Fayat Group Bomag BW 138 AD-5 Instructions for use

BW 138 AD-5
Tandem vibratory roller
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 650 37 1334>
© 10/2017008 201 92 EN

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Table of contents
1 Introduction.......................................................................................... 11
1.1 Foreword....................................................................................... 12
1.2 Machine type plate and engine type plate................................. 14
2 Technical data...................................................................................... 15
2.1 Noise and vibration data.............................................................. 19
2.1.1 Noise data................................................................................... 19
2.1.2 Vibration data.............................................................................. 20
3 Concerning your safety...................................................................... 21
3.1 Basic prerequisites...................................................................... 22
3.1.1 General........................................................................................ 22
3.1.2 Explanation of signal words used:............................................... 23
3.1.3 Personal protective equipment.................................................... 24
3.1.4 Intended use................................................................................ 25
3.1.5 Improper use............................................................................... 25
3.2 Definition of responsible persons.............................................. 27
3.2.1 Operating company..................................................................... 27
3.2.2 Expert / qualified person.............................................................. 27
3.2.3 Driver / operator.......................................................................... 28
3.3 Fundamentals for safe operation................................................ 29
3.3.1 Remaining dangers, remaining risks........................................... 29
3.3.2 Regular safety inspections.......................................................... 29
3.3.3 Modifications and alterations to the machine.............................. 29
3.3.4 Damage, defects, misuse of safety devices................................ 30
3.3.5 Roll Over Protective Structure (ROPS)....................................... 30
3.4 Handling fuels and lubricants..................................................... 31
3.4.1 Preliminary remarks.................................................................... 31
3.4.2 Safety regulations and environmental protection regulations for
handling diesel fuel...................................................................... 32
3.4.3 Safety regulations and environmental protection regulations for
handling oil.................................................................................. 34
3.4.4 Safety regulations and environmental protection regulations for
handling hydraulic oil................................................................... 36
3.4.5 Safety regulations and environmental protection regulations for
handling coolants........................................................................ 38
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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; working operation.................................... 46
3.7.1 Persons in the danger area......................................................... 46
3.7.2 Driving the machine..................................................................... 46
3.7.3 Driving up and down slopes........................................................ 47
3.7.4 Cross slope................................................................................. 48
3.7.5 Working with vibration................................................................. 48
3.7.6 Working with the chip spreader................................................... 48
3.7.7 Parking the machine.................................................................... 49
3.8 Refuelling...................................................................................... 51
3.9 Emergency procedures............................................................... 52
3.9.1 Actuating the emergency stop switch.......................................... 52
3.9.2 Disconnecting the battery............................................................ 52
3.9.3 Towing the machine..................................................................... 52
3.10 Maintenance work...................................................................... 54
3.10.1 Preliminary remarks.................................................................. 54
3.10.2 Work on hydraulic lines............................................................. 54
3.10.3 Working on the engine.............................................................. 55
3.10.4 Maintenance work on electric components and battery............ 56
3.10.5 Cleaning work............................................................................ 56
3.10.6 After maintenance work............................................................. 57
3.11 Repair.......................................................................................... 58
3.12 Signage....................................................................................... 59
4 Indicators and control elements........................................................ 69
4.1 Driver’s stand............................................................................... 70
4.1.1 Overview..................................................................................... 70
4.1.2 Rotary switch for direction indicators........................................... 72
4.1.3 Rotary switch for working lights................................................... 72
4.1.4 Rotary switch for lighting............................................................. 73
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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................................. 75
4.1.11 Emergency stop switch.............................................................. 76
4.1.12 Instrument cluster...................................................................... 77
4.1.13 ECONOMIZER display.............................................................. 79
4.1.14 Rotary switch for seat heating................................................... 79
4.1.15 Rotary switch for water spraying system................................... 79
4.1.16 Starter switch............................................................................. 80
4.1.17 12 V DIN socket........................................................................ 81
4.1.18 Travel lever, right....................................................................... 81
4.1.19 Travel lever, left......................................................................... 82
4.1.20 Push button assignment travel lever......................................... 82
4.1.21 Throttle lever............................................................................. 85
4.2 Outside of machine...................................................................... 86
4.2.1 Water level gauge........................................................................ 86
4.2.2 Adjustment lever for chip quantity............................................... 86
4.3 Engine compartment.................................................................... 87
4.3.1 Main battery switch...................................................................... 87
4.3.2 Air filter maintenance indicator.................................................... 87
4.3.3 Hydraulic oil filter maintenance indicator..................................... 88
5 Checks prior to start up...................................................................... 89
5.1 Notes on safety............................................................................. 90
5.2 Visual inspections and function tests........................................ 91
5.3 Checking the engine oil level...................................................... 92
5.4 Checking the fuel level, topping up fuel.................................... 93
5.4.1 Checking the fuel level................................................................ 93
5.4.2 Refuelling.................................................................................... 93
5.5 Checking the hydraulic oil level.................................................. 95
5.6 Checking the hydraulic oil filter.................................................. 96
5.7 Checking the coolant level.......................................................... 97
5.8 Checking the air filter................................................................... 98
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5.9 Checking the water level, topping up......................................... 99
5.10 Checking, adjusting the scrapers........................................... 100
6 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..................................................................... 105
6.4 Travel operation.......................................................................... 108
6.4.1 Preliminary remarks and safety notes....................................... 108
6.4.2 Driving the machine................................................................... 109
6.4.3 Stopping the machine, applying the parking brake................... 109
6.4.4 Seat contact switch.................................................................... 110
6.5 Working with vibration............................................................... 111
6.5.1 Preliminary remarks and safety notes........................................ 111
6.5.2 Preparing to work with vibration................................................ 112
6.5.3 Manual vibration........................................................................ 113
6.5.4 Vibration in automatic mode...................................................... 114
6.5.5 Stop working with vibration........................................................ 114
6.5.6 ECONOMIZER.......................................................................... 115
6.6 Water spraying system.............................................................. 117
6.7 Crabwalk...................................................................................... 118
6.7.1 Operating the crabwalk via the travel lever............................... 118
6.7.2 Manually adjusting the crabwalk................................................ 119
6.8 Parking the machine in secured condition.............................. 121
6.9 Edge cutter.................................................................................. 123
6.9.1 Mounting the tool....................................................................... 123
6.9.2 Lifting / lowering the edge cutter............................................... 123
6.10 Chip spreader........................................................................... 125
6.10.1 Mounting / removing the chip spreader................................... 125
6.10.2 Filling the chip spreader.......................................................... 128
6.10.3 Emptying the chip spreader..................................................... 128
6.10.4 Working with chip spreader..................................................... 130
6.11 Emergency procedures............................................................ 134
6.11.1 Actuating the emergency stop switch...................................... 134
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6.11.2 Disconnecting the battery........................................................ 134
6.11.3 Towing the machine................................................................. 134
6.11.4 After towing.............................................................................. 138
7 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............... 145
7.3 Lashing the machine to the transport vehicle......................... 148
7.4 Loading by crane........................................................................ 149
7.5 After transport............................................................................ 151
7.5.1 Erecting the foldable ROPS...................................................... 152
7.5.2 Erecting the foldable ROPS with protective roof....................... 152
8 Maintenance....................................................................................... 155
8.1 Preliminary remarks and safety notes..................................... 156
8.2 Fuels and lubricants.................................................................. 158
