Four rollers in Bomag's BW 125 to 138 range, tandem and combination models both, share this 462-page Bomag BW 138 AD service manual PDF, issued under OEM number 008 914 56. Wiring and hydraulic diagrams fill the closing chapter, while the front of the book takes you through pressure tests in the closed-loop travel circuit, flushing the drum drives, and a troubleshooting diagram that traces each symptom back to its cause. Drum and oscillating articulated joint rebuilds get their own chapters, backed by supplier documentation for the A10VG28 and Series 42 travel pumps and the MK drum drive motors. Swap the fuel filter cartridges at 1000 operating hours; torque M6 grade 8.8 screws to 10 Nm. A roller parked mid-shift bleeds hours your crew never gets back. Bookmarks and a clean text layer put the right diagram two clicks from opening the file.
What's Inside This Bomag BW 125 ADH, 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 | Weights, Dimensions, Travel Characteristics, Drive, Brakes, Steering, Vibration System |
| 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 | Vibration Reed Frequency Meter, Sirometer, Hydraulic Test Case, Digital RPM-Meter, Crimping Pliers, Disassembly Tools |
| 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, Pressure Cut-Off Valve, Control Unit, Rotary Group |
| Travel Pump Series 42 | 281-318 | Mdc Control Module, Edc Control Module, Charge Relief Valve, Loop Flushing Valve, Shaft Seal, Filtration |
| Drum Drive MK05/08/11/18 | 319-380 | Parking Brake, Motor, Cylinder-Block, Cam Assembly, Brake Piston, Valving |
| Wheel Drive Ms/Mse 02...18 | 381-430 | Poclain MS/MSE 02, 05, 08, 11 and 18 Hydraulic Motors, Trouble Shooting, Maintenance, Repairs, Spare Parts |
| Circuit Diagrams | 431-462 | Wiring Diagram, Hydraulic Diagram |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for M4 screw (8.8) | 3 Nm | p. 19 |
| Tightening torque for M5 screw (8.8) | 6 Nm | p. 19 |
| Fuel pre-filter cartridge replacement interval | 1000 operating hours | p. 29 |
| Fuel filter cartridge replacement interval | 1000 operating hours | p. 29 |
| Dry air filter maintenance interval | 10 operating hours | p. 29 |
| Maximum leakage rate of the vibration motor | 0.5 l/min | p. 52 |
| Maximum leakage rate of the vibration motors | 1.5 l/min | p. 36 |
| Final discharging voltage | 10.5 Volt | p. 95 |
| Open circuit voltage for recharge | 12.25 Volt | p. 95 |
| Regulator voltage limit | 14.4 V | p. 100 |
| Pre-excitation current | 250 mA | p. 101 |
| output current | 4-20 mA | p. 114 |
Bomag BW 125 ADH, BW 135 AD, BW 138 AD, BW 138 AC Common Problems This Manual Covers
Bomag BW 138 AD cranks slowly or will not start in cold weather, starter clicks once
Test battery open circuit voltage before anything else; below 12.25 volts, recharge it first, following the battery test values on page 95. Check electrolyte density in each cell: 1.285 kg/dm3 means fully charged at 27°C. Then bleed air from the fuel lines and fit new fuel filter cartridges; the maintenance chart on page 29 calls for replacement every 1000 operating hours.
Manual Section: Fundamental Electrics p. 95Machine loses travel drive after ten minutes of rolling, comes back after cooling down
Start with the troubleshooting diagram on page 57 and split hydraulic causes from electrical ones. Wiggle-test the harness at the travel lever and the park brake solenoid against the wiring diagram on page 436; heat-soaked connectors open up intermittently. On Series 42 travel pumps, torque the solenoid override housing and retaining nut to 2-4 Nm on reassembly.
Manual Section: Trouble Shooting p. 57Front drum vibration weak or completely dead, rear drum shakes normally at same amplitude setting
Measure case drain leakage from the vibration motor on the dead drum; more than 0.5 l/min during the test on page 52 means a worn rotating group. Before pulling the motor, test the acceleration sensor circuit: output current should read 4-20 mA (page 114). A loose or dead sensor mimics a failed exciter and costs you the mat for nothing.
Manual Section: Tests and Adjustments p. 52Battery goes flat overnight and charge warning light glows dim with engine running
Read voltage at the battery with the engine at working speed; the regulator should hold no more than 14.4 V (page 100). If it reads low, check belt tension and clean the D+ and B+ connections. Measure rotor coil resistance: 3 to 6 Ohm is healthy (page 102). Replace carbon brushes worn shorter than 5 mm, page 105.
Manual Section: Fundamental Electrics p. 100Knocking or rumbling noise from drum during vibration, gets louder at high amplitude
Remove the drum and dismantle the exciter housing following the drum repair section starting on page 183. Measure exciter shaft end float: 0.6 mm to 1.9 mm is the acceptable range (page 200); replace bearings outside that spec. On assembly, torque the rubber buffers to 211 Nm (page 190) and the drum drive motor bolts to 300 Nm (page 202).
Manual Section: Drum p. 200Frequently Asked Questions
What are the torque specifications for M10 bolts on the BOMAG BW 135 AD?
For screws with metric unified thread, the tightening torque for an M10 bolt with a strength class of 8.8 is 50 Nm, 75 Nm for 10.9, and 83 Nm for 12.9. p. 19
What is the roller drum bolt torque spec for the Bomag BW 125 ADH, BW 135 AD, BW 138 AD, BW 138 AC?
Tighten the rubber buffers on the drum to 211 Nm. p. 190
What are the fuel filter replacement specs for the Bomag BW 125 ADH, BW 135 AD, BW 138 AD, BW 138 AC?
Change the fuel filter cartridge every 1000 operating hours. p. 29
What is the engine oil capacity for the BW 125 ADH?
Engine oil capacity for the BW 125 ADH runs approximately 6.0 litres (1.6 USgal). p. 27
What is the nominal exciter shaft end float on the Bomag BW 125 ADH, BW 135 AD, BW 138 AD, BW 138 AC?
Nominal end float for the exciter shaft runs 0.6 mm minimum to 1.9 mm maximum. p. 200
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