BW138AD Operation Maintenance PDF

Operating instructions
Maintenance instructions
BW 125 ADH / BW 135 AD
BW 138 AD / BW 138 AC
S/N 101 650 12.... > S/N 101 170 21....>
S/N 101 650 14 .... > S/N 101 650 15 .... >
Tandem Vibratory Roller

Combination Roller
Catalogue number
008 138 01
04/2004
Foreword
BOMAG machines are products from the wide

range of BOMAG compaction equipment.
F oreword
BOMAGs vast experience in connection with

state-of-the-art production and testing methods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your machine.
You should only operate the machine after you

have been instructed and in compliance with these
instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil Engineering Liability Association Safety Rules for
the Operation of Road Rollers and Soil Compactors and all relevant accident prevention regulations.
This manual comprises:

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Safety regulations
Operating instructions
Maintenance instructions
Trouble shooting
For your own personal safety you should only

use original spare parts from BOMAG.
In the course of technical development we reserve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Using these instructions will

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help you to become familiar with the machine.
avoid malfunctions caused by unprofessional

operation.
Compliance with the maintenance instructions will

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enhance the reliability of the machine on construction sites,
prolong the lifetime of the machine,
reduce repair costs and downtimes.
BOMAG will not assume liability for the function of

the machine
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if it is handled in a way that does not comply

with the usual modes of use,
if it is used for purposes other than the ones it

is intended for, see safety regulations.
Furthermore, the spare parts catalogue is available from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with information about the correct use of our machines in
soil and asphalt construction.
The above notes do not constitute an extension of
the warranty and liability conditions specified in the
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
No warranty claims can be lodged in case of damage resulting from

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operating errors,
insufficient maintenance and
wrong fuels and lubricants.
Please note!
This manual was written for operators and maintenance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and maintenance instructions are part of the machine.
BW 125 ADH/ BW 135AD/138 AD/AC
BOMAG
Foreword
Please fill in
............................
Machine type (Fig. 1)
............................
Serial-number (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine number (Fig. 3)
Note
Fig. 1
Supplement the above data together with the commissioning protocol.

During commissioning our organisation will instruct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 2
Fig. 3
BOMAG
Table of Contents
Technical Data
Safety regulations
15
Indicators and Controls
23
3.1 General notes
27
3.2 Description of indicators and control elements
27
Operation
35
4.1 General notes
36
4.2 Inspections before starting operation
36
4.3 Starting the engine
37
4.4 Starting with jump wires
39
4.5 Driving the machine
39
4.6 Stopping the machine / applying the brake
41
4.7 Switching the vibration on and off
41
4.8 Switching the vibration on or off
43
4.9 Switching the pressure sprinkler system on or off
44
4.10 Stopping the engine/machine
45
4.11 Adjusting the driver's seat
46
4.12 Towing
46
4.13 Loading and transport
48
4.14 Foldable roll over protection structure (ROPS)
49
Maintenance
51
5.1 General notes on maintenance
52
5.2 Fuels and lubricants
53
5.3 Table of fuels and lubricants
55
5.4 Running-in instructions
56
5.5 Maintenance chart
57
5.6 Check the engine oil level
59
5.7 Checking the dry air filter
59
5.8 Checking the hydraulic oil level
60
5.9 Checking the hydraulic oil filter element
60
5.10 Checking the fuel level
61
5.11 Checking the water level
61
5.12 Checking the emulsion oil level
62
5.13 Lubricating the articulated joint
62
5.14 Cleaning cooling fins and engine oil cooler
63
5.15 Cleaning the hydraulic oil cooler
64
5.16 Adjusting the scrapers
64
5.17 Checking the battery condition, greasing the poles
65
5.18 Draining the slurry from the fuel tank
66
5.19 Changing the engine oil
67
5.20 Change the engine oil filter cartridge
68
BOMAG
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
6.2 Engine problems
83
BOMAG
1 Technical Data
BOMAG
Technical Data
Fig. 4
Dimensions in
mm
H2
BW 125 ADH
1790
1280
650
800
1900
2700
320
2590
40
17,0
1200
BW 135 AD
1790
1380
650
800
1900
2700
320
2590
40
17,0
1300
BW 138 AD
1790
1460
650
810
1905
2705
325
2600
40
22
1380
Weights
Operating weight (CECE)
Mean axle load (CECE)
Mean static linear load
(CECE)
Dimensions
Oscillation angle
Inner track radius
BW 125 ADH
BW 135 AD
BW 138 AD
kg
kg
kg/cm
3360
1680
14
3560
1780
13,7
4200
2100
15,2
+/-
mm
13
3700
13
3650
13
3610
BOMAG
Technical Data
Travel characteristics
Travel speed I
Travel speed II
Max. gradability/with vibration (soil dependent)
Drive
Engine manufacturer
Type
Cooling
Number of cylinders
Rated power ISO 9249
Rated speed
Fixed engine speed 1
Fuel tank capacity
Electrical equipment
Drive system
Driven axles
Vibration system
Drive system
Frequency
Amplitude
Vibrating drum
Water sprinkler system
Type of sprinkling
Interval control
Water tank capacity
*
BW 135 AD
BW 138 AD
0...5,0
0...10
40/30
0...5,0
0...10
40/30
0...5,0
0...10
40/30
Deutz
F3L 2011
Air-oil
3
34
2800
2200
2700
55
12
hydrost.
front+rear
Deutz
F3L 2011
Air-oil
3
34
2800
2200
2700
55
12
hydrost.
front+rear
Deutz
F3L 2011
Air-oil
3
34
2800
2500
2800
55
12
hydrost.
front+rear
hydrost.
hydr.-mech.
hydrost.
hydr.-mech.
hydrost.
hydr.-mech.
Oscill.-articul.
hydrost.
25
Oscill.-articul.
hydrost.
25
Oscill.-articul.
hydrost.
25
hydrost.
50/60
0,45
front+rear
hydrost.
50/60
0,40
front+rear
hydrost.
46/52
0,50
front+rear
Pressure
Standard
230
Pressure
Standard
230
Pressure
Standard
230
km/h
km/h
%
kW
rpm
rpm
rpm
l
V
Brakes
Service brake
Parking brake
Steering
Type of steering
Steering operation
Steering angle +/-
BW 125 ADH
Degree
Hz
mm
The right for technical modifications remains reserved
BOMAG
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 operators 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 (drivers seat)
The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2.
Hand-arm vibration values
The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2.
10
BOMAG
Technical Data
Fig. 5
Dimensions in
mm
H2
BW 138 AC
1790
1460
650
810
1905
2705
325
2580
40
22
1380
Weights
Operating weight (CECE)
Axle load, drum (CECE)
Axle load, wheels (CECE)
Mean static linear load
Dimensions
Oscillation angle
Inner track radius
BW 138 AC
kg
kg
kg
kg/cm
4000
2050
1950
14,9
+/-
mm
13
3610
BOMAG
11
Technical Data
BW 138 AC
Travel characteristics
Travel speed I
Travel speed II
Max. gradability/with vibration (soil dependent)
Drive
Engine manufacturer
Type
Cooling
Number of cylinders
Rated power ISO 9249
Rated speed
Fuel tank capacity
Electrical equipment
Drive system
Driven axles
km/h
km/h
%
0...5,0
0...10
40/30
Deutz
F3L 2011
Air-oil
3
34
2800
2250
2800
55
12
hydrostatic
front+rear
kW
rpm
rpm
rpm
l
V
Tires
Number of tires
Tire size
4
225/75 R16
Brakes
Service brake
Parking brake
hydrost.
hydr.-mech.
Steering
Type of steering
Steering operation
Steering angle +/Vibration system
Drive system
Frequency
Amplitude
Vibrating drum
Water sprinkler system
Type of sprinkling
Interval control
Water tank capacity
Emulsion tank capacity
*
12
Oscill.-articul.
hydrost.
25
Degree
hydrost.
46/52
0,5
front
Hz
mm
Pressure
Standard
230
20
l
l
The right for technical modifications remains reserved
BOMAG
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 operators 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 (drivers seat)
The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2.
Hand-arm vibration values
The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2.
BOMAG
13
Technical Data
14
BOMAG
2 Safety regulations
BOMAG
15
Safety regulations
General Notes
Unintended use
This BOMAG machine has been built in accordance with the latest technical standard
and complies with the applicable regulations
and technical rules. However, dangers for persons and property may arise from this machine, if:
However, dangers may arise from this machine if

it is operated by untrained personnel or if it is subject of unintended use.
it is used for purposes other than the ones it is

intended for
it is operated by untrained personnel
it is changed or converted in an unprofessional

way
Each person involved in the operation, maintenance and repair of the machine must therefore read and comply with these safety
regulations. If necessary, this must be confirmed by obtaining the signature of the customer.
Furthermore, the following instructions and regulations must obviously also be complied with:
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applicable accident prevention instructions
generally accepted safety and road traffic regulations
country specific safety regulations. It is the

duty of the operator to be acquainted with
these instructions and to apply these accordingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instructions be different from the regulations valid in
your country, you must comply with the safety
regulations valid in your country.
This machine must only be used for:

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compaction of bituminous material, e.g. road

surface layers. (Only AC and AD machines)
medium to heavy compaction work in earth

construction (road sub-bases)
You should only operate the unit with fully

functional safety equipment.
Have the machine inspected by an expert

once every year.
16
Starting and operation of the machine in explosive

environments is prohibited.
Who has permission to operate the machine?
the safety instructions are not observed
Intended use
Do not work with vibration on hard concrete, cured

bitumen layers or extremely frozen ground.
Only trained and instructed persons of at least 18

years of age are permitted to drive and operate
this machine. For operation of the machine the responsibilities must be clearly specified and complied with.
Persons under the influence of alcohol, medicine
or drugs are not allowed to operate, service or repair the machine.
Maintenance and repair work requires specific
knowledge and must therefore only be performed
by trained specialists.
Conversions and changes to the machine

Unauthorized alterations to the machine are prohibited for safety reasons.
Original parts and accessories have been specially designed for this machine. We wish to make explicitly clear that we have not tested or approved
any parts or accessories not supplied by us. The
installation and/or use of such products may have
an adverse effect on the active and/or passive
driving safety. The manufacturer explicitly excludes any liability for damage caused by the use
of non-original parts or accessories.
Notes on safety in the operating and

maintenance instructions:
Danger
Paragraphs marked like this highlight possible
dangers for persons.
!
Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
!
BOMAG
Safety regulations
Checking the roll over protection

structure (ROPS)
Note
Paragraphs marked like this contain technical information for the optimal economical use of the
machine.
The frame of the machine must not be warped,

bent or cracked in the area of the ROPS fastening.
Environment
Paragraphs marked like this point out practices for safe and environmental disposal of fuels
and lubricants as well as replacement parts.
Observe environmental regulations.
Information and safety stickers/decals

on the machine
Keep safety stickers in good and legible condition
(see parts manual) and comply with their meaning.
The ROPS must not show any rust, damage, hairline cracks or open fractures.
The ROPS must not rattle about when driving.
This would indicate that it is not properly fastened.
All bolted connections must comply with the specifications and should be absolutely tight (observe
the tightening torques). Screw and nuts must not
be damaged, bent or deformed.
No accessories may be welded or bolted on and
no additional holes must be drilled without the consent of the distributor, since this will impair the
strength of the unit.
Replace damaged and illegible stickers/decals.
Starting the machine

Loading the machine
Before starting
Use only strong and stable loading ramps of sufficient load bearing capacity. The ramp inclination
must be less than the gradability of the machine.
Secure the machine against tipping or slipping off.
Secure the machine on the transport vehicle
against rolling, slipping and turning over.
The machine must only be operated from the driver's seat.

Use only machines which are serviced at regular
intervals.
Become acquainted with the equipment, the control elements, the working principle of the machine
and the working area.
Persons are highly endangered when

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they step or stand under loads being lifted
they remain in the drive range of the machine

during an instruction and during loading.
Wear your personal protective outfit (hard hat,

safety boots, etc.).
Before climbing on the machine check whether:
The machine must not swing about when being lifted.
persons or obstructions are beside or under

the machine
Use only safe lifting gear of sufficient load bearing

capacity.
the machine is free of oily and combustible

material
Fasten the lifting gear only at the specified lifting

points.
all grips, steps and platforms are free of

grease, oils, fuel, dirt, snow and ice
the engine hood is closed and locked
Towing the machine

You should generally use a tow bar.
Max. towing speed 1 km/h, max. towing distance
500 m.
Before releasing the multi-disc brake secure the
machine against unintended rolling.
Use steps and grips to climb onto the machine.

Before starting the machine check whether:
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the machine shows any obvious faults
all guards and safety elements are in place
steering, brakes, control elements, light system and warning horn work correctly
BOMAG
17
Safety regulations
the seat is correctly adjusted
mirrors (if present) are clean and correctly adjusted.
Do not start the machine with defective gauges,

control lights or control elements.
not use the emergency stop switch as service

brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop switch
has been eliminated.
If the engine oil pressure control light lights up stop
the engine immediately.
Do not take any loose objects with you or fasten

them to the machine.
If the machine has contacted high-voltage power

lines:
On machines with roll over protection system you

must always wear your seat belt.
Do not leave the operator's platform
Warn others from coming close to or touching

the machine
if possible drive the machine out of the danger

zone
Have the electric power switched off
Starting
Start and operate the machine only from the driver's seat.
For starting set all control levers to 'neutral position'.
Do not use any starting aids like start pilot or ether.
After starting check all gauges and control lights.
Operate the machine only from the operator's

stand.
Starting with jump wires
Keep the cabin doors closed.
Connect plus with plus and minus with minus

(ground cable) - always connect the ground strap
last and disconnect it first! A wrong connection will
cause severe damage in the electric system.
Do not adjust the driver's seat while driving.

Do not climb onto or off the machine while the machine is driving.
Do not start the engine by shorting the electric terminals on the starter motor, because the machine
may start to drive immediately.
Starting in closed rooms
Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting
in closed rooms!
Do not use the machine to transport persons.

In case of unusual noises and development of
smoke perform trouble shooting and have the fault
corrected.
Always keep a sufficient distance to excavation
walls and embankments and do not use working
methods that could impair the stability of the machine.
Driving the machine
Do not work with vibration on hard concrete, cured

bitumen layers or extremely frozen ground.
Persons in the danger area
Always keep a sufficient distance when passing

through subways, under bridges, tunnels, electric
power lines etc.
Before taking up work, also after breaks, you

should always convince yourself that the danger
zone is free of persons or obstructions, especially
when driving in reverse.
Driving on inclinations and slopes
If necessary give warning signals. Stop work immediately if persons remain in the danger zone,
despite the warning.
Do not drive on gradients exceeding the maximum

gradability of the machine.
On slopes drive extremely carefully and always directly up or down the slope. Change to a lower
gear before starting to drive.
Do not step or stand in the articulation area of the

machine when the engine is running. Danger of
squashing!
Driving
In events of emergency and in case of danger actuate the emergency stop switch immediately. Do
18
Change the travel direction only at standstill.
Wet and loose soils considerably reduce the

ground adhesion of the machine on inclinations
and slopes. Higher risk of accident!
BOMAG
Safety regulations
Leaking fuel tanks can cause explosions. Ensure

tight fit of the fuel tank cover, if necessary replace
immediately.
Behaviour in traffic
Match the speeds to the working conditions.
Always allow loaded transport vehicles to pass.
Switch the lights on if the visibility is poor.
Fire protection measures
Keep away from edges and embankments.
Familiarise yourself with the location and the operation of fire fighting equipment. Observe all fire reporting and fire fighting possibilities.
Check the effect of vibration

When compacting with vibration you must always
check the effect of the vibration on nearby buildings and underground supply lines (gas, water,
sewage, electric power) and stop compaction work
with vibration, if necessary.
Do not switch the vibration on when working on
hard (frozen, concrete) ground. Danger of bearing
damage!
Maintenance work
Comply with the maintenance work described in
the operating and maintenance instructions, including the information concerning the replacement of parts.
Maintenance work must only be performed by
qualified and authorized persons.
For overhead maintenance and assembly work
use the access steps and working platforms provided or other secure means. Do not use machine
parts as access steps.
Parking the machine

Park the machine on level and firm ground.
Before leaving the machine:
Keep unauthorized persons away from the machine.
return the control lever to neutral position
apply the parking brake
shut the engine down and pull the ignition key

out
lock the cabin door
Park the machine on horizontal, level and firm

ground.
secure the machine against unintended use.
Pull the key out of the ignition switch.
Do not perform maintenance work while the machine is driving or the engine is running.
Do not jump off the machine, but use access steps

and grips.
Secure the articulated joint with the articulation

lock.
Mark machines, which could be in the way, with a

clearly visible sign.
Working on hydraulic lines
Parking on slopes and inclinations

Secure the machine against rolling, place metal
chocks in front of and behind the drums.
Filling the fuel tank

Do not inhale any fuel fumes.
Refuel only with the engine stopped and the auxiliary heater switched off.
Do not refuel in closed rooms.
Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe
injury. When being injured by hydraulic oil consult
a medical doctor immediately, as otherwise this
may cause severe infections.
Do not step in front of or behind the drums/rubber
wheels when performing adjustment work in the
hydraulic system.
Do not change the setting of pressure relief valves.
No open fire, do not smoke.
Drain hydraulic oil at operating temperature - danger of scalding!
Do not spill any fuel. Catch running out fuel, do not

let it seep into the ground.
Catch running out hydraulic oil and dispose of environmentally.
Wipe off spilled fuel. Keep dirt and water away

from the fuel.
Always catch and dispose of biodegradable hydraulic oils separately.
BOMAG
19
Safety regulations
Do not start the engine after draining the hydraulic

oil.
Do not leave any tools or other objects, that could

cause damage, in the engine compartment.
Once all work is completed (with the system still

depressurized!) check all connections and fittings
for leaks.
Working on electric components

Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.
Changing hydraulic hoses

Hydraulic hoses must be visually inspected at regular intervals.
Hydraulic hoses must be immediately replaced if:
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the outer layer is damaged down to the inlay

(e.g. chafing, cuts, cracks)
the outer layer is brittle (formation of cracks in

the hose material)
Do not use fuses with higher ampere ratings and

do not repair fuses with a piece of wire. Fire hazard!
Before starting welding work on the machine disconnect the battery.
Working on the battery
When working on the battery do not smoke, do not
use open
the hose shows deformations in pressurized

and depressurized condition, which do not
comply with the genuine shape of the hydraulic hose
Do not let acid come in contact with hands or

clothes! When injured by acid flush off with clear
water and seek medical advice.
the hose shows deformations in bends, e.g.

squeezing, buckling, layer separation, formation of blisters
Metal objects (e.g. tools, rings, watch straps) must

not come in contact with the battery poles - danger
of short circuit and burning!
leakages.
incorrect installation.
When recharging serviceable batteries remove all

plugs, to avoid the accumulation of explosive gases.
the hydraulic hose has separated from the fitting
mixing up of hoses by mistake.
the fitting shows corrosion that impairs both

function and strength.
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.
fittings are damaged or deformed, whereby

the function and strength of the hose/hose
connection is impaired.
Ensure sufficient ventilation, especially if the battery is to be charged in a closed room.
Only genuine BOMAG replacement hydraulic hoses ensure that the correct hose type (pressure
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!
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
Wipe off spilled oil, catch running out oil and dispose of environmentally.
Explosion-like bursting of tires or parts of tires and

rims can cause most severe or even deadly injuries.
Store used filters and other oil contaminated materials in a separate, specially marked container
and dispose of environmentally.
Assembly of tires must only be performed with appropriate experience and tools. If necessary have
tires assembled in a qualified workshop.
20
BOMAG
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 manufacturer of the anti-sticking agent. Observe applicable environmental regulations.
Cleaning work
Do not clean the machine while the engine is running.
Do not use gasoline or other inflammable substances 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 instructions for this work.
Exhaust gases are highly dangerous! Always ensure 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.
BOMAG
21
Safety regulations
22
BOMAG
3 Indicators and Controls
BOMAG
23
Fig. 6
24
BOMAG
Fig. 7
BOMAG
25
Hydraulic oil temperature control light
15 Momentary contact switch for edge cutter*
Oil pressure control light
16 Seat contact control light
Oil temperature control light
17 Throttle lever
Charge control light
18 Locking lever for throttle lever
Emergency stop push button
19 Travel lever / brake
Brake control light
20 Push button for vibration
Rotary switch for pressure sprinkler system
21 Ball valve, vibration (only AD)
Interval switch for pressure sprinkler system
22 Lever for transverse sliding seat adjustment
Rotary switch for lighting (STVZO)
10 Rotary switch for indicator light, with control

light *
11 Rotary switch for hazard light system, with
control light *
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
12 Push button for warning horn
26 Fuse box A, top
13 Rotary switch for working light
27 not used
14 Rotary switch for flashing beacon*
28 Ignition switch
26
Optional equipment
29 Operating hour meter, in engine compartment
BOMAG
3.1
General notes
3.2
Description of indicators
and control elements
Please read this section thoroughly before operating 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 descriptions of the individual operating steps.
Fig. 8
No. 1 = Hydraulic oil temperature control

light
lights up
= if the hydraulic oil overheats

(the warning buzzer sounds at
the same time), shut down the
engine and perform trouble
shooting.
No. 2 = Oil pressure control light

lights up
= when switching the ignition on,

in case of an engine oil pressure 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
goes out
= after starting the engine
BOMAG
when switching the ignition

on, in case of charge failures
during operation, perform trouble shooting.
27
goes out
= with travel lever in positions "I",

"II" or "III".
Fig. 9
No. 5 = Emergency stop push button

Fig. 11
Danger
Danger of accident!
No. 7 = Rotary switch for pressure sprinkler

system
Use only in events of emergency during operation.
Position "left"
Do not use as parking brake.
No. 8 = Interval switch for pressure sprinkler

system
Position "right" = Sprinkling "ON"
Restart the machine only after the danger that

caused the actuation of the emergency stop
switch has been eliminated.
turn clockwise
Position "left"
The machine is braked immediately, the engine

is shut down.
actuate
switch off/unlock
= Sprinkling "OFF"
further positions
= press the button completely

down, it automatically locks in
fully pressed position.
= permanent sprinkling
= various sprinkling intervals
from 4...32 seconds, activation
time always 5 seconds.
= Turn button clockwise. Restart the engine.
Fig. 12
No. 9 = Rotary switch for lighting (STVZO)*

Position "left"
= Light off
Position "middle"
= Parking light on
Fig. 10
No. 6 = Brake control lamp

lights up
28
= with travel lever in position "0".
BOMAG
Optional equipment
Position "right" = Travel light and parking light

on, with ignition switch 28 in
position "I".
No. 10 = Rotary switch for direction indicators
with control light *
Position "middle"
= direction indicators off
Position "left"
= direction indicator left,the control light in the rotary switch

lights up.
Position "right" = direction indicator right,the

control light in the rotary switch
lights up.
No. 14 = Rotary switch for flashing beacon***
No. 11 = Rotary switch for hazard light with

control light **
Position "left"
Fig. 14
Position "left"
= hazard light switched off
= Flashing beacon off
Position "right" = Flashing beacon on
Position "right" = hazard light switched on, the

control lights in the rotary
switches (10) and (11) light up.
No. 15 = Rotary key switch for edge cutter****

POsition "middle"
= the edge cutter remains in the
current position
Position "left"
= the edge cutter is lifted up
Position "right" = the edge cutter is lowered

down
Fig. 13
No. 12 = Push button for warning horn

No. 13 = Rotary switch for work light
Position "left"
= work light off
Position "right" = work light on with the ignition

switch 28 in position "I".
Fig. 15
No. 16 = Seat contact control light*

goes out
= when the drivers seat is occupied.
lights up when
the machine is at
rest
= when the drivers seat is unoccupied. Drive operation is not
possible. (The brake is
closed).
*
**
Option
Option
*** Optional equipment

**** Option
BOMAG
29
Note
Standard design
pull
= the throttle lever can be moved
release
= the throttle lever will engage in

position "I" and "II".
lights when the

machine is driving
= when the drivers seat is unoccupied.
Note
Design with seat contact for engine shut-down

lights when the
machine is driving*
= when the drivers seat is unoccupied. Warning buzzer
sounds. Engine is shut down
after 8 seconds.
Fig. 17
No. 19 = Travel lever / brake

Position "0"
= Neutral position for engine

start, brake closed.
Position "I"
= Forward travel without vibration, brake is released.
Position "II"
= Backward travel without vibration, brake is released.
Position "III"
= max. forward/reverse travel

with vibration, brake is released.
No. 20 = Push button for vibration

press
Fig. 16
= to switch the vibration on or off
No. 17 = Throttle lever

Position "0"
= Idle speed position, engine

start.
Position "I"
= Full load position (2200 rpm),

operating position for driving
and vibration, BW125ADH and
BW135AD.
and vibration, BW138 AD/AC.
Position "II"

and vibration, BW125ADH and
BW135AD.
and vibration, BW138 AD/AC.
Fig. 18
No. 21 = Cock valve for vibration (only AD)

Position "I"
= vibration of both drums
Position "II"
= vibration of front drum only
No. 18 = Locking lever for throttlelever
30
BOMAG
Fig. 19
Fig. 21
Ball valve for 3-stage vibration*
No. 23 = Foot switch for tire sprinkler system

(only AC)
Position upward
press
= sprinkling on.
release
= sprinkling off.
= Vibration of rear drum only
Position horizontal
= Vibration of both drums
Position downward
= Vibration of front drum only
Fig. 22
Foot switch for flow divider* (only AD)

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
press
= flow divider switched on
release
= flow divider switched off
Danger
Danger of accident!
Optional equipment
BOMAG
31
(2) 15A = (F12) working lights, right*

(3) 15A = (F08) direction indicators* and working head lights
(4) 15A = (F10) parking and tail light, right hand
side*
(5) 15A = (F09) parking and tail light, left hand
side*
(6) 15A = (F11) head lights, left*
(7) 10A = (F142) seat contact
(8) 10A = (F36) fault indicator
No. 26 = Fuse box A, top
Fig. 23
(1) 40A = (F01) Main fuse
No. 24 = Ball valve, brake releasing device (only AC-machines)
(2) 15A = (F06) sprinkler system (only AD **)
Position "I"
(3) 10A = (F41) flashing beacon * / backup

alarm *
= Brake released
(4) 10A = (F45) edge cutter *
Note
Release brake by turning the steering wheel in

clockwise direction.
Position "II"
= Brake applied
(5) 15A = (F27) wiper/washer, front*

(6) 20A = (F141) hydraulic oil cooler
(7) 10A = (F03) vibration
(8) 15A = (F37) sprinkler pump
Danger
Danger of accident!
!
No. 27 = not used
Always secure with locking screw.
Fig. 25
No. 28 = Ignition switch

Fig. 24
Position "0"/"P" = ignition off, key can be pulled

out.
Position "I"
Danger
Fire hazard!
!
= ignition on, oil pressure control

light (2) and charge control
light (4) light up.
Do not use fuses with higher ampere ratings

and do not repair fuses with a piece of wire.
No. 25 = Fuse box B, bottom
(1) 15A = (F07) hazard light*
32
*
**
BOMAG
Optional equipment
Optional equipment
Note
For starting the driver's seat must be occupied and

the emergency stop switch must be unlocked.
Position "II"
= turn further against spring

pressure, start the engine. Release the ignition key, the control lights go out.
Note
The ignition switch is designed with a lock to prevent repetitive starting. For a new starting attempt
the ignition key must first be turned back to position "0".
No. 29 = Operating hour meter, in engine compartment
counts the operating hours while the engine is running
All maintenance work must be performed according to the indicated operating hours.
BOMAG
33
34
BOMAG
4 Operation
BOMAG
35
Operation
4.1
General notes
Please read section 3 Indicators and Control Elements 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 working period the following tests and inspections must
be performed.
Danger
Please observe strictly the safety regulations
in chapter 2 of these operating and maintenance instructions.
!
Park the machine on level ground.
Test:
l
Check fuel tank and fuel lines for leaks
Screw connections
Function of steering
Function of parking brake
Machine for damage
Note
The following inspection work is described in

chapter 'Maintenance every 10 Operating Hours'.
36
Engine oil level
Dry air filter service indicator
Hydraulic oil level
Fuel level
Water level in sprinkler system
Emulsion level
Tire pressure
BOMAG
Operation
4.3
Starting the engine
Fasten/release your seat belt *.
!
Caution
In this chapter it is assumed that the operator
is fully acquainted with the functions of the
various control elements on the machine.
Fig. 28
Fasten
l
Press the releasing button 1 (Fig. 28), pull the

seat belt vertically out of the retractor unit and
press the tongue into the buckle on the right
hand side of the drivers seat.
Fig. 26
Always start the engine from the drivers seat

with seat contact switch (Fig. 26).
Open
Danger
Danger of accident!
!
Always wear your seat belt.
Fig. 29
l
Press the release button on the buckle and

pull the tongue out.
Press the button 1 (Fig. 29) on the retractor

unit until the seat belt is completely retracted.
Fig. 27
l
Fasten your seat belt (Fig. 27).
BOMAG
Optional equipment
37
Operation
Fig. 30
l
Shift travel lever 19 (Fig. 30) to position '0'. The

brake is closed.
Fig. 33
Turn ignition key 28 (Fig. 33) to position "I".

Charge control light (4) and oil pressure warning light (2) light up.
Note
If the vibration starts to run in ignition switch position "II", press the vibration push button (20) to
switch the vibration off.
l
Then turn the ignition key further to position "II"

to start the engine.
As soon as the engine is running turn the ignition key back to position "I", charge control
light and oil pressure control light go out.
Fig. 31
l
Pull the locking lever 18 (Fig. 31) and shift the

throttle lever (17) to position '0', idle speed.
Note
Run the engine warm for a short while before starting work.
Fig. 32
l
38
Check, whether the emergency stop switch

(Fig. 32) is unlocked.
BOMAG
Operation
4.4
Starting with jump wires
4.5
!
Driving the machine
Danger
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive on gradients exceeding the maximum gradability of the machine.
Before starting to drive make sure that the
drive range is absolutely safe.
Fig. 34
Always give way to loaded transport vehicles!
Caution
A wrong connection will cause severe damage
in the electric system.
!
Only use a 12 Volt battery to bridge the machine.
When jump starting with an external battery

connect both plus poles first.
Then connect the ground cable first to the minus pole of the current supplying battery and
then to engine or chassis ground, as far away
from the battery as possible (Fig. 34).
Start as described under 'Starting the engine'.
Once the engine is running switch on a powerful consumer (working light, etc.).
Fig. 35
Note
Seat contact control light (Fig. 35):

!
Caution
goes out
If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which
could damage electrical components.
l
After starting disconnect the negative poles

(ground cable) first and the positive poles after.
Switch off the consumer.
= when the drivers seat is occupied.
lights up when
the machine is at
rest
= when the drivers seat is unoccupied. Drive operation is not
possible. (The brake is
closed).
Note
Standard design
BOMAG
39
Operation
lights when the

machine is driving
= when the drivers seat is unoccupied.
Note
Design with seat contact for engine shut-down*

lights when the
machine is driving*
= when the drivers seat is unoccupied. Warning buzzer
sounds. Engine is shut down
after 8 seconds.
Fig. 37
Caution
Do not operate jerkily!

l
Shift the travel lever 19 (Fig. 37) slowly to the

desired travel direction.
Position "I"
= max. forward travel without vibration
Position "II"
= max. backward travel without

vibration
Position "III"
= Max. forward/backward travel

with vibration.
Fig. 36
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
BW138AD/AC
Position "II"

BW125ADH/BW135AD
BW138AD/AC
Note
During operation the throttle lever always remains

locked in one of the full load positions.
Control the travel speed with the travel lever.
40
Optional equipment
BOMAG
Operation
4.6
Stopping the machine / applying the brake
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 underground 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.
Fig. 38
l
Move the travel lever 19 (Fig. 38) slowly to position "0". The machine is automatically braked
by the hydrostatic drive. The brake closes.
Note
Activate the vibration only at full engine speed,

with the throttle lever in full load positions "I" or "II"
17 (Fig. 41).
Vibration at standstill causes transverse ruts,
therefore:
switch the vibration on only after shifting the

travel lever to the desired travel direction.
Switch the vibration off before stopping the

machine.
BOMAG
41
Operation
Pre-selecting vibration (only AD)
Switch over only with the vibration switched

off.
l
Pre-select the desired drum or drums with the

ball valve (Fig. 40).
Position upward
= Vibration of rear drum only
Position horizontal
Position downward
Switch the vibration on

Fig. 39
Caution
Destruction of hydraulic components!

Switch over only with the vibration switched
off.
Pre-select the desired drum or drums with ball
valve 21 (Fig. 39).
Position "I"
Position "II"

Fig. 41
Pre-selecting vibration (3 stages, only

AD)*
Pull up locking lever 18 (Fig. 41) and shift

throttle lever (17) to full load position "I" (55
Hz) or "II" (66 Hz).
Fig. 40
Fig. 42
Caution
Destruction of hydraulic components!
!
42
Actuate vibration push button 20 (Fig. 42) only

after shifting travel lever (19) to the desired
travel direction.
Optional equipment
BOMAG
Operation
Note
When shifting the travel lever through position "III"

to position "I" or "II", the vibration will be automatically switched off.
4.8
Switching the vibration off

l
Press push button (20) again.
Switching the vibration on

or off
Note
Only AC-machines.
Fig. 43
l
Press the foot switch 23 (Fig. 43).
press
= on.
release
= off.
BOMAG
43
Operation
4.9
Switching the pressure

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

ztravel lever out of braking position towards
"0"-position (Fig. 46).
Fig. 44
l
Position "I"
= open
Position "II"
= closed
Fig. 45
l
Operate the rotary switch for the pressure

sprinkler system 7 (Fig. 45).
= sprinkler system "OFF"
Position "I"
= sprinkler system "ON"
Set the interval switch (8) to the desired flow

interval.
Position "A"
Position
"B"..."F"
44
Note
The sprinkler system will only work when the travel

lever is in direction "0"-position. This is also the
testing position.
Fig. 47
Position "0"
Open the shut-off cock valve (Fig. 44).
To switch the sprinkler system off return the

travel lever to the position "brake closed" (Fig.
47).
Note
The brake control light must light up.
= permanent sprinkling
= sprinkling intervals of 32, 24,
16, 8 and 4 seconds, sprinkling
time always 5 seconds.
BOMAG
Operation
4.10 Stopping the engine/machine
Note
Do not shut the engine down all of the sudden from

full speed, but let it idle for a while for temperature
equalization.
Fig. 48
Fig. 50
l
Danger
Danger of accident!
!
Turn the ignition switch 28 (Fig. 50) to position

