Bomag issued this 162-page factory repair manual for the BW 125 ADH, BW 135 AD and BW 138 AD tandem vibratory rollers; if a Bomag BW 138 AD repair manual PDF is what you came for, this is the original book. Hydraulic schematics trace the closed-loop travel and vibration circuits from travel pump to drum drive motor, the electrical block walks the monitoring board by its LEDs, potentials and plug decals, and the troubleshooting block runs from engine faults through steering system diagnosis. Behind that sit complete teardown sequences for the drum, vibrator shaft, rubber buffers, pendulum center joint and the travel pump with its servo control. Set your travel and vibration circuit pressures against the printed test values, then refill the 32-liter hydraulic tank after flushing. When the exciter dies mid-lift, you are usually alone. Buy this bookmarked, text-searchable PDF once and it is yours for as long as the roller is.
What's Inside This Bomag BW 125–138 Series Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety Regulations | 7-10 | General Safety Notes, Hydraulic System Safety |
| General Notes for Repairs | 11-12 | General Repair Procedures, Electrical System Repairs |
| Tightening Torques | 13 | Metric Unified Threads |
| Connecting Plan and Travel Pump | 14-16 | Travel Pump Components, Control Lever, Flushing Valve, Servo Control |
| Tests and Adjustments | 17-34 | Technical Data, Rotary Speeds, Travel Circuit Pressure Tests, Vibration Circuit Pressure Tests, Steering System Pressure Tests |
| Flushing Procedures | 35-56 | Flushing Schematic, Travel Circuit Flushing, Vibration Circuit Flushing, Flushing Filter Installation, Bleeding Procedures |
| Trouble Shooting | 57-84 | Engine Faults, Electrical System, Monitoring Board, Hydraulic System Faults, Steering System Troubleshooting |
| Drum Repairs | 85-104 | Drum Disassembly, Drum Assembly, Rubber Buffers, Vibrator Shaft, Drum Drive Motor |
| Pendulum Center Joint | 105-130 | Pendulum Center Joint Disassembly, Steering Cylinder, Rod End Bearing, Tapered Roller Bearing, Steering Unit |
| Travel Pump and Motor Repairs | 131-162 | Travel Pump Repair, Travel Motor with Brake, Brake Discs, Distributor Housing, Servo Control |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Operating voltage | 12 V | p. 20 |
| Battery-voltage / Capacity | 12/88 V/Ah | p. 20 |
| Generator voltage/current | 14/55 V/A | p. 20 |
| Vibration motor leakage rate | 0.5 L/min | p. 24 |
| Travel pump weight | 37.8 kg | p. 150 |
| BW 100 AD-3, BW 120 AD-3 | ||
| Fuel tank capacity (BW 100 AD-3 / BW 120 AD-3, second publication bound in this file) | 35 L | p. 22 |
| Hydraulic oil tank capacity (BW 100 AD-3 / BW 120 AD-3, second publication bound in this file) | 28 L | p. 22 |
| BW 125 ADH, BW 135 AD, BW 138 AD | ||
| Travel pump high pressure setting | 385 bar | p. 24 |
| Vibration pump operating pressure | 100 bar | p. 24 |
| Hydraulic oil tank capacity | 32 L | p. 25 |
| BW 125 ADH, BW 135 AD | ||
| Fuel tank capacity (BW 125 ADH / BW 135 AD) | 55 L | p. 25 |
| BW 138 AD | ||
| Fuel tank capacity (BW 138 AD) | 65 L | p. 25 |
Bomag BW 125–138 Series Common Problems This Manual Covers
Bomag BW 138 AD engine won't start or cranks slowly in cold weather
Check fuel level; the 138 AD tank holds 65 L (page 25) and runs dry faster than crews expect. Replace the clogged fuel filter and bleed the lines. In winter, verify winter-grade diesel before condemning the injection pump; gelled summer fuel mimics a dead pump. Run the no-start checks in order from the engine fault table on page 61.
Manual Section: Engine Faults p. 61Machine stops driving after it warms up, park brake will not release
Test for 12 V at the park brake solenoid connector with the engine warm (operating voltage spec, page 20); a failing solenoid often drops out only after heat soak. Wiggle the harness while watching the meter to catch intermittent breaks. Work through the machine drive checks in the troubleshooting section starting on page 57 before pulling the travel pump.
Manual Section: Machine Drive TroubleshootingVibration weak or missing on one drum, exciter slow to come up to frequency
Verify the acceleration sensor is bolted down tight before condemning hydraulics; a loose sensor reads as a vibration fault. Measure the vibration motor case drain leakage next; anything over 0.5 L/min (page 24) means a worn rotating group. Run the vibration circuit pressure tests starting on page 17 to isolate pump from motor before splitting the drum.
Manual Section: Tests and Adjustments p. 24Battery charge warning light stays on with the engine running at working speed
Check charging output at the battery with the engine at working speed; the generator should hold 14 V and up to 55 A on this 12 V system (page 20). Below that, load-test the battery and inspect the generator belt and connections before replacing the regulator. Follow the charge control light checks in the engine fault table on page 61.
Manual Section: Engine Faults p. 61Engine loses power and smokes heavily halfway through a pass on the mat
Pull the air filter cartridge and hold it to the light; replace it if the paper is torn or soaked. Check the engine oil level, since overfilling causes heavy smoke. If fuel quality is suspect on a BW 125 ADH, drain its 55 L tank (page 25), refill with clean diesel, and rerun the engine fault checks on page 61.
Manual Section: Engine Faults p. 61Frequently Asked Questions
What are the torque specifications for M10 bolts with metric unified threads?
For M10 bolts with metric unified threads, the torque specifications are 50 Nm (37 ft-lb) for 8.8 grade, 75 Nm (55 ft-lb) for 10.9 grade, and 83 Nm (61 ft-lb) for 12.9 grade. p. 13
What is the nominal high idle engine speed for the BW 138 AD?
The nominal high idle engine speed for the BW 138 AD is 3000 rpm. p. 24
What is the maximum leakage rate for the vibration motor without flushing?
The maximum leakage rate for the vibration motor without flushing is approximately 0.5 l/min (0.13 Usgal/min). p. 24
What is the procedure for bleeding the travel circuit after maintenance?
Bleeding is performed by cranking the engine for 10 seconds with the starter while pressing the emergency stop button, repeating after a one-minute pause until oil flows from the measuring hoses. Then, run the engine at idling speed for 15 seconds while monitoring the charge pressure gauge until it shows a constant 29 to 32 bar. p. 43
What is the required end float for the vibrator shaft?
The nominal end float for the vibrator shaft is a minimum of 0.52 mm and a maximum of 2.00 mm. p. 81
What format is this Bomag BW 100 AD-3 manual in?
All 162 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Can I print just the pages I need from this Bomag BW 100 AD-3 manual?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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