8.2.1 Engine oil................................................................................... 158
8.2.2 Fuel........................................................................................... 159
8.2.3 Coolant...................................................................................... 161
8.2.4 Hydraulic oil............................................................................... 162
8.3 List of fuels and lubricants........................................................ 164
8.4 Running-in instructions............................................................. 165
8.4.1 General...................................................................................... 165
8.4.2 After 50 operating hours............................................................ 165
8.5 Maintenance Table..................................................................... 166
8.6 Every 50 operating hours.......................................................... 168
8.6.1 Checking radiator hoses and hose clamps............................... 168
8.6.2 Checking, cleaning the water separator.................................... 168
8.6.3 Lubricating the chip spreader.................................................... 169
8.7 Every 250 operating hours........................................................ 170
8.7.1 Change engine oil and oil filter cartridge................................... 170
8.7.2 Checking, tensioning the V-belt................................................. 171
8.7.3 Check the air intake lines.......................................................... 172
8.7.4 Checking radiator hoses and hose clamps............................... 173
8.7.5 Cleaning the radiator module.................................................... 173
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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....................................................................................... 179
8.8.4 Checking the hydraulic lines...................................................... 180
8.9 Every 1000 operating hours...................................................... 182
8.9.1 Adjusting the valve clearance.................................................... 182
8.9.2 Checking the engine mounts..................................................... 184
8.9.3 Checking the ROPS.................................................................. 185
8.9.4 Checking the travel control........................................................ 186
8.9.5 Replacing the hydraulic oil filter................................................. 186
8.10 Every 2000 operating hours.................................................... 189
8.10.1 Changing the hydraulic oil....................................................... 189
8.10.2 Changing the coolant.............................................................. 192
8.10.3 Replacing hoses...................................................................... 194
8.10.4 Check the injection valves....................................................... 195
8.11 Every 3000 operating hours.................................................... 196
8.11.1 Checking the fuel injection pump............................................. 196
8.12 As required............................................................................... 197
8.12.1 Air filter maintenance............................................................... 197
8.12.2 Checking the water spraying system....................................... 200
8.12.3 Cleaning the water spraying system....................................... 203
8.12.4 Measures if there is a risk of frost........................................... 205
8.12.5 Draining the fuel tank sludge................................................... 206
8.12.6 Measures prior to extended shutdown period......................... 207
9 Troubleshooting................................................................................. 211
9.1 Preliminary remarks................................................................... 212
9.2 Starting the engine with jump leads......................................... 213
9.3 Fuse assignment........................................................................ 214
9.3.1 Notes on safety......................................................................... 214
9.3.2 Fuses in engine compartment................................................... 214
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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
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1 Introduction
Introduction
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1.1 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.
These operating and maintenance instructions
are part of your machine.
They provide necessary information to operate
your machine safely and properly.
They also contain information on required oper-
ating, maintenance and repair measures.
Carefully read the operating and maintenance
instructions before taking your machine into
operation.
Please observe the safety regulations strictly
and follow all instructions to ensure safe opera-
tion.
If you are not yet acquainted with the controls
and indicating elements on this machine, you
should thoroughly read the corresponding
chapter
Ä Chapter 4 „Indicators and control
elements“ on page 69.
The description of the individual operating
steps including the notes on safety to be fol-
lowed can be found in chapter “Operation”
Ä Chapter 6 „Operation“ on page 101.
Before every start up, carry out all required
visual inspections and function tests
Ä Chapter
5 „Checks prior to start up“ on page 89.
Ensure the compliance with the specified oper-
ating, maintenance and repair measures to
maintain the functional safety of your machine.
Introduction – Foreword
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A description of all necessary maintenance
work, maintenance intervals as well as informa-
tion on fuels and lubricants can be found in the
chapter “Maintenance”
Ä Chapter 8 „Mainte-
nance“ on page 155.
Do not service or repair your machine by your-
self to avoid harming persons or damaging
material or environment.
The machine must only be serviced and
repaired by qualified and authorized personnel.
Contact our Customer Service to carry out the
required maintenance work or necessary
repairs.
In case of operating errors, inadequate mainte-
nance or the use of unapproved fuels and lubri-
cants all warranty claims will become null and
void.