"0" and pull the ignition key out.
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.
Move the travel lever (19) slowly to position

"0". The brake closes.
Pull the locking lever (18) and shift the throttle

lever (17) to position "0" (idle speed).
BOMAG
45
Operation
4.11 Adjusting the driver's seat
4.12 Towing
!
Danger
Danger of accident!
Secure the machine against unintended rolling.
Releasing the brakes on front and rear

drums mechanically (only AD-machines)
Fig. 51
Danger
Danger of accident!
!

l
Disengage the lever 1 (Fig. 51) and adjust the

seat in longitudinal direction.
Pull the lever (2) up and adjust the backrest.
Use lever (3) to adjust to the weight of the operator.
Fig. 52
l
Note
Take the brake releasing device 1 (Fig. 52) out

of the access steps.
In this adjustment the lever (3) is locked in upwards direction. If a lighter driver's weight is to be
adjusted, the lever must first be pressed down to
the stop in order to release the lock. Then adjust
again in downward direction.
Fig. 53
l
46
BOMAG
Unscrew the protective plug 6 (Fig. 53).
Operation
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.
Turn the nut (5) down and tighten it approx. 1

to 2 turns.
Towing the machine
Releasing the brakes on drum and rubber wheels (only AC-machines)
Fig. 55
Caution
Generally use a draw bar (Fig. 55), max. towing

speed 1 km/h, max. towing distance 500 m.
Fig. 54
l
Unscrew locking screw 1 (Fig. 54).
Operate the cock valve.
Position "I"
= brake released
Position "II"
= brake closed
Turn the steering wheel slowly approx. two

turns in clockwise direction.
Fig. 56
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-machines).
Reset the cock valve to position "II", turn the
locking screw back in and counter it with the
hexagon nut (only AC-machines).
BOMAG
47
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 machine 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.
Fig. 58
l
Do not stand or step under loads being lifted.
Tie the machine down on the transport vehicle,

use the lifting hooks 1 (Fig. 58) on front and
rear frame for this purpose.
Fig. 57
l
48
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. 59
l
BOMAG
Use the four lifting eyes to lift the machine (Fig.

59).
Operation
Loading weight: See technical data
After transport
4.14 Foldable roll over protection structure (ROPS)

Split foldable roll over protection
structure * (ROPS)
Fig. 60
l
Pull the bolt 2 (Fig. 60) out of the articulation

lock and swash the locking rod (1) back into
the bracket.
Fig. 61
l
Unscrew the bolts, fold the roll over protection

structure down to transport position and fasten
it again (Fig. 61).
The tools are stored in the engine compartment.
Danger
Mortal danger!
!
Operate the machine only with the ROPS folded up and the fastening screws tightened with
the correct tightening torque.
BOMAG
Option
49
Operation
Fig. 62
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!
!
50
BOMAG
5 Maintenance
BOMAG
51
Maintenance
5.1
General notes on maintenance
Do not let the hose stir up the slurry at the bottom of the drum.
Do not draw off fuel from near the bottom of

the drum.
The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.
When performing maintenance work always comply with the appropriate safety regulations.
Thorough maintenance of the machine guarantees higher functional safety of the unit and prolongs the lifetime of important components. The
effort needed for this work is only little compared
with the problems that may arise when not observing this rule.
The terms right/left correspond with travel direction forward.
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.
Always clean machine and engine thoroughly

before starting maintenance work.
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.
For maintenance work stand the machine on

level ground.
Notes on the hydraulic system
Perform maintenance work generally with the

engine stopped.
Relieve hydraulic pressures before working on

hydraulic lines.
Before working on electric parts of the machine disconnect the battery and cover it with
insulation material.
When working in the area of the articulated

joint attach the articulation lock (transport
lock).
During maintenance work on the hydraulic system

cleanliness is of major importance. Make sure that
no dirt or other contaminating substances can enter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clog nozzles and pilot bores, thereby making expensive repairs 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 components for leaks.
Seal external leaks immediately. If necessary

inform the responsible customer service.
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.
Keep fuel free of contaminants and water,

since this will damage the injection elements
of the engine.
Always use the filling and filtering unit

(BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is fitted with a fine filter to clean the hydraulic oil, thereby
prolonging the lifetime of the filter.
Drums with inside zinc lining are not suitable to

store fuel.
Clean fittings, filler covers and the area around

such parts before disassembly to avoid entering of dirt.
Do not leave the tank opening unnecessarily

open, but cover it so that nothing can fall in.
Environment
During maintenance work catch all oils and fuels and do not let them seep into the ground or
into the sewage system. Dispose of oils and fuels environmentally.
Notes on the fuel system

The lifetime of the diesel engine depends to a
great extent on the cleanliness of the fuel.
l
52
The fuel drum must rest for a longer period of

time before drawing off fuel.
BOMAG
Maintenance
5.2
fect the cold starting ability of the engine, but will

not cause any engine damage.
Fuels and lubricants
Temperature related lubrication oil changes can

be avoided by using multi-purpose oils. The following oil change intervals apply also when using multi-purpose oils.
Engine oil
l
Use winter grade engine oil for winter operation!
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.
Regular lubrication oil changes

The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the following oil change intervals are not reached over a period 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: E296, E3-96/
E5-02, E499
= 1000 operating hours
API: CF/
CF-4, CG4/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.
!
Fig. 63
Lubrication oil with a too high viscosity index causes starting difficulties. The temperature when
starting the engine is therefore of highest importance 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 operating location of the engine is of utmost importance when choosing the viscosity class (SAEclass) (see diagram).
When using fuels with a sulphur content of

more than 0.5% to 1% or under ambient temperatures below -10 C the oil change intervals
specified in the table must be halved. When using fuels with a sulphur content higher than 1%
... 1,5% the engine oil must have a TBN of approx. 12 x the S-content in % by weight if the
service intervals are halved.
Occasional falling short of the temperature limit

(e.g. use of SAE 15W/40 down to -15 C) may ef-
BOMAG
53
Maintenance
type HV according to ISO 6743/3. The viscosity index (VI) must be at least 150. (Observe the information of the manufacturer).
Example aspirating engine:

Use in tropical climate, fuel 0.8% sulphur, lubrication oil change every 250 operating
hours.
Bio-degradable hydraulic oil
Lubrication oil quality classes
On request the hydraulic system can also be filled

with ester based biodegradable hydraulic oil (Panolin HLP Synth. 46).
The ACEA- and the API-classifications are used to

classify the oil quality.
The biologically degradable hydraulic oil meets all

demands of a mineral oil based hydraulic oil according to DIN 51524.
The oil manufacturer is solely responsible for assigning a product to a certain quality class.
In hydraulic systems filled with Panolin HLP Synth.

46 always use the same oil to top up.
Note
When 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.
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.
Fuels
Lubrication grease
Quality
For lubrication use only EP-high pressure grease,

lithium saponified (penetration 2).
You should only use commercially available brand

diesel fuel with a sulphur content below 0.5% and
ensure strict cleanliness when filling in. A higher
sulphur content has a negative effect on the oil
change intervals. Use only winter-grade diesel fuel
under low ambient temperatures. The fuel level
should always be topped up in due time so that the
fuel tank is never run dry, as otherwise filter and injection 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 separation can also be expected when using winter diesel
fuel.
Mineral oil based hydraulic oil

The hydraulic system is operated with hydraulic oil
HV 46 (ISO) with a kinematic viscosity of
46 mm2/s at 40 C. For topping up or for oil changes use only high-quality hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils
54
BOMAG
Maintenance
5.3
Table of fuels and lubricants
Assembly
Fuel or lubricant
Summer
Winter
Quantity approx.
Attention
Observe the level marks
Engine
Engine oil ACEA: E2-96, E3-96/E5-02, E4-99;
6.0 litres (1.6 USgal)
API: CF/CF-4, CG-4/CH-4

SAE 10W/40
(-20 C to +30 C)
SAE 15W/40
(-10 C to +40 C)
SAE 30
SAE 10W
(+5 C to +30 C)
(-5 C to -30 C)
SAE 40
SAE 20W/20
(+25 C to +40 C)
(+10 C to -10 C)
Fuel
Diesel
Hydraulic system
Winter diesel fuel (down

to -12 C)*
Hydraulic oil (ISO), HV46, kinem. viscosity
55 litres (17.2 USgal)

46 mm2/s at 40 C
or
ester based biodegradable hydraulic oil
Sprinkler system
Water
Sprinkling of tires
Articulated joint
Anti-freeze mixture water 230 litres (60.8 USgal)

Emulsion
High pressure grease (lithium saponified)

as required
*For lower temperatures refer to the mixing table in

chapter 5.2
BOMAG
55
Maintenance
5.4
Running-in instructions
The following maintenance work must be performed 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
56
Check the fuel pre-filter cartridge
Check the engine for leaks
Check the valve clearance, adjust if necessary
Retighten bolted connections on intake and

exhaust tubes, oil sump and engine mounts.
Retighten the bolted connections on the machine.
BOMAG
Maintenance
5.5
Maintenance chart
With all maintenance intervals perform also

the work for shorter preceding service intervals.
No.
Designation
Note
Every 10 operating hours

5.6
5.7
5.8
5.9
5.10
5.11
Check the engine oil level

Checking the dry air filter
Check the hydraulic oil level
Checking the hydraulic oil filter element
Check the fuel level
Checking the water level in the sprinkler system
Observe the dipstick marks

Winter: Anti-freeze mixture

5.12
5.13
Checking the emulsion level

Grease the articulated joint
High pressure grease

5.14
5.15
5.16
Clean cooling fins and engine oil cooler

Cleaning the hydraulic oil cooler
Adjust the scrapers

5.17
5.18
Service the battery

Drain the sludge from the fuel tank
distilled water, pole grease

5.19
5.20
5.21
5.22
5.23
5.24
Changing the engine oil (at least 1x per year)**

Change the engine oil filter cartridge
Checking the valve clearance
Check the V-belt tension
Change the fuel pre-filter cartridge
Change the fuel filter cartridge

5.25
5.26
Change the hydraulic oil*** screen filter (at least after Observe the dipstick marks
2 years)
Change the hydraulic oil filter element****

5.27
Check the injection valves
BOMAG
57
Maintenance
No.
Designation
Note
5.28
Replace toothed belts, timing belt and toothed belt for at the latest after 5 years
hydraulic pump
As required
5.29
5.30
5.31
5.32
5.33
5.34
Checking the tire pressure

Clean, change the dry air filter cartridge*
Clean the water tank
Maintenance in case of frost
Engine conservation
Observe the tightening torques
*At the latest after 1 years

**With more than 1% sulphur in the fuel every 250
operating hours
***Also in case of repairs in the hydraulic system.
****At the latest after 2 years
58
BOMAG
Every 10 operating hou rs
5.6
Check the engine oil level
5.7
Checking the dry air filter
Note
The machine must be in horizontal position.

Run the engine 2 minutes with idle speed and shut
it down.
Fig. 65
l
If the red indicator 1 (Fig. 65) is visible with the

engine shut down, clean the filter cartridge, refer to the section " maintenance as required".
Press the reset button (2), the red indicator

will disappear.
Fig. 64
Pull the dipstick out, wipe it off with a lint-free,

clean cloth and reinsert it until it bottoms.
Pull the dipstick back out again.
The oil level should reach the "MAX"-mark

(Fig. 64).
If the oil level is too low top up oil immediately.
Caution
If the red indicator appears again after starting
the engine, you must change the filter cartridge and, if necessary, also the safety cartridge*.
!
Note
For quality and quantity of oil refer to the table of

fuels, lubricants and filling capacities.
l
Check the oil level again after running the engine for approx. 1 minute.
BOMAG
Option
59
5.8
Checking the hydraulic oil

level
Fig. 66
l
Clean the area around the filler opening.
Remove the filler cap.
Check the hydraulic oil level on the oil dipstick.

The oil level must be between the "MIN" and
"MAX" marks (Fig. 66).
If the oil is below this level top up hydraulic oil
immediately.
5.9
Checking the hydraulic oil

filter element
Fig. 67
l
Check the service indicator 1 (Fig. 67) at operating temperature and with the engine running
at maximum speed.
If necessary press the pin in.
Pin remains depressed

= hydraulic oil filter element ok.
Pin pops up
= replace the hydraulic oil filter

element
Note

"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.
Note
If 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.
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.
60
BOMAG
5.10 Checking the fuel level

!
5.11 Checking the water level
Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke.
Do not refuel in closed rooms.
Fig. 69
l
Open the filler cap and check the water level.
Fill in water, as far as this is necessary (Fig.

69).
In the event of frost observe the special service instructions under "maintenance in the event of
frost".
Fig. 68
l
Open the fuel filler cap (Fig. 68) and check the
fuel level visually.
Note
Close the filler cap.
If necessary top up with fuel (diesel or winter

diesel), see table of fuels and lubricants.
!
Caution
Fill in fuel through a screen filter.
BOMAG
61
Every 50 oper ating hours
5.12 Checking the emulsion oil

level
5.13 Lubricating the articulated

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

drum) with approx. 5 shots of high pressure
grease from the grease gun.
Fig. 70
l
Open the filler cap and check the emulsion level, top up if necessary (Fig. 70).
62
Note
For quality of grease refer to the table of "fuels, lubricants and filling capacities".
BOMAG
If necessary repeat this procedure.
Reassemble the cooling air duct cover, run the

engine warm for a while to avoid corrosion.
5.14 Cleaning cooling fins and

engine oil cooler
!
Danger
Danger of injury!
Perform cleaning work only with engine
stopped and cooled down!
Note
Dirty operating conditions, particularly lubrication

oil and fuel deposits on the cooling fins of the engine and the engine oil cooler have an adverse effect on the cooling of the engine. You should
therefore immediately seal any oil or fuel leaks
near cooling fan, cylinder or engine oil cooler and
subsequently clean the cooling fins.
Fig. 72
l
Remove the cooling air duct cover.
Blow the cooler out with compressed air, starting from the air discharge side. Remove all dirt
that has been blown into the air duct (Fig. 72).
In case of oily dirt spray the engine with a cold

cleansing agent and let it soak in for about 10
minutes.
Caution
Environmental damage!
!
Catch running off fluids and dispose of environmentally.

l
Clean the engine off with a water or steam jet

(do not aim at sensitive engine components).
BOMAG
63
5.15 Cleaning the hydraulic oil

cooler
5.16 Adjusting the scrapers
i
!
Danger
Danger of injury!
Note
If the scrapers (2 per drum) are worn, they must be

adjusted or replaced.
Perform cleaning work only with engine

stopped and cooled down.
Fig. 74
Fig. 73
Open the flap 1 (Fig. 74).
Loosen the hexagon screws (2).
Remove dried on dirt from the hydraulic oil

cooler using a suitable brush.
Adjust the scraper (3) so that it touches the

drum lightly (slight bending of plastic insert).
Blow the cooling passages out with compressed air, starting from the air discharge
side (Fig. 73).
Tighten the hexagon screws.
Fig. 75
l
64
BOMAG
Turn the screws 1 (Fig. 75) to adjust the scraper, that it has a uniform distance of approx. 2
mm to the rubber tires (only AC-machines).
5.17 Checking the battery condition, greasing the poles
Caution
Top up missing fluid with distilled water.
!
Unscrew the plugs and check the acid level, if

necessary top up with distilled water.
Danger
With control inserts
Danger of explosion, causticization!

When working on the battery do not use open
fire, do not smoke!
Do not let acid come in contact with hands or
clothes!
The acid level must reach the bottom of the control

inserts.
Without control inserts
The acid level must reach 10 to 15 mm above the
upper edge of the lead plates.
Wear safety goggles.

Do not lay any tools on the battery!
For recharging remove the plugs from the battery to avoid an accumulation of highly explosive gases.
Caution
Dispose of used batteries environmentally.
!
Note
Measure the acid level with a clean wooden stick.

With transparent battery housing
The acid level must reach the mark on the housing.
l
Clean battery poles and pole clamps and

grease them with pole grease (Vaseline).
Retighten the terminal clamps.
Check the fastening of the battery.
Fig. 76
Maintenance free batteries:

l
Clean battery and battery compartment (Fig.

76).
Clean battery poles and pole clamps and

grease them with pole grease (Vaseline).
Retighten the terminal clamps.
Check the fastening of the battery.
Serviceable batteries:
l
Clean battery and battery compartment.
BOMAG
65
5.18 Draining the slurry from the

fuel tank
!
Danger
Fire hazard!
Do not spill any fuel.
Catch running out fuel, do not let it seep into
the ground.
Note
When performing this work the fuel tank shall only

hold max. 1.5 litres of fuel, pump off if necessary.
Fig. 77
l
Unscrew the drain plug 1 (Fig. 77) from under

the fuel tank and let the fuel run out.
Once all fuel has run out screw the oil drain
plug back in with a new seal ring.
66
BOMAG
5.19 Changing the engine oil

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

filler neck.
Screw the cap back on again.
Note
Drain the engine oil only when the engine is warm.

