be limited by the max. permis- sible slanted position of the engine.

  • Page 49: Parking The Machine

    Concerning your safety – Driving the machine; working operation Do not step between chip spreader and machine while the engine is running. Always empty the chip spreader before mounting or removing it. Loads must only be attached and hoisted by an expert / capable person.
  • Page 50 Concerning your safety – Driving the machine; working operation shut down the engine, pull off the ignition key, pull off the main battery switch, secure the machine against unauthorized use. Do not jump off the machine, but use hand grips and access steps. Mark machines, which could be in the way, with a clearly visible sign.

  • Page 51: Refuelling

    Concerning your safety – Refuelling Refuelling Do not inhale any fuel fumes. Refuel only with the engine shut down. Do not refuel in closed rooms. No open fire, do not smoke. Static charges may be generated in the fuel as it passes through the filling system.

  • Page 52: Emergency Procedures

    Concerning your safety – Emergency procedures Emergency procedures 3.9.1 Actuating the emergency stop switch In events of emergency and in case of danger actuate the emergency stop switch immedi- ately. The machine is braked immediately, the engine is shut down. Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.
  • Page 53 Concerning your safety – Emergency procedures Before starting towing operations make sure that the fastening means are able to withstand the load and are fastened at the points pro- vided for this purpose. Before removing the towing facility apply appropriate measures to secure the machine against unintended rolling.

  • Page 54: Maintenance Work

    Concerning your safety – Maintenance work 3.10 Maintenance work 3.10.1 Preliminary remarks Adhere to the specified operating, maintenance and repair measures. The machine must only be serviced by quali- fied personnel authorised by the operating company. Keep unauthorised persons away from the machine.

  • Page 55: Working On The Engine

    Concerning your safety – Maintenance work Do not start the engine after draining the hydraulic oil. Once all work is completed (with the system still depressurized!) check all con- nections and fittings for leaks. Hydraulic hoses must be visually inspected at regular intervals.

  • Page 56: Maintenance Work On Electric Components And Battery

    Concerning your safety – Maintenance work Engine and exhaust system work at high tem- peratures. Keep combustible materials away and do not touch any hot surfaces. Check and change coolant only when the engine is cold. Collect coolant and dispose of it in an environmentally friendly way.

  • Page 57: After Maintenance Work

    Concerning your safety – Maintenance work Do not guide the water jet into the exhaust pipe and into the air filter. 3.10.6 After maintenance work Reassemble all guards and protective devices. Close all maintenance flaps and maintenance doors again. BW 138 AD-5...

  • Page 58: Repair

    Concerning your safety – Repair 3.11 Repair Identify a defective machine with a warning sign. Only operate the machine after it has been repaired. Repairs must only be performed by an expert/ qualified person. When replacing safety relevant components, only original spare parts must be used. BW 138 AD-5...

  • Page 59: Signage

    Concerning your safety – Signage 3.12 Signage Keep stickers and signage in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or sig- nage immediately. BW 138 AD-5...
  • Page 60 Concerning your safety – Signage Nm 75-200 Nm 75-200 ft.lb. 55-147 ft.lb. 55-147 20 kg 20 kg ~ 200 Nm ~ 200 Nm 25 kg 25 kg ~ 75 Nm ~ 75 Nm Hydraulic Oil B-880-0151 Fig. 10 BW 138 AD-5...
  • Page 61 Concerning your safety – Signage B-880-0150 Fig. 11 BW 138 AD-5...
  • Page 62 Concerning your safety – Signage B-880-0148 Fig. 12: Signage on the chip spreader Warning sticker - Follow operating instructions Fig. 13 Warning sticker - Danger of crushing Fig. 14 BW 138 AD-5...
  • Page 63 Concerning your safety – Signage Prohibition sticker - High pressure cleaning Fig. 15 Instruction sticker - Always wear your seat belt Fig. 16 Information sticker - Lifting point Fig. 17 Information sticker - Lashing point Fig. 18 BW 138 AD-5...
  • Page 64 Concerning your safety – Signage Information sticker - Filler opening for hydraulic Hydraulic Oil B-DEC-0214 Fig. 19 Information sticker - Engine oil drain B-DEC-0211 Fig. 20 Information sticker - Hydraulic oil drain B-DEC-0210 Fig. 21 Information sticker - Coolant drain B-DEC-0212 Fig.
  • Page 65 Concerning your safety – Signage Information sticker - Disconnecting the battery B-DEC-0219 Fig. 23 Information sticker - Main battery switch plus side Fig. 24 Operation sticker - Throttle lever B-DEC-0236 Fig. 25 Information sticker - Low sulphur fuel Fig. 26 BW 138 AD-5...
  • Page 66 Concerning your safety – Signage Information sticker - Temperature of spreading material (optional equipment) B-DEC-0209 Fig. 27 Information sticker - Guaranteed sound capacity level Fig. 28 Information sticker - Foldable ROPS operation Nm 75-200 ft.lb. 55-147 20 kg ~ 200 Nm 25 kg ~ 75 Nm B-DEC-0208...
  • Page 67 Concerning your safety – Signage Machine type plate (example) Fig. 31 BW 138 AD-5...
  • Page 68 Concerning your safety – Signage BW 138 AD-5...

  • Page 69: Indicators And Control Elements

    Indicators and control elements Indicators and control elements BW 138 AD-5...

  • Page 70: Driver's Stand

    Indicators and control elements – Driver’s stand Driver’s stand 4.1.1 Overview B-880-0161 Fig. 32 1 Operating console 2 Starter switch 3 12 V DIN socket 4 Travel lever, right 5 Travel lever, left (optional equipment) 6 Throttle lever BW 138 AD-5...
  • Page 71 Indicators and control elements – Driver’s stand B-880-0162 Fig. 33 1 Rotary switch for direction indicators (optional equipment) 2 Rotary switch for working lights 3 Rotary switch for lighting (optional equipment) 4 Rotary switch for hazard light system (optional equipment) 5 Rotary switch for flashing beacon (optional equipment) 6 Rotary switch for push button assignment of travel lever (optional equip- ment)

  • Page 72: Rotary Switch For Direction Indicators

    Indicators and control elements – Driver’s stand 4.1.2 Rotary switch for direction indicators Position Direction indicators off “middle” Position “Left” Front and rear direction indi- or “Right” cators on the corresponding side are flashing Optional equipment B-SWI-1081 Fig. 34 If the cable to the chip spreader is plugged in, the control light in the rotary switch will also flash.