For your own personal safety you should only
use original parts from BOMAG.
For your machine we offer service kits to make
maintenance easier.
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.
Apart from that, you can also order the spare
parts catalogue against the serial number of
your machine.
The above notes do not constitute an extension
of the warranty and liability conditions specified
in the general sales and delivery conditions of
BOMAG GmbH.
We wish you successful work with your
BOMAG machine.
Introduction – Foreword
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1.2 Machine type plate and engine type plate
Please enter here:
Machine type (1):
Serial number (2):
Please enter here:
Engine type (Fig. 1)
Engine number (2):
Fig. 1: Machine type plate
(example)
Fig. 2: Engine type plate
(example)
Introduction – Machine type plate and engine type plate
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2 Technical data
Technical data
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Fig. 3
A B C D H H2
1900
(74.8)
1470
(57.9)
700
(27.6)
900
(35.4)
1900
(74.8)
2700
(106.3)
Dimensions in millimetres
(Dimensions in inch)
K L O S W
340
(13.4)
2840
(111.8)
44
(1.7)
18
(0.7)
1380
(54.3)
Dimensions in millimetres
(Dimensions in inch)
Dimensions
Technical data
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Length with chip spreader (optional equipment) 3687
(145.2)
mm
(in)
Height with protective roof and flashing beacon
(optional equipment)
3040
(119.7)
mm
(in)
Weights
Max. operating weight 4700
(10362)
kg
(lbs)
Operating weight with ROPS (CECE) 4300
(9480)
kg
(lbs)
Average static linear load (CECE) 15.6
(87)
kg/cm
(pli)
Travel characteristics
Travel speed 0 - 10
(0 - 6.2)
km/h
(mph)
Working speed with vibration 0 - 10
(0 - 6.2)
km/h
(mph)
Max. gradability without/with vibration (soil
dependent)
40/30 %
Drive
Engine manufacturer Kubota
Type V2203
Cooling Water
Number of cylinders 4
Rated power ISO 14396 33.3 kW
Rated power SAE J 1995 45.3 hp
Nominal speed 2600 min-1
Technical data
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Drive
Fixed engine speed (1) 2300 min-1
Fixed engine speed (2) 2600 min-1
Electric system
Voltage 12 V
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering angle +/- 32 °
Oscillation angle +/- 10 °
Inner track radius 2616
(103.0)
mm
(in)
Crabwalk, lateral offsetting of drum right/left 50
(2.0)
mm
(in)
Exciter system
Vibrating drum front + rear
Frequency (1/2) 42/58
(2520/3480)
Hz
(vpm)
Amplitude (1/2) 0.5/0.2
(0.02/0.008)
mm
(in)
Centrifugal force (1/2) 57/24
(12814/5395)
kN
(lbf)
Technical data
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Filling capacities
Fuel (diesel) 55
(14.5)
l
(gal us)
Water 310
(82)
l
(gal us)
2.1 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:
nEU Machine Directive edition 2006/42/EU
nNoise Emission Directive 2000/14/EU, Noise
Protection Directive 2003/10/EU
nVibration Protection Directive 2002/44/EU
During operation these values may vary
because of the prevailing operating conditions.
2.1.1 Noise data
LpA = 83 dB(A), determined acc. to ISO 11201
and EN 500.
WARNING!
Loss of hearing caused by too
high noise burdens!
– Wear your personal protective
equipment (ear protection).
LWA = 106 dB(A), determined acc. to ISO 3744
and EN 500
Sound pressure level at
the operator's stand
Guaranteed sound
power level
Technical data – Noise and vibration data
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2.1.2 Vibration data
The weighted effective acceleration value
determined according to ISO 7096 is ≤ 0.5
m/s2.
The weighted effective acceleration value
determined according to EN 500/ISO 5349 is ≤
2.5 m/s2.
Vibration of the entire
body (driver’s seat)
Hand-arm vibration
Technical data – Noise and vibration data
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