The oil change after 500 operating hours refers to
a fuel sulphur content < / - of 0.5%.
For other fuels the oil change intervals must be
shortened accordingly. (See section 5.2, lubrication oil change intervals).
Note

fuels, lubricants and filling capacities.
l
Run the engine 2 minutes with idle speed and

shut it down.
Fig. 78
l
Unscrew the oil filler cap (Fig. 79).
Fig. 80
Unscrew drain plug 1 (Fig. 78) and catch running out oil.
Turn the oil drain plug back in with a new seal

ring.
BOMAG
Check the oil level on the dipstick (Fig. 80).

The oil level must reach the "MAX"-mark, top
up oil if necessary.
67
5.20 Change the engine oil filter

cartridge
!
5.21 Check, adjust the valve

clearance
Danger
Danger of scalding!
Caution
Perform inspection and adjustment work only

when the engine is cold.
Danger of scalding by hot oil when unscrewing

the engine oil filter.
Valve clearance:
Intake valve 0.3 mm
Caution
!
Exhaust valve 0.5 mm
Catch the oil and dispose of environmentally

together with the engine oil filter cartridge.
Fig. 82
l
Remove valve cover 1 (Fig. 82).
Fig. 81
l
Loosen and unscrew the engine oil filter cartridge (Fig. 81) using an appropriate filter
wrench.
Wipe the sealing face on the engine clean.
Cover the rubber seal of the new filter cartridge slightly with clean oil.
Spin the new fuel filter cartridge on and tighten

it hand tight.
Perform a short test run and inspect the engine for leaks and check the oil level, if necessary top up oil.
Fig. 83
l
68
BOMAG
Crank the engine by the front crankshaft end

(Fig. 83) in direction of arrow,
Adjusting the valve clearance
Fig. 84
until both valves on cylinder 1 are "overlapping" (i.e. the exhaust valve is not yet closed,
the inlet valve starts to open).
Fig. 86
Loosen counter nut 2 (Fig. 86) for 2 to .3 turns.

Adjust the setscrew (1) with a screwdriver, until the feeler gauge can be inserted and pulled
out with little resistance after retightening the
counter nut.
Check and, if necessary, adjust the valves

marked black (Fig. 84).
Note
E = Intake valve
A = Exhaust valve
Note
As a control measure mark each adjusted valve

with chalk.
Checking the valve clearance
Fig. 87
Fig. 85
l
A feeler gauge of appropriate thickness 2 (Fig.

85) must fit with little resistance between rocker arm (1) and valve (3).
Turn the crankshaft another revolution (360

Grad) further (for this purpose mark the flywheel or V-belt pulley with chalk).
If the gap is too narrow or too wide for the feeler gauge, the valve must be adjusted.
Check and, if necessary, adjust the valves

marked black (Fig. 87).
Assemble the cylinder head cover with a new

gasket.
BOMAG
69
Note
After a short test run check the engine for leaks.
5.22 Checking, tensioning,

changing the V-belt
Checking the V-belt
Fig. 88
l
Check the entire circumference of the V-belt

for damage and cracks. Replace damaged or
cracked V-belts.
Check with thumb pressure whether the V-belt

can be depressed more than 10...0,15 mm between the V-belt pulleys, retighten if necessary
(Fig. 88).
Tensioning the V-belt
Fig. 89
70
Slacken the hexagon screws 1 (Fig. 89).
Press the idling pulley (2) in direction "I", until

the correct V-belt tension is achieved.
Tighten the hexagon screws again.
BOMAG
Changing the V-belt

l
Slacken the hexagon screws 1 (Fig. 89).
Swivel the idling pulley (2) in direction "II".
Take the old V-belt off the V-belt pulley.
5.23 Changing the fuel pre-filter

!
Install the new V-belt and tension it as described above.
Danger
Fire hazard!
Do not spill any fuel.
Note
Tension the new V-belt after a running time of approx. 30 minutes.
!
Caution
Catch running out fuel, do not let it seep into

the ground.
Fig. 90
Loosen the hose clamps (Fig. 90).
Pull the fuel filter out of the hoses.
Install the new fuel filter by observing the flow

direction (arrow).
BOMAG
71
5.24 Change the fuel filter cartridge

!
Danger
Fire hazard!
Caution
!
Catch running out fuel and dispose of environmentally together with the fuel filter!
Fig. 91
l
Loosen and unscrew fuel filter cartridge 1 (Fig.

91) using an appropriate filter wrench.
Clean the sealing face on the filter bowl.
Slightly oil the rubber seal on the new filter cartridge.
Spin on the new fuel filter cartridge and tighten

it hand tight.
Note
The fuel system is self-bleeding.
72
BOMAG
pump the oil from the tank into a clean vessel

or oil bag using the filling and filtering unit.

!
Danger
Catch the hydraulic oil and dispose of environmentally!
Danger of scalding!
Thoroughly clean the inside of the hydraulic oil

tank.
Caution
Caution
Catch old oil and dispose of environmentally.
Do not start the engine after draining the hydraulic oil. Do not run the pumps without oil.
When changing from mineral oil based hydraulic oil to an ester based biodegradable oil, you
should consult the lubrication oil service of the
oil manufacturer for details.
Note
Apart from the normal oil change intervals, the hydraulic oil must also be changed after major repairs in the hydraulic system.
Fig. 93
The hydraulic oil filter element must be changed

with every hydraulic oil change (see next chapter).
See also chapter 5.1 "Notes on the hydraulic system".
Note
We recommend to use a filtering unit with fine filter

to fill in hydraulic oil.
Drive the machine, until the hydraulic oil has

reached operating temperature.
Fill in new engine oil (Fig. 93).
Open the filler cap (Fig. 93).
Screw the filler cap back on.
Check the hydraulic oil level on the oil dipstick.

The oil level must be between the "MIN" and
"MAX" marks.
Perform a test run and check the system for

leaks.

"fuels, lubricants and filling capacities".
Bleeding the hydraulic system

l
Run the engine for about 3 minutes with low

speed, this will bleed the hydraulic system.
Fig. 92
l
Unscrew the fastening screws (Fig. 92), remove the cover from the hydraulic oil tank and
BOMAG
73

filter element
!
Run the engine for about 3 minutes with low

speed, this will bleed the hydraulic system.
After a short test run check for leaks and press

the rubber cap (5).
Danger
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter element.
Caution
!
Catch running out oil and dispose of environmentally.

Do not use the oil in the filter bowl again.
Note
Apart from the normal oil change intervals, the hydraulic oil must also be changed after major repairs in the hydraulic system.
If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the
oil change and after the test run.
Fig. 94
l
Loosen the knurled nut 4 (Fig. 94) on the filter

housing.
Take the filter bowl (3) off with the filter element.
Take the old filter element (2) out, clean the filter bowl.
Clean the thread on the filter bowl.
Assemble the filter bowl with a new filter element, check the condition of the seal rings (1).
74
BOMAG
5.27 Checking the injection

valves
Note
This work must only be performed by authorized

service personnel.
The injection valves must be replaced every
12000 operating hours.
BOMAG
75
Every 5000 operating hour s
5.28 Replacing the toothed belt

!
Caution
The toothed belt must only be changed by a
specialist workshop or by the After Sales Service of BOMAG.
Do not retension toothed belts, replace them

together with the idler pulley.
Replace a toothed belt at the latest after 5
years, even if the number of operating hours
has not yet been reached.
Fig. 95
l
76
Have the toothed belt (Fig. 95) replaced by a

specialist workshop.
BOMAG
As required
As r equired
5.29 Checking the tire pressure
5.30 Cleaning, changing the dry

air filter
Note
Only AC-machines.
Fig. 97
Dry air filter service is necessary if the message appears in the inspection glass 2 (Fig.
97) of the vacuum gauge (1), however, at the
latest after one year.
Fig. 96
Check the tire pressure with a pressure gauge

on the tire inflation valve (Fig. 96).
Nominal value: 2,2 bar (32 psi)
Note
Ensure equal pressure in all tires.
Caution
Do not use gasoline or hot fluids to clean the
filter element.
!
After cleaning the filter element must be inspected with a torch for damage.
Dry air filter elements with damaged filter element or seal ring must be replaced in any case.
It is therefore recommended to keep at least
one filter element in stock.
The dry air filter element must be changed after 5 times cleaning, but at the latest after 1
year. Each cleaning interval must be marked
with a cross on the cover of the filter element.
Cleaning is useless if the air filter element is
covered with a sooty deposit. Use a new filter
cartridge.
Incorrectly handled inserts may be ineffective
because of damage (e.g. cracks) and cause
damage to the engine.
BOMAG
77
As required
5.31 Cleaning the water tank
Fig. 98
l
Fold both clamps 1 (Fig. 98) back.
Take the filter cover (2) off, pull the filter element (3) out and clean it.
Fig. 99
Install the filter cartridge.
Unscrew the cover 1 (Fig. 99).
Reset the service indicator by pressing the reset button (4).
Flush the water tank out with a strong water

jet.
Let all water with dirt run out.
Screw the cover back in.
Fill the water tank with clean water.
Pull the rubber caps off the sprinkler tubes.
Activate the sprinkler system for a short while

so that all coarse dirt is flushed out of the lines.
Press the rubber caps back on.
Dry cleaning:
l
Blow the filter cartridge out from inside to outside with dry compressed air (max. 5 bar).
Wet cleaning:
l
78
Clean the filter cartridge by moving it to and fro

in luke-warm water containing a commercial
fine detergent. Then rinse it well in clear water,
shake all water off and let it dry properly.
BOMAG
As required
5.32 Water sprinkler system,

maintenance in the event of
frost
5.33 Engine conservation

If the engine is to be shut down for a longer period
of time (e.g. over winter), we recommend the following engine conservation measures to avoid
corrosion:
Caution
If there is a risk of frost the water sprinkler system must be emptied or filled with an antifreeze mixture.
!
Clean engine and cooling system: With cold

cleansing agent and water jet or, even better,
with steam cleaning equipment.
Run the engine warm and shut it down.
Drain the still warm engine oil and fill in anticorrosion engine oil.
Drain the fuel from the fuel tank, mix it well with
10% anti-corrosion oil and fill it back in. Instead of mixing the fuel with anti-corrosion oil
you may also fill the tank with injection pump
testing oil with anti-corrosive properties (e.g.
Calibration fluid B).
Then run the engine for 10 minutes, so that

lines, filter, pump and nozzles are filled with
the conserving mixture and the new engine oil
is distributed to all parts.
After running the engine take the cylinder head

cover off, spray the rocker chambers with a
mixture of diesel fuel and 10% anti-corrosion
oil. Then fasten the cover again.
Crank the engine several times without ignition

in order to spray all combustion chambers.
Take the V-belt off and spray the grooves of

the V-belt pulley with anti-corrosion oil. Remove the anti-corrosion oil before taking the
machine back into service.
Close air intake on air filter and exhaust opening tightly.
Clean the water tank.
Fig. 100
l
Open drain tap 1 (Fig. 100) and drain off all

water.
Position "0"
= Drain tap closed
Position "I"
= Drain tap open.
Switch the sprinkler system on and drain all

water from the piping.
Fill the water tank with approx. 5 l of an antifreeze mixture (water and anti-freeze agent,
e.g. glysantene).
Switch the sprinkler system on, until antifreeze mixture comes running out of the sprinkler tubes.
Note
Depending on weather conditions these conservation measures will protect the machine for approx.
6 to 12 months.
Before taking the machine back into service you
must drain off the conservation oil and replace it
with engine oil (see table of fuels and lubricants)
according to API-(MIL-) classification.
BOMAG
79
As required
Anti-corrosion oils are all oils complying with

the specification MIL-L-21260 B or TL 9150037/2 or Nato Code C640/642.
!
5.34 Tightening torques for

screws with metric unified
thread
Caution
A machine with conserved engine must be

clearly marked by attaching a clear warning label.
Fig. 101
* Strength classes for screws with untreated, nonlubricated surface. Screw quality designations are
stamped on the screw heads.
8.8 = 8G
10.9 = 10K
12.9 = 12K
The values result in a 90% utilization of the screw's
yield point at a coefficient of friction total = 0,14.
Compliance with the tightening torque is checked
with torque wrenches.
The specified tightening torques do not apply
when using MoS2 lubricants.
Note
Self-locking nuts must always be replaced once

they have been unscrewed.
80
BOMAG
6 Trouble shooting
BOMAG
81
Trouble shooting
6.1
General notes
The following work must only be carried out by

qualified and trained personnel or by the
BOMAG sales service.
Please observe strictly the safety regulations
in chapter 2 of these operating and maintenance instructions.
Malfunctions are frequently caused by incorrect
operation of the machine or insufficient maintenance. Whenever a fault occurs you should therefore thoroughly read these instruction on correct
operation and maintenance. If you cannot locate
the cause of a fault or rectify it yourself by following
the trouble shooting chart, you should contact the
service departments at our branch offices or dealers.
On the following pages you will find a selection of
fault remedies. It goes without saying that not all
possible reasons for faults could be listed.
!
Danger
Danger of injury!
Do not touch rotating parts of the engine.
82
BOMAG
Trouble shooting
6.2
Engine problems
Faults
Possible cause
Remedy
Engine does not

start
Fuel tank empty
Fill the fuel tank
Fuel filter clogged, in winter due to paraffin separation
Change the filter, use winter fuel
Fuel lines leaking
Check the line connections for leaks and

tighten the fittings.
Neutral start switch on travel lever defective or no contact between switch and
travel lever.
change, position correctly
Battery not charged or not connected
Terminal clamps on battery tighten,

check line connections
Battery power to low
Have battery checked
Battery pole clamps loose or oxidized,

causing the starter to turn too slow
Clean the pole clamps, tighten and cover

them with acid-free grease
Especially during winter: use of too viscous engine oil
Use an engine oil complying with the ambient temperatures
Fuel supply restricted, Clogging of fuels

system by paraffin separation during winter
Change the engine oil filter cartridge.

Check the line connections for leaks and
tighten the fittings. Use winter fuel under
cold conditions
Valve clearance not as specified
Adjust the valve clearance
Injection valves or plug-type injection

pump defective
Have inspected by a specialist
Dry air filter cartridge dirty
clean, replace if necessary
Excessive play in throttle cable
Adjust the throttle cable, replace if necessary
Engine oil level too high
Drain the engine oil down to the top dipstick mark
Poor compression due to burned or broken compression rings or incorrect valve

clearance
Have compression rings and pistons examined by a specialist, adjust the valve
clearance
Injection valves defective
Poor starting of
engine or engine works irregularly with poor
power
Excessive exhaust smoke
BOMAG
83
Trouble shooting
Faults
Possible cause
Remedy
Engine overheating, engine

must be shut
down immediately!
Cooling fins or engine oil cooler excessively soiled
Clean cooling fins and cooling air intake
Injection valves defective
Capacity of plug-type injection pumps not

correctly adjusted
Have corrected by a specialist
Lack of cooling air flow at the cooling

blower
Clear the air duct
V-belt loose or torn
Tighten or replace the V-belt
Engine has too

low oil pressure,
engine must be
immediately
shut down!
Leaks in the lubrication system, oil level

too low
Check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary
tighten all fittings
Wrong SAE-class of engine oil
Change the engine oil.
The charge control light lights up

during operation
Generator speed too low
Check the V-belt tension, tighten if necessary.
The generator does not charge the battery, because of a defect on generator or
regular
84
BOMAG

BW138AD Operation Maintenance PDF

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Operating instructions

Tandem Vibratory Roller

BOMAG machines are products from the wide

BOMAGs vast experience in connection with

You should only operate the machine after you

This manual comprises:

For your own personal safety you should only

Using these instructions will

help you to become familiar with the machine.

avoid malfunctions caused by unprofessional

Compliance with the maintenance instructions will

enhance the reliability of the machine on construction sites,

prolong the lifetime of the machine,

reduce repair costs and downtimes.

BOMAG will not assume liability for the function of

if it is handled in a way that does not comply

if it is used for purposes other than the ones it

No warranty claims can be lodged in case of damage resulting from

insufficient maintenance and

wrong fuels and lubricants.

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

Supplement the above data together with the commissioning protocol.

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

Indicators and Controls

3.1 General notes

3.2 Description of indicators and control elements

4.2 Inspections before starting operation

4.3 Starting the engine

4.4 Starting with jump wires

4.5 Driving the machine

4.6 Stopping the machine / applying the brake

4.7 Switching the vibration on and off

4.8 Switching the vibration on or off

4.9 Switching the pressure sprinkler system on or off

4.10 Stopping the engine/machine

4.11 Adjusting the driver's seat

4.13 Loading and transport

4.14 Foldable roll over protection structure (ROPS)

5.2 Fuels and lubricants

5.3 Table of fuels and lubricants

5.4 Running-in instructions

5.5 Maintenance chart

5.6 Check the engine oil level

5.7 Checking the dry air filter

5.8 Checking the hydraulic oil level

5.9 Checking the hydraulic oil filter element

5.10 Checking the fuel level

5.11 Checking the water level

5.12 Checking the emulsion oil level

5.13 Lubricating the articulated joint

5.14 Cleaning cooling fins and engine oil cooler

5.15 Cleaning the hydraulic oil cooler

5.16 Adjusting the scrapers

5.17 Checking the battery condition, greasing the poles

5.18 Draining the slurry from the fuel tank

5.19 Changing the engine oil

5.20 Change the engine oil filter cartridge

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

5.21 Check, adjust the valve clearance

5.22 Checking, tensioning, changing the V-belt

5.23 Changing the fuel pre-filter

5.24 Change the fuel filter cartridge