  • Page 73: Rotary Switch For Lighting

    Indicators and control elements – Driver’s stand 4.1.4 Rotary switch for lighting Position "Left" Light off Position Side light on “Middle” Position "Right" Travel light on Optional equipment Fig. 36 4.1.5 Rotary switch for hazard light system Position "Left" Hazard light system off Position "Right"...

  • Page 74: Rotary Switch For Push Button Assignment On Travel Lever

    Indicators and control elements – Driver’s stand 4.1.7 Rotary switch for push button assignment on travel lever On machines with chip spreader the assign- ment of push button (a) on the travel lever can be switched over. Position “left” Pre-selection vibration Push button (a) switches the vibration on/off.

  • Page 75: Rotary Switch For Vibration Pre-Selection

    Indicators and control elements – Driver’s stand 4.1.9 Rotary switch for vibration pre-selection Position “left” Pre-selection vibration in manual mode Vibration is switched on or off via the vibration push button in the travel lever. Position Vibration off “middle” B-SWI-1485 Position “right”...

  • Page 76: Emergency Stop Switch

    Indicators and control elements – Driver’s stand 4.1.11 Emergency stop switch press In events of emergency and in case of danger actuate the emergency stop switch immediately by pressing it fully down. It automatically locks in end position. The machine will be braked immediately.

  • Page 77: Instrument Cluster

    Indicators and control elements – Driver’s stand 4.1.12 Instrument cluster 1/ 2 3/ 4 1/ 4 100 120 140 160 °C 140 176 212 248 284 320 °F B-DIS-0516 Fig. 44 1 Control and warning lights 2 Fuel level gauge 3 Display field 4 Function key [F1] (not assigned) 5 Function key [F2]...
  • Page 78 Indicators and control elements – Driver’s stand Designation Note Engine oil pressure Lights up if the engine oil pressure is too low. warning light Warning buzzer sounds. The engine is shut down after a short while. Check the engine oil level, if necessary, repair the engine.

  • Page 79: Economizer Display

    Indicators and control elements – Driver’s stand 4.1.13 ECONOMIZER display The ECONOMIZER shows the compaction status of the road substructure or the asphalt layer. Description of display possibilities Ä Chapter 6.5.6 „ECONO- MIZER“ on page 115. Optional equipment Fig. 46 4.1.14 Rotary switch for seat heating Position “left”...

  • Page 80: Starter Switch

    Indicators and control elements – Driver’s stand 4.1.16 Starter switch Position "P"/"0" Ignition off Ignition key can be removed Position "I" Ignition on All control and warning lamps light up for a moment (test function). Position "II" Under low temperatures the Fig.

  • Page 81: Din Socket

    Indicators and control elements – Driver’s stand 4.1.17 12 V DIN socket Permanent current, loadable up to 10 A. Fig. 50 4.1.18 Travel lever, right Shift forward Forward travel Position I: up to approx. 5 km/h (3.1 mph) Position II: up to approx. 10 km/h (6.2 mph) Pull back Backward travel...

  • Page 82: Travel Lever, Left

    Indicators and control elements – Driver’s stand 4.1.19 Travel lever, left Shift forward Forward travel Position I: up to approx. 5 km/h (3.1 mph) Position II: up to approx. 10 km/h (6.2 mph) Pull back Backward travel Position I: up to approx. Fig.
  • Page 83 Indicators and control elements – Driver’s stand 4.1.20.2 Push button assignment travel lever left Vibration on/off Warning horn B-ELE-0150 Fig. 54 Machines with edge cutter left (optional equipment) Lift edge cutter on left hand side Lower edge cutter on left hand side B-ELE-0151 Fig.
  • Page 84 Indicators and control elements – Driver’s stand 4.1.20.3 Push button assignment on chip spreader On machines with chip spreader the assign- ment of push button (a) on both travel levers can be switched over. The rotary switch for travel lever push button assignment is used for switching over.

  • Page 85: Throttle Lever

    Indicators and control elements – Driver’s stand 4.1.21 Throttle lever Position “MIN” Idle speed position Position “MAX Full load position I I” Position “MAX Full load position II II” B-880-0159 Fig. 58 BW 138 AD-5...

  • Page 86: Outside Of Machine

    Indicators and control elements – Outside of machine Outside of machine 4.2.1 Water level gauge Fig. 59 4.2.2 Adjustment lever for chip quantity to the left Reduce chip quantity to the right Increase chip quantity Optional equipment Fig. 60 BW 138 AD-5...

  • Page 87: Engine Compartment

    Indicators and control elements – Engine compartment Engine compartment 4.3.1 Main battery switch Position “On” Main battery switch locked Normal position, operation turn anticlock- Main battery switch can be wise pulled off Separates batteries from the on-board electrics in case of cable fire and fire in the engine compartment as well Fig.

  • Page 88: Hydraulic Oil Filter Maintenance Indicator

    Indicators and control elements – Engine compartment 4.3.3 Hydraulic oil filter maintenance indicator Fig. 63 BW 138 AD-5...

  • Page 89: Checks Prior To Start Up

    Checks prior to start up Checks prior to start up BW 138 AD-5...

  • Page 90: Notes On Safety

    Checks prior to start up – Notes on safety Notes on safety If the following tests reveal damages or other defects, the machine must not be operated, until these deficiencies have been corrected. Do not operate the machine with defective indi- cators and control elements.

  • Page 91: Visual Inspections And Function Tests

    Checks prior to start up – Visual inspections and function tests Visual inspections and function tests 1. Check hydraulic oil tank and lines for con- dition and leaks. 2. Check fuel tank and lines for condition and leaks. 3. Check cooling system for contamination, damage and leaks.

  • Page 92: Checking The Engine Oil Level

    Checks prior to start up – Checking the engine oil level Checking the engine oil level NOTICE! Danger of engine damage! – If the engine is warm, shut it down and check the oil level after five minutes. With a cold engine the oil level can be checked immediately.

  • Page 93: Checking The Fuel Level, Topping Up Fuel

    Checks prior to start up – Checking the fuel level, topping up fuel Checking the fuel level, topping up fuel 5.4.1 Checking the fuel level 1. Check the filling level on the fuel gauge. 1/ 2 2. Refuel if required, after first shutting down 1/ 4 3/ 4 the engine.
  • Page 94 Checks prior to start up – Checking the fuel level, topping up fuel Protective equip- Working clothes ment: Protective gloves 1. Clean the area around the filler opening. 2. Fill in fuel. Fig. 66 BW 138 AD-5...

  • Page 95: Checking The Hydraulic Oil Level

    Checks prior to start up – Checking the hydraulic oil level Checking the hydraulic oil level NOTICE! Components may get damaged! – Check the hydraulic oil level at room temperature (approx. 20 °C (68 °F)). – If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components...

  • Page 96: Checking The Hydraulic Oil Filter

    Checks prior to start up – Checking the hydraulic oil filter Checking the hydraulic oil filter Protective equip- Working clothes ment: Protective gloves NOTICE! Components may get damaged! – Check the maintenance indicator at operating temperature. 1. Check the maintenance indicator at max- imum engine speed.

  • Page 97: Checking The Coolant Level

    Checks prior to start up – Checking the coolant level Checking the coolant level NOTICE! Danger of engine damage! – If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks. –...

  • Page 98: Checking The Air Filter

    Checks prior to start up – Checking the air filter Checking the air filter Protective equip- Working clothes ment: Protective gloves 1. Check the air filter at the maintenance indi- cator. 2. If the yellow pin has reached the red area (1) conduct maintenance of the air filter Ä...

  • Page 99: Checking The Water Level, Topping Up

    Checks prior to start up – Checking the water level, topping up Checking the water level, topping up 1. Check the filling level on the water level gauge, fill up if necessary. Fig. 71 Protective equip- Working clothes ment: Protective gloves NOTICE! Components may get damaged by frost!

  • Page 100: Checking, Adjusting The Scrapers

    Checks prior to start up – Checking, adjusting the scrapers 5.10 Checking, adjusting the scrapers DANGER! Danger to life caused by machine movements! – Never step in front of or behind the drums/wheels while the engine is running. Protective equip- Working clothes ment: Protective gloves...

  • Page 101: Operation

    Operation Operation BW 138 AD-5...

  • Page 102: Setting-Up The Work Place

    Operation – Setting-up the work place Setting-up the work place 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 6.1.1 Adjust the driver’s seat 1. To adjust the inclination of the backrest operate lever (c) and tilt the backrest for- ward or back.

  • Page 103: Sliding The Driver's Seat Sideways

    Operation – Setting-up the work place 6.1.2 Sliding the driver’s seat sideways 1. Pull the lever up and slide the driver's seat sideways 2. Always lock the driver's seat safely in one of the locking positions. Fig. 75 BW 138 AD-5...

  • Page 104: Electronic Immobilizer

    Operation – Electronic immobilizer Electronic immobilizer Optional equipment Before starting the engine the anti-theft protec- tion* must be disarmed by entering a code. With the electronic immobilizer armed, the light emitting diode (a) flashes slowly. 1. Slowly enter the six-digit user code. ð...

  • Page 105: Starting The Engine

    Operation – Starting the engine Starting the engine WARNING! Loss of hearing caused by too high noise burdens! – Wear your personal protective equipment (ear protection). Protective equip- Hearing protection ment: Prerequisites: Main battery switch (if present) switched on Emergency stop switch is unlocked Travel lever in parking brake position When closing the dashboard cover, the emergency stop switch will lock...
  • Page 106 Operation – Starting the engine 2. Turn the ignition key to position “I”. ð All control and warning lights in the instrument cluster light up for a moment. B-ELE-0070 Fig. 78 3. With cold ambient temperatures hold the ignition key up to 10 seconds in position “II”.
  • Page 107 Operation – Starting the engine NOTICE! Danger of engine damage! – Warm up engine for a short while before starting work. Do not operate the engine immediately under full load. BW 138 AD-5...

  • Page 108: Travel Operation

    Operation – Travel operation Travel operation 6.4.1 Preliminary remarks and safety notes Before starting to drive make sure that the drive range is absolutely safe. Do not drive in public traffic with the precision spreader laterally extended. DANGER! Danger to life caused by the machine turning over! –...

  • Page 109: Driving The Machine

    Operation – Travel operation 6.4.2 Driving the machine 1. Fasten your seat belt. 2. Set the throttle lever to position “MAX I” or “MAX II”. B-880-0160 Fig. 81 3. Disengage the travel lever out of braking position and move it slowly to the desired travel direction.

  • Page 110: Seat Contact Switch

    Operation – Travel operation 6.4.4 Seat contact switch If the operator leaves his seat while travelling, the driver's seat warning lamp will light up. The warning buzzer sounds and the engine is shut down after two seconds and the parking brake is applied.

  • Page 111: Working With Vibration

    Operation – Working with vibration Working with vibration 6.5.1 Preliminary remarks and safety notes NOTICE! Possible damage to neigh- bouring buildings! – When compacting with vibration you must always check the effect of the vibration on nearby build- ings and underground supply lines (gas, water, sewage, elec- tric power).

  • Page 112: Preparing To Work With Vibration

    Operation – Working with vibration 6.5.2 Preparing to work with vibration 1. Turn the rotary switch for travel lever push button assignment to position “Left”. B-SWI-1498 Fig. 85 2. Use the rotary switch for drum pre-selec- tion to pre-select the desired drum(s). Drum pre-selection is only acti- vated, if the vibration has been switched off beforehand.

  • Page 113: Manual Vibration

    Operation – Working with vibration 4. Pre-select the desired amplitude with the rotary switch for amplitude pre-selection. B-SWI-1496 Fig. 88 6.5.3 Manual vibration 1. Turn the rotary switch for vibration pre- selection to position “Left”. B-SWI-1486 Fig. 89 NOTICE! Vibration at standstill causes transverse marks! –...

  • Page 114: Vibration In Automatic Mode

    Operation – Working with vibration 6.5.4 Vibration in automatic mode 1. Turn the rotary switch for vibration pre- selection to position “Right”. B-SWI-1487 Fig. 91 2. Shift the travel lever slowly in the desired travel direction. ð The vibration comes on at a low travel speed.

  • Page 115: Economizer

    Operation – Working with vibration 6.5.6 ECONOMIZER The ECONOMIZER continuously informs the driver about the compaction status of the road subbase or the asphalt layer and enables the detection and selected re-compaction of weak spots. The acceleration transducer on the front drum measures the reaction of the road subbase on the vibrating drum.
  • Page 116 Operation – Working with vibration The warning display (a): Flashes for 1 - 2 seconds after the vibration has been switched on. The display goes out as soon as the vibration motor has reached its nominal frequency. flashes if the drum is in jump operation. Ä...

  • Page 117: Water Spraying System

    Operation – Water spraying system Water spraying system 1. Set the rotary switch for the water spraying system to the desired spraying interval. 2. Disengage the travel lever from parking brake position. ð Spraying will only become active after the travel lever is actuated in travel direction, or after the rotary switch for B-SWI-1494 the water spraying system has been set...

  • Page 118: Crabwalk

    Operation – Crabwalk Crabwalk On machines with hydraulic crabwalk, the crab- walk is operated via the left travel lever. On machines without hydraulic crabwalk, the crabwalk can be manually adjusted. 6.7.1 Operating the crabwalk via the travel lever Optional equipment Only operate the crabwalk at low travel speed or when the machine is at a standstill.

  • Page 119: Manually Adjusting The Crabwalk

    Operation – Crabwalk 6.7.2 Manually adjusting the crabwalk Loads must only be attached and hoisted by an expert / capable person. Do not use damaged or in any other way impaired lashing points. Use only lifting gear and lifting tackle with suffi- cient load bearing capacity for the loads to be lifted.
  • Page 120 Operation – Crabwalk 8. Retighten the screws (1). Fig. 101 BW 138 AD-5...

  • Page 121: Parking The Machine In Secured Condition

    Operation – Parking the machine in secured condition Parking the machine in secured condition 1. Drive the machine onto level, firm ground. 2. Shift the travel lever to “Middle” position and engage it in parking brake position. ð The machine will decelerate down to a standstill and the parking brake will be applied after approx.
  • Page 122 Operation – Parking the machine in secured condition 5. Turn the main battery switch (if present) anticlockwise and pull it out. B-SWI-0079 Fig. 105 BW 138 AD-5...

  • Page 123: Edge Cutter

    Operation – Edge cutter Edge cutter 6.9.1 Mounting the tool 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Mount the tool (2) using the star handle screw (1) on the edge cutter. Fig.
  • Page 124 Operation – Edge cutter 3. Press button (e) on the travel lever left to lift the left edge cutter. WARNING! Danger of crushing when lowering the edge cutter! – Make sure that no persons B-ELE-0063 are in the danger area. Fig.

  • Page 125: Chip Spreader

    Operation – Chip spreader 6.10 Chip spreader 6.10.1 Mounting / removing the chip spreader 6.10.1.1 Preliminary remarks and safety notes Lifting tackle must only be attached to loads by expert personnel (qualified person). Do not use damaged or in any other way impaired lashing points.
  • Page 126 Operation – Chip spreader DANGER! Danger to life caused by sus- pended loads! – Do not step or stand under suspended loads. Lift the chip spreader and hook it carefully into the fixing points on the machine. 4. Assemble the bolt (1) and secure it with the split pin (2).
  • Page 127 Operation – Chip spreader 4. Disconnect the chip spreader hydraulically and electrically from the machine. Fig. 113 5. Fasten the lifting tackle at the lifting points (1). 6. Attach the chip spreader to the lifting tackle. Fig. 114 7. Disassemble split pin (2) and bolt (1). DANGER! Danger to life caused by sus- pended loads!

  • Page 128: Filling The Chip Spreader

    Operation – Chip spreader 6.10.2 Filling the chip spreader Protective equip- Working clothes ment: Protective gloves NOTICE! The spreading shaft may get damaged! – The temperature of the chip- ping material to be filled in should not exceed 80 °C (176 °F).
  • Page 129 Operation – Chip spreader Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Folding up the cover Fig. 116 3. Loosen the star handle screws (1). 4.

  • Page 130: Working With Chip Spreader

    Operation – Chip spreader 6.10.4 Working with chip spreader 6.10.4.1 Preparing for work 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Adjust the desired chipping quantity by the adjustment lever.
  • Page 131 Operation – Chip spreader 2. Turn the rotary switch for push button assignment to travel lever position “Right”. B-SWI-1499 Fig. 122 3. Press the push button (a) on the left or right travel lever. ð The chip spreader is switched on. 4.
  • Page 132 Operation – Chip spreader WARNING! Danger of body parts getting drawn in and crushed by the rotating shaft! – Never carry out work while the engine is running. Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä...
  • Page 133 Operation – Chip spreader 5. Clean the spreading beam from any dirt, from asphalt in particular. 6. Fold the spreading beam back up and fasten it with star handle screws. Fig. 127 7. Close the cover. Fig. 128 NOTICE! Components may get dam- aged! –...

  • Page 134: Emergency Procedures

    Operation – Emergency procedures 6.11 Emergency procedures 6.11.1 Actuating the emergency stop switch 1. In events of emergency and in case of danger actuate the emergency stop switch immediately. ð The engine is shut down and the parking brake is closed. Fig.
  • Page 135 Operation – Emergency procedures Before towing make sure that: the tractor vehicle has sufficient traction and braking power for the unbraked towed load, tow bar and fastening means are able to withstand the load and are fastened at the points provided for this purpose. The machine cannot be steered.
  • Page 136 Operation – Emergency procedures Short-circuiting the Protective equip- Protective gloves travel pump ment: WARNING! Danger of burning on hot compo- nents! – Wear your personal protective equipment (protective gloves, protective clothing). – Avoid touching hot components. 1. Loosen the counter nuts (2) on the high pressure relief valves of the travel pump.
  • Page 137 Operation – Emergency procedures Releasing the brake Protective equip- Protective gloves ment: WARNING! Danger of injury caused by uncontrolled machine movement! – Always secure the machine against unintended rolling. 1. Disassemble the brake releasing device from the holding fixture. Fig. 134 2.

  • Page 138: After Towing

    Operation – Emergency procedures 6.11.4 After towing Protective equip- Protective gloves ment: WARNING! Danger of injury caused by uncontrolled machine movement! – Always secure the machine against unintended rolling. 1. After towing, park the machine in a safe place and secure it against accidentally rolling away.
  • Page 139 Operation – Emergency procedures 4. Loosen the counter nuts (2) on the high pressure relief valves of the travel pump. 5. Unscrew the socket head cap screws (1) against the end stop. 6. Tighten the counter nuts, tightening torque: 22 Nm (16 ft·lbf). B-HYD-0003 Fig.
  • Page 140 Operation – Emergency procedures 7. Open the engine hood and reconnect the plug (Y04) to the solenoid valve for the parking brake. 8. Close the engine hood. B-880-0049 Fig. 141 1 Plug (Y04) BW 138 AD-5...

  • Page 141: Loading / Transporting The Machine

    Loading / transporting the machine Loading / transporting the machine BW 138 AD-5...

  • Page 142: Prepare For Transport

    Loading / transporting the machine – Prepare for transport Prepare for transport Ä Chapter 6.10.3 1. Empty the chip spreader „Emptying the chip spreader“ on page 128. 2. Centre the chip spreader. 3. On machines with protective roof: Dis- mount the chip spreader to be able to fold down the foldable ROPS with the protec- Ä...

  • Page 143: Loading The Machine

    Loading / transporting the machine – Loading the machine Loading the machine Use only stable loading ramps of sufficient load bearing capacity. Loading ramps and transport vehicle must be free of grease, oil, snow and ice. The ramp inclination must be less than the gra- deability of the machine.

  • Page 144: Fold Down The Foldable Rops

    Loading / transporting the machine – Loading the machine The foldable ROPS can be folded down to reduce the transport height. 5. Fold down the foldable ROPS, if necessary Ä Chapter 7.2.1 „Fold down the foldable ROPS“ on page 144. 6.

  • Page 145: Folding Down The Foldable Rops With Protective Roof

    Loading / transporting the machine – Loading the machine 7.2.2 Folding down the foldable ROPS with protective roof 7.2.2.1 Rolling up the protective canopy 1. Loosen the canopy from the frame. 2. Open the zips between the canopies. 3. Roll the protective canopies inwards and fix them on the roof with the straps (1).
  • Page 146 Loading / transporting the machine – Loading the machine 7.2.2.3 Folding down the foldable ROPS 1. Loosen the eye bolts and adjust the clamping plates vertically. Fig. 147 CAUTION! Head injuries caused by folding the foldable ROPS! – Do not step into the slewing area of the foldable ROPS.
  • Page 147 Loading / transporting the machine – Loading the machine 6. Secure the lever (2) with the spring pin (1). Fig. 150 BW 138 AD-5...

  • Page 148: Lashing The Machine To The Transport Vehicle

    Loading / transporting the machine – Lashing the machine to the transport vehicle Lashing the machine to the transport vehicle Do not use damaged or in any other way impaired lashing points. Always use appropriate lifting and lashing means on the lifting and lashing points. Use lifting and lashing gear only in the pre- scribed direction of load application.

  • Page 149: Loading By Crane

    Loading / transporting the machine – Loading by crane Loading by crane Loads must only be attached and hoisted by an expert / capable person. Do not use damaged or in any other way impaired lashing points. Use only lifting gear and lifting tackle with suffi- cient load bearing capacity for the weight to be loaded.
  • Page 150 Loading / transporting the machine – Loading by crane 4. If necessary fold down the foldable ROPS Ä Chapter 7.2.2 with protective roof „Folding down the foldable ROPS with pro- tective roof“ on page 145. NOTICE! The protective roof may get damaged when lifting! –...

  • Page 151: After Transport

    Loading / transporting the machine – After transport After transport DANGER! Danger of injury caused by the machine turning over! – Only resume operation of the machine with the Foldable ROPS in upright position. – Observe the specified tightening torques. WARNING! Danger of crushing by the articulating machine!

  • Page 152: Erecting The Foldable Rops

    Loading / transporting the machine – After transport 7.5.1 Erecting the foldable ROPS 1. Erect the clamping plates on both sides vertically. B-650-0019 Fig. 155 CAUTION! 75-200 Nm Danger of crushing when 55-148 ft.lbf erecting the foldable ROPS! – Do not reach with your hands into the slewing area of the foldable ROPS.
  • Page 153 Loading / transporting the machine – After transport 3. Unfold the protective roof until the lever (2) clicks into place. 4. Fasten the split pin (1) on the frame. B-650-0007 Fig. 158 5. Erect the clamping plates on both sides vertically.
  • Page 154 Loading / transporting the machine – After transport 7.5.2.2 Unfolding the protective roof CAUTION! Head injuries when unfolding the protective roof! – Do not stand in the swashing area of the protective roof. Loosen lever (1). Fig. 162 ð The protective roof unfolds automati- cally.

  • Page 155: Maintenance

    Maintenance Maintenance BW 138 AD-5...

  • Page 156: Preliminary Remarks And Safety Notes

    Maintenance – Preliminary remarks and safety notes Preliminary remarks and safety notes DANGER! Danger to life caused by an operationally unsafe machine! – The machine must only be serv- iced by qualified and authorized personnel. – Follow the safety regulations for Ä...
  • Page 157 Maintenance – Preliminary remarks and safety notes Use only the intended access steps and grips to mount the machine. For overhead maintenance work use the access steps and working platforms provided or other secure means. Do not step on machine parts which are not intended for this purpose.

  • Page 158: Fuels And Lubricants

    Maintenance – Fuels and lubricants Fuels and lubricants 8.2.1 Engine oil 8.2.1.1 Oil quality The following engine oil specifications are per- mitted: Engine oils as per API-classification CF, CF-4, CG-4, CH-4 and CI-4 For operation of an engine with high sulphur fuels we recommended to use an engine oil of API-classification CF or higher with a total base number of at least 10.

  • Page 159: Fuel

    Maintenance – Fuels and lubricants Ambient temperature Oil viscosity higher than 25 °C SAE 30 (77 °F) SAE 10W-30 SAE 15W-40 -10 °C to 25 °C (14 °F SAE 10W-30 to 77 °F) SAE 15W-40 below - 10 °C (14 °F) SAE 10W-30 8.2.1.3 Oil change intervals...
  • Page 160 Maintenance – Fuels and lubricants The recommended Cetan index number is 45. A Cetan index number higher than 50 should preferably be used, especially at ambient tem- peratures below -20 °C (-4 °F) and when working at altitudes of more than 1500 m (4921 ft).

  • Page 161: Coolant

    Maintenance – Fuels and lubricants Copper containing materials (copper lines, brass items) should be avoided, because they can cause catalytic reactions in the fuel with subsequent depositing in the injection system. 8.2.3 Coolant Always use a mixture of anti-freeze agent and clean, dehardened water with a mixing ratio of 1:1.

  • Page 162: Hydraulic Oil

    Maintenance – Fuels and lubricants Add anti-freeze agent: If the coolant level drops because of evapo- ration,only clean water is to be used for top- ping up. In case of leakages you must always fill in anti-freeze agents of the same brand and the same mixing ratio.
  • Page 163 Maintenance – Fuels and lubricants 8.2.4.2 Bio-degradable hydraulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil. The biologically quickly degradable hydraulic oil Panolin HLP Synth.46 meets all demands of a mineral oil based hydraulic oil according to DIN 51524.

  • Page 164: List Of Fuels And Lubricants

    Maintenance – List of fuels and lubricants List of fuels and lubricants Assembly Fuel or lubricant Spare Filling group parts quantity number Summer Winter Observe the level mark! Engine oil SAE 10W-40 009 920 06 9.5 l Ä Chapter 8.2.1 Specification: 20 l (2.5 gal us)

  • Page 165: Running-In Instructions

    Maintenance – Running-in instructions Running-in instructions 8.4.1 General The following maintenance work must be per- formed when running in new machines or over- hauled engines. NOTICE! Danger of engine damage! – Up to approx. 250 operating hours check the engine oil level twice every day.

  • Page 166: Maintenance Table

    Maintenance – Maintenance Table Maintenance Table Maintenance works Page Every 50 operating hours 8.6.1 Checking radiator hoses and hose clamps 8.6.2 Checking, cleaning the water separator 8.6.3 Lubricating the chip spreader Every 250 operating hours 8.7.1 Change engine oil and oil filter cartridge 8.7.2 Checking, tensioning the V-belt 8.7.3...
  • Page 167 Maintenance – Maintenance Table Maintenance works Page 8.10.3 Replacing hoses 8.10.4 Check the injection valves Every 3000 operating hours 8.11.1 Checking the fuel injection pump As required 8.12.1 Air filter maintenance 8.12.2 Checking the water spraying system 8.12.3 Cleaning the water spraying system 8.12.4 Measures if there is a risk of frost 8.12.5...

  • Page 168: Every 50 Operating Hours

    Maintenance – Every 50 operating hours Every 50 operating hours 8.6.1 Checking radiator hoses and hose clamps Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2.

  • Page 169: Lubricating The Chip Spreader

    Maintenance – Every 50 operating hours Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Place the transparent container under the drain plug. 3.

  • Page 170: Every 250 Operating Hours

    Maintenance – Every 250 operating hours Every 250 operating hours 8.7.1 Change engine oil and oil filter cartridge Perform this maintenance work at the latest after one year. NOTICE! Danger of engine damage! – Change the oil only with the engine at operating temperature.

  • Page 171: Checking, Tensioning The V-Belt

    Maintenance – Every 250 operating hours 4. Thoroughly clean the outside of the oil filter cartridge. 5. Unscrew the oil filter cartridge using an appropriate strap wrench. 6. Clean the sealing face on the filter carrier from any dirt. 7. Thinly apply oil to the rubber seal of the B-880-0108 new oil filter cartridge.

  • Page 172: Check The Air Intake Lines

    Maintenance – Every 250 operating hours 3. Check the entire circumference of the V- belt for damage and cracks. 4. Replace a damaged or cracked V-belt Ä Chapter 8.8.2 „Replacing the V- belt“ on page 178. 5. Check with thumb pressure whether the V- belt can be depressed more than 7 to 9 mm (0.28 –...

  • Page 173: Checking Radiator Hoses And Hose Clamps

    Maintenance – Every 250 operating hours 8.7.4 Checking radiator hoses and hose clamps Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Allow the engine to cool down. 3.
  • Page 174 Maintenance – Every 250 operating hours Cleaning with com- Protective equip- Working clothes pressed air ment: Protective gloves Safety goggles CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protec- tive working clothes, goggles). 1.

  • Page 175: Battery Service

    Maintenance – Every 250 operating hours Cleaning with cold Protective equip- Working clothes cleansing agent ment: Protective gloves NOTICE! Electric components can be dam- aged by water entering into the system! – Protect electrical equipment such as generator, regulator and starter against the direct water jet.

  • Page 176: Check The Parking Brake

    Maintenance – Every 250 operating hours Protective equip- Working clothes ment: Protective gloves Safety goggles 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Remove the battery and clean the battery compartment.

  • Page 177: Every 500 Operating Hours

    Maintenance – Every 500 operating hours Every 500 operating hours 8.8.1 Replacing the fuel filter NOTICE! Danger of engine damage! – Ensure strict cleanliness! Thor- oughly clean the area around the fuel filters. – Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting...

  • Page 178: Replacing The V-Belt

    Maintenance – Every 500 operating hours 5. Unscrew the drain plug (1) and catch run- ning out fuel. 6. Open the quick lock (2) and take off the fuel filter (3). 7. Clean the sealing face on the filter carrier from any dirt.

  • Page 179: Checking The Anti-Freeze Concentration And The Condition Of The Coolant

    Maintenance – Every 500 operating hours Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Allow the engine to cool down. 3. Loosen the tensioning screw (1) and the screw (2) on the generator.

  • Page 180: Checking The Hydraulic Lines

    Maintenance – Every 500 operating hours 3. Remove the cover (1) from the compensa- tion tank and check the anti-freeze concen- tration with a conventional tester. 4. Check the condition of the coolant. 5. Thoroughly flush the cooling system if the coolant is contaminated by corrosion resi- Ä...
  • Page 181 Maintenance – Every 500 operating hours 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Check all hydraulic lines. Hydraulic hoses must be immediately replaced if: the outer layer is damaged down to the inlay (e.g.

  • Page 182: Every 1000 Operating Hours

    Maintenance – Every 1000 operating hours Every 1000 operating hours 8.9.1 Adjusting the valve clearance NOTICE! Danger of engine damage! We recommend to have this work carried out by trained personnel or our after sales service. – Before checking the valve clear- ance let the engine cool down for at least 30 minutes.
  • Page 183 Maintenance – Every 1000 operating hours 4. Align the marking “1TC” on the flywheel and the marking on the housing. Fig. 180 5. Check if cylinder 1 is overlapping, if neces- sary rotate the flywheel by another 360°. 6. Check the valve clearance on the valves marked black, adjust if necessary.

  • Page 184: Checking The Engine Mounts

    Maintenance – Every 1000 operating hours 9. Install the cylinder head cover with a new gasket. 10. After a short test run check the engine for leaks. Fig. 183 Checking the valve clear- ance 1. Check valve clearance (A) between rocker arm and valve with a feeler gauge.

  • Page 185: Checking The Rops

    Maintenance – Every 1000 operating hours 6. Check condition and tight fit of engine pillow blocks. 8.9.3 Checking the ROPS 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.

  • Page 186: Checking The Travel Control

    Maintenance – Every 1000 operating hours 8.9.4 Checking the travel control 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Move the travel lever forward, backwards and to braking position. Thereby check for function, light movement, clearance and damage.
  • Page 187 Maintenance – Every 1000 operating hours Preparations 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Allow the engine to cool down. Hydraulic oil filter Protective equip- Working clothes ment: Protective gloves 1.
  • Page 188 Maintenance – Every 1000 operating hours High pressure filter Protective equip- Working clothes ment: Protective gloves 1. Clean the area around the high pressure filter. 2. Disconnect the hydraulic oil lines (1) from the high pressure filter (2). 3. Remove the high pressure filter and assemble the new high pressure filter, pay attention to the flow direction (arrow).

  • Page 189: Every 2000 Operating Hours

    Maintenance – Every 2000 operating hours 8.10 Every 2000 operating hours 8.10.1 Changing the hydraulic oil Perform this maintenance work at the latest after two years. The hydraulic oil must also be changed after major repairs in the hydraulic system. Always replace the hydraulic oil filter after each hydraulic oil change.
  • Page 190 Maintenance – Every 2000 operating hours Protective equip- Working clothes ment: Protective gloves Ä Chapter 6.8 1. Park the machine safely „Parking the machine in secured condi- tion“ on page 121. 2. Clean the area around hydraulic oil tank, filler opening and filler cap. 3.
  • Page 191 Maintenance – Every 2000 operating hours NOTICE! This will contaminate the hydraulic oil! – Never use detergents. Wipe the inside of the hydraulic oil tank clean with a lint-free cloth. 8. Attach the cap and tighten the strap. We recommend to use our filling and filtering unit with fine filter to fill the system.

  • Page 192: Changing The Coolant

    Maintenance – Every 2000 operating hours 8.10.2 Changing the coolant Perform this maintenance work at the latest after two years. Do not start the engine after draining off the coolant. In case of lubrication oil entering into the cooling system or a suspicious turbidity caused by corrosion residues or other suspended matter, the coolant must be drained off and the complete cooling system needs to be cleaned.
  • Page 193 Maintenance – Every 2000 operating hours Protective equip- Working clothes ment: Protective gloves Safety goggles Ä Chapter 6.8 1. Park the machine safely „Parking the machine in secured condi- tion“ on page 121. 2. Allow the engine to cool down. 3.

  • Page 194: Replacing Hoses

    Maintenance – Every 2000 operating hours 16. Fill in coolant until the level reaches the bottom edge of the filler socket. 17. Screw the filler cap back on again. B-880-0112 Fig. 194 18. Fill in coolant up to the “MAX” mark on the compensation tank.

  • Page 195: Check The Injection Valves

    Maintenance – Every 2000 operating hours 8.10.4 Check the injection valves This work must only be performed by authorized service personnel. BW 138 AD-5...

  • Page 196: Every 3000 Operating Hours

    Maintenance – Every 3000 operating hours 8.11 Every 3000 operating hours 8.11.1 Checking the fuel injection pump This work must only be performed by authorized service personnel. BW 138 AD-5...

  • Page 197: As Required

    Maintenance – As required 8.12 As required 8.12.1 Air filter maintenance NOTICE! Danger of engine damage! – Do not start the engine after having removed the air filter. – If necessary, the air filter may be cleaned up to six times. After one year at the latest it must be replaced together with the safety element.
  • Page 198 Maintenance – As required Protective equip- Working clothes ment: Protective gloves Safety goggles Air filter maintenance is due when the yellow piston in the maintenance indicator has reached the red sector (1), but at the latest after one year. 1. Park the machine in secured condition Ä...
  • Page 199 Maintenance – As required CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protec- tive working clothes, goggles). 6. Blow the air filter out with dry compressed air (max. 2.1 bar (30 psi)) from inside to outside by moving the gun up and down inside the element, until it if free of dust.

  • Page 200: Checking The Water Spraying System

    Maintenance – As required 11. Press the reset button (1) for the yellow piston on the maintenance indicator. Fig. 202 8.12.1.1 Replacing the safety element NOTICE! Danger of engine damage! The safety element must not be cleaned and should not be used again after it has been removed.
  • Page 201 Maintenance – As required NOTICE! The spraying pump may get damaged if the tank is empty! – Always keep the water tank filled with a sufficient amount of water. B-880-0032 Fig. 204 Check the filling level on the water level gauge, fill up if necessary.
  • Page 202 Maintenance – As required 6. Check water output and spray pattern on all nozzles (1) for both drums. B-880-0070 Fig. 207 7. Turn the rotary switch for pressure spraying to “0” to switch the water spraying system off. 8. Turn the ignition key back to position “0” and pull it out.

  • Page 203: Cleaning The Water Spraying System

    Maintenance – As required 8.12.3 Cleaning the water spraying system Perform this maintenance work at the latest after one year. Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“...
  • Page 204 Maintenance – As required 9. Clean the water filter (1) and check for damage, replace if necessary. 10. Screw the drain cover with water filter and a new seal (2) back on. Fig. 211 11. Unscrew the caps (1) and all nozzles (2) from all spraying tubes and let the water run out.

  • Page 205: Measures If There Is A Risk Of Frost

    Maintenance – As required 8.12.4 Measures if there is a risk of frost Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.8 „Parking the machine in secured condition“ on page 121. 2. Open the drain cover on the water tank and let all water run out.

  • Page 206: Draining The Fuel Tank Sludge

    Maintenance – As required 11. Close the drain tap on the water pump (lever across the flow direction) and route the water line back into the machine. 12. Unscrew the caps (1) and all nozzles (2) from all spray tubes and let the water run out.

  • Page 207: Measures Prior To Extended Shutdown Period

    Maintenance – As required 8.12.6 Measures prior to extended shutdown period 8.12.6.1 Measures before shutting down If the machine is shut down for a longer period of time (e.g. winter season), the following work must be carried out: 1. Clean the machine thoroughly. 2.
  • Page 208 Maintenance – As required 8.12.6.2 Battery service during prolonged machine downtimes WARNING! Danger of injury caused by exploding gas mixture! – Remove the plugs before starting to recharge the battery. – Ensure adequate ventilation. – Smoking and open fire is pro- hibited! –...
  • Page 209 Maintenance – As required 4. Switch off the charging current before removing the charging clamps. 5. After each charging process allow the bat- tery to rest for one hour before taking it into service. 6. For standstill periods of more than one month you should always disconnect the battery.
  • Page 210 Maintenance – As required BW 138 AD-5...

  • Page 211: Troubleshooting

    Troubleshooting Troubleshooting BW 138 AD-5...

  • Page 212: Preliminary Remarks

    Troubleshooting – Preliminary remarks Preliminary remarks Malfunctions are frequently caused by incorrect operation of the machine or insufficient mainte- nance. Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance. If you cannot locate the cause of a fault or rec- tify it yourself by following the trouble shooting chart, you should contact our customer service department.

  • Page 213: Starting The Engine With Jump Leads

    Troubleshooting – Starting the engine with jump leads Starting the engine with jump leads NOTICE! A wrong connection will cause severe damage in the electric system. – Bridge the machine only with a 12 Volt auxiliary battery. 1. Connect the plus pole of the external bat- tery first with the plus pole of the vehicle battery using the first jump lead.

  • Page 214: Fuse Assignment

    Troubleshooting – Fuse assignment Fuse assignment 9.3.1 Notes on safety WARNING! Danger of injury by fire in the machine! – Do not use fuses with higher ampere ratings and do not bridge fuses. 9.3.2 Fuses in engine compartment Fig. 219 Pos.

  • Page 215: Central Electrics

    Troubleshooting – Fuse assignment 9.3.3 Central electrics The central electrics are located in the oper- ating console. 1. Unscrew the fastening screws and fold out the central electrics against the end stop. The printed circuit board is equipped with a fuse test socket „Fuse Test“...
  • Page 216 Troubleshooting – Fuse assignment Fuse Amperage Designation F139 30 A Engine solenoid F153 10 A Potential 15 F156 15 A Lighting F157 30 A Starter F241 15 A Optional headlights F274 10 A Chip spreader / hydraulic cutting tool F275 Economizer F276 10 A...

  • Page 217: Engine Faults

    Troubleshooting – Engine faults Engine faults Fault Possible cause Remedy Engine does Fuel tank empty Refuel, bleed the fuel system not start Fuel filter clogged, in winter Change the fuel filter, use due to paraffin separation winter fuel Fuel lines leaking Check all line connections for leaks and tighten the fittings, bleed the fuel system...
  • Page 218 Troubleshooting – Engine faults Fault Possible cause Remedy Moving parts overheating Check the engine oil level, because of a lack of lubrica- correct if necessary tion Check the engine oil filter, replace if necessary Check the lubrication system Excessive Engine oil level too high Check, drain off if necessary exhaust Insufficient fuel quality...
  • Page 219 Troubleshooting – Engine faults Fault Possible cause Remedy Engine has Engine oil level too low Check, fill up if necessary insufficient Lubrication system leaking Have the lubrication system engine oil examined by a specialist pressure (engine oil pressure warning lamp lights) The charge Generator speed too low...

  • Page 220: Trouble Shooting Economizer

    Troubleshooting – Trouble shooting ECONOMIZER Trouble shooting ECONOMIZER Fig. 221: Economizer dis- play Fault Possible cause Remedy LED (a) Switching on: The LED (a) flashes flashes for approx 1 - 2 sec- onds after the vibration has been switched on. Jump operation of the drum on hard ground Acceleration sensor is not...
  • Page 221 Troubleshooting – Trouble shooting ECONOMIZER Fault Possible cause Remedy The displayed The acceleration sensor is Shut down the engine and measuring not fastened correctly. check the fastening screws of values are not the acceleration sensor. plausible. Weak spots in the road sub- In unfavourable cases, an base are also measured excessively varying material...
  • Page 222 Troubleshooting – Trouble shooting ECONOMIZER BW 138 AD-5...

  • Page 223: Disposal

    Disposal Disposal BW 138 AD-5...

  • Page 224: Final Shut-Down Of Machine

    Disposal – Final shut-down of machine 10.1 Final shut-down of machine If the machine can no longer be used and needs to be finally shut down you must carry out the following work and have the machine disassembled by an officially recognized spe- cialist workshop.
  • Page 226 Head Office/Hauptsitz BOMAG Hellerwald D-56154 Boppard Germany Telefon: +49 6742 100-0 Fax: +49 6742 3090 e-mail: info@bomag.com BOMAG BOMAG BOMAG Niederlassung Berlin Niederlassung Boppard Niederlassung Chemnitz Gewerbestraße 3 Hellerwald Querstraße 6 15366 Hoppegarten 56154 Boppard 09247 Chemnitz GERMANY GERMANY GERMANY Tel.: +49 3342 369410 Tel.:...

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