This is the factory service manual Bomag wrote for the BW 141 AD-4, BW 151 AD-4, BW 151 AC-4 and BW 161 ADCV tandem asphalt rollers, including the combination AC with rear tires and the crab-walk ADCV. It goes far past an operator book: pressure tests in the travel and vibration circuits, adjusting the angle sensor, checking exciter shaft speed, flushing and bleeding the hydraulics with the proper filter setup, and the full electrics chapter that teaches you to read Bomag's circuit diagrams with current paths and cross references. Fault codes of the ESX control are documented on p.176. Covers the Deutz BF4M 2011 (60 kW at 2500 rpm), drum and vibrator unit repair, the oscillating articulated joint, and hydraulic diagrams 920 100 51/57/63 plus wiring diagrams 920 100 04 through 07.
What's Inside This Bomag BW 141 AD-4, BW 151 AD-4, BW 151 AC-4, BW 161 ADCV Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 1-28 | Bw 141 Ad-4 / Bw 151 Ad-4, Bw 151 AC-4 / Bw 161 Adcv, Tandem Vibratory Roller, Safety Regulations, Important Notes, Old Oils, Hydraulics |
| Maintenance | 29-36 | General Notes on Maintenance, Notes on the Fuel System, Notes on the Engine Performance, Notes on the Hydraulic System, Fuels and Lubricants, Engine Oil, Oil Viscosity |
| Technical Data | 37-44 | Dimensions, Weights, Travel Speeds, Vibration Data, Engine Data, Filling Capacities |
| Connection Overview | 45-48 | - |
| Tests and Adjustments | 49-72 | Special Tools, Adjusting the Angle Sensor, Checking the Rotation Speeds, Check the Engine Speed, Checking the Exciter Shaft Speed, Pressure Tests in the Travel Circuit, Mechanical Neutral Position |
| Flushing and Bleeding | 73-106 | Special Tools for Flushing, Filling and Filtering Unit with Oil Bag, Filter Element, Flushing Filter (S Connection), Filter Element 1m, Flushing Hose 20S - 25S (2 Pieces), Screw Socket R1“ - 25S (2 Pieces) |
| Electrics | 107-161 | Fundamental Electrics, Understanding Circuit Diagrams, Structure, Potential Cross References, Relay Cross Reference, Current Paths, Component Cross References |
| Special Tools, Electrics | 162-172 | - |
| Electronic Modules | 173-305 | Bem, BOMAG Evib-Meter, Electrics Module A03, Electrics Module A68, Electrics Module A71, Electrics Module A04, Heating/Air Conditioning Control, Speedometