service repair manual

1. Operating instructions
Maintenance instructions
Catalogue number
008 138 01 04/2004
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

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

4. Foreword
BOMAG
4 BW 125 ADH/ BW 135AD/138 AD/AC
Please fill in
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine type (Fig. 1)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial-number (Fig. 1 and 2)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine type (Fig. 3)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine number (Fig. 3)
i Note
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 1
Fig. 2
Fig. 3

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

6. Table of Contents
BOMAG
6 BW 125 ADH/ BW 135AD/138 AD/AC
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

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

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

9. Technical Data
BOMAG 9
BW 125 ADH/ BW 135AD/138 AD/AC
Travel characteristics
Travel speed I km/h 0...5,0 0...5,0 0...5,0
Travel speed II km/h 0...10 0...10 0...10
Max. gradability/with vi-
bration (soil dependent)
% 40/30 40/30 40/30
Drive
Engine manufacturer Deutz Deutz Deutz
Type F3L 2011 F3L 2011 F3L 2011
Cooling Air-oil Air-oil Air-oil
Number of cylinders 3 3 3
Rated power ISO 9249 kW 34 34 34
Rated speed rpm 2800 2800 2800
Fixed engine speed 1 rpm 2200 2200 2500
Fixed engine speed 2 rpm 2700 2700 2800
Fuel tank capacity l 55 55 55
Electrical equipment V 12 12 12
Drive system hydrost. hydrost. hydrost.
Driven axles front+rear front+rear front+rear
Brakes
Service brake hydrost. hydrost. hydrost.
Parking brake hydr.-mech. hydr.-mech. hydr.-mech.
Steering
Type of steering Oscill.-articul. Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost. hydrost.
Steering angle +/- Degree 25 25 25
Vibration system
Drive system hydrost. hydrost. hydrost.
Frequency Hz 50/60 50/60 46/52
Amplitude mm 0,45 0,40 0,50
Vibrating drum front+rear front+rear front+rear
Water sprinkler system
Type of sprinkling Pressure Pressure Pressure
Interval control Standard Standard Standard
Water tank capacity l 230 230 230
* The right for technical modifications remains reserved
* BW 125 ADH BW 135 AD BW 138 AD

10. Technical Data
BOMAG
10 BW 125 ADH/ BW 135AD/138 AD/AC
The following noise and vibration values according to the EC-directive for machines, edition (98/37/
EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with
the vibration switched on. The machine was standing on an elastic base.
During operation these values may vary because of the existing operating conditions.
Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
sound pressure level on the operator’s stand:
BW 125 ADH
LpA =79 dB(A)
BW 135 AD
LpA =83,5 dB(A)
BW 138 AD
LpA =86 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is
guaranteed sound capacity level of the machine:
BW 125 ADH
LWA = 107 dB(A)
BW 135 AD
LWA = 107 dB(A)
BW 138 AD
LWA = 104 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO
11204 for sound pressure level (LpA) at the place of the operator.
Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:
Vibration of the entire boy (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2
.
Hand-arm vibration values
The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2
.

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

12. Technical Data
BOMAG
12 BW 125 ADH/ BW 135AD/138 AD/AC
Travel characteristics
Travel speed I km/h 0...5,0
Travel speed II km/h 0...10
Max. gradability/with vi-
bration (soil dependent)
% 40/30
Drive
Engine manufacturer Deutz
Type F3L 2011
Cooling Air-oil
Number of cylinders 3
Rated power ISO 9249 kW 34
Rated speed rpm 2800
Fixed engine speed 1 rpm 2250
Fixed engine speed 2 rpm 2800
Fuel tank capacity l 55
Electrical equipment V 12
Drive system hydrostatic
Driven axles front+rear
Tires
Number of tires 4
Tire size 225/75 R16
Brakes
Service brake hydrost.
Parking brake hydr.-mech.
Steering
Type of steering Oscill.-articul.
Steering operation hydrost.
Steering angle +/- Degree 25
Vibration system
Drive system hydrost.
Frequency Hz 46/52
Amplitude mm 0,5
Vibrating drum front
Water sprinkler system
Type of sprinkling Pressure
Interval control Standard
Water tank capacity l 230
Emulsion tank capacity l 20
* The right for technical modifications remains reserved
* BW 138 AC

13. Technical Data
BOMAG 13
BW 125 ADH/ BW 135AD/138 AD/AC
The following noise and vibration values according to the EC-directive for machines, edition (98/37/
EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with
the vibration switched on. The machine was standing on an elastic base.
During operation these values may vary because of the existing operating conditions.
Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
sound pressure level on the operator’s stand:
BW 138 AC
LpA =81 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is
guaranteed sound capacity level of the machine:
BW 138 AC
LWA = 102 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO
11204 for sound pressure level (LpA) at the place of the operator.
Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:
Vibration of the entire boy (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2
.
Hand-arm vibration values
The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2
.

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

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

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

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

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