Covering the BW 135 AD, BW 138 AD, and BW 138 AC tandem vibratory and combination rollers, this 478-page publication is the official Bomag BW 135 AD, BW 138 AD, BW 138 AC service manual pdf (OEM ID 008 914 44) for diagnosing and repairing your compaction equipment. The documentation anchors troubleshooting with complete wiring diagrams and extensive hydraulic schematics detailing the closed-loop travel and vibration circuits. Your technicians will find clear teardown instructions for the oscillating articulated joint, plus precise flushing procedures for the front and rear drum drives. Verify system health by confirming the travel circuit charge pressure hits 20 ±2 bar at high idle, or check that the vibration motor leakage rate stays below the maximum 0.5 l/min threshold. A roller stalled mid-mat means the whole paving train stands still, but this bookmarked and text-searchable digital manual lets you locate the exact spec you need to get the machine back in the pass.
What's Inside This Bomag BW 135 AD, BW 138 AD, BW 138 AC Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 5-22 | Introduction, Safety Regulations, General Repair Instructions |
| Maintenance | 23-30 | Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Chart |
| Technical Data | 31-38 | Engine, Brakes, Steering, Vibration System, Water Sprinkler System, Travel Pump |
| Tests and Adjustments | 39-54 | Special Tools, Checking the Rotation Speeds, Pressure Tests in the Travel Circuit, Checking / Adjusting the Neutral Positions of the Travel Pump |
| Trouble Shooting | 55-70 | Trouble Shooting Diagram |
| Fundamental Electrics | 71-124 | Understanding Circuit Diagrams, Terminal Designations, Current and Voltage, Resistance, Series / Parallel Connection, Ohm's Law, Electrical Energy, Formula Diagram |
| Special Tools, Electrics | 125-134 | Frequency Meter, Multimeter, Hydraulic Test Case, Crimping Pliers, Disassembly Tools, Measuring Adapter |
| Machine Related Electrics | 135-154 | Vibration Module, Module A68 |
| Flushing and Bleeding | 155-182 | Special Tools for Flushing, Flushing - General, Flushing Schematic for Front Drum Drive, Flushing the Front Drum Drive, Flushing Schematic for Rear Drum Drive System |
| Drum | 183-204 | Special Tools, Repair Overview for Drum, Removing and Installing the Drum, Dismantling the Drum, Assembling the Drum |
| Oscillating Articulated Joint | 205-220 | Special Tools, Repair Overview Oscillating Articulated Joint, Removing and Installing the Oscillating Articulated Joint, Dismantling the Oscillating Articulated Joint |
| Travel Pump A10VG28 ....63 | 223-280 | Drive Shaft, Boost Pump, Control Piston Cover, Valves, Pressure Cut-Off Valve, Rotary Group |
| Travel Pump Series 42 | 281-318 | Pump Neutral Adjustment, Mdc Control Module, Edc Control Module, Charge Relief Valve, Loop Flushing Valve, Filtration |
| Drum Drive MK05/08/11/18 | 319-380 | Parking Brake, Motor, Brake Piston, Cylinder-Block, Cam Assembly, Sensor |
| Wheel Drive Ms/Mse 02...18 | 381-430 | Parking Brake, Motor, Brake Piston, Bearing Support, Brake Shoes, Sensor |
| Circuit Diagrams | 431-478 | Wiring Diagram, Hydraulic Diagram |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for M4 screw (8.8) | 3 Nm | p. 19 |
| Charge pressure, high idle | 20 ±2 bar | p. 46 |
| Charge pressure low idle speed | 15...20 bar | p. 46 |
| leakage rate of the vibration motor | max. 0.5 l/min | p. 52 |
| leakage rate of the vibration motors | max. 1.5 l/min | p. 36 |
| Final discharging voltage | 10.5 Volt | p. 95 |
| Recharge threshold open circuit voltage | 12.25 Volt | p. 95 |
| Pre-excitation current | 250 mA | p. 101 |
| Total resistance of disconnected dead supply line D+ | 48 Ohm | p. 101 |
| Rubber buffers tightening torque | 211 Nm | p. 190 |
| NSS control nut torque | 4.1-6.8 Nm | p. 297 |
| NSS connection torque | 25-29 Nm | p. 297 |
Bomag BW 135 AD, BW 138 AD, BW 138 AC Common Problems This Manual Covers
Bomag BW 135 AD tandem roller stops traveling after warming up and machine will not drive
Connect a gauge to the travel circuit and test the charge pressure at high idle. Verify the reading reaches 20 ±2 bar as detailed on page 46. If the pressure drops below the minimum 18 bar on page 47 when the oil warms, inspect the charge relief valve.
Manual Section: Tests and Adjustments p. 46Engine will not start in cold weather and starter only emits a clicking sound
Measure the battery open circuit voltage before cranking. Verify the voltage sits above the 12.25 Volt recharge threshold. If voltage drops to the 10.5 Volt final discharging voltage under load, as noted on page 95, replace the battery and check the generator connections.
Manual Section: Fundamental Electrics p. 95Weak vibration on one drum or vibration shaft speed too low during compaction passes
Test the leakage rate of the vibration motors to determine if the rotating group is worn. Disconnect the case drain line and measure the flow. If the leakage rate exceeds the maximum 1.5 l/min specification shown on page 36, replace the motor seals or rotating group.
Manual Section: Technical Data p. 36Travel intermittently cuts out or machine refuses to move out of neutral position
Inspect the neutral start switch wiring harness for loose connections. Torque the NSS connection to 25-29 Nm and tighten the control nut to 4.1-6.8 Nm as specified on page 297. If the switch fails continuity tests, replace the unit to restore travel function.
Manual Section: Travel Pump Series 42 p. 297Frequently Asked Questions
What are the torque specifications for the wheel nuts on the BOMAG BW 135 AD?
The tightening torque for wheel nuts (fine thread) on the BW 135 AD depends on the thread diameter. For M12x1.5, the torque is 100 Nm; for M14x1.5, it is 150 Nm; for M18x1.5, it is 300-350 Nm; for M20x1.5, it is 400-500 Nm; and for M22x1.5, it is 500-600 Nm. p. 20
What are the fuel filter replacement specifications for the Bomag BW 135 AD, BW 138 AD, BW 138 AC?
The fuel filter cartridge should be changed every 1000 operating hours. The fuel pre-filter cartridge is replaced on the same 1000-hour interval. p. 29
What is the engine oil capacity for the BW 135 AD and BW 138 AD?
The engine oil capacity for these models is approximately 6.0 litres (1.6 USgal). p. 27
What is the correct procedure for checking the leakage rate of the vibration motor on the Bomag BW 135 AD?
To check the leakage rate, disconnect the leak oil hose, connect a measuring hose, and hold it into a measuring beaker. Start the engine, set to max speed, and measure the running out leak oil for one timed minute. The nominal value is a maximum of 0.5 l/min. p. 52
What is the nominal value for the steering pressure in the steering circuit on the Bomag BW 135 AD?
The nominal value for the steering pressure is approximately 160 to 180 bar. This is measured by connecting a 600 bar pressure gauge to the steering pressure test port and turning the steering against an end stop. p. 53
What exactly do I receive with this Bomag BW 135 AD Service Manual?
You download the Service Manual yourself: 478 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Are there any print restrictions on this Bomag BW 135 AD manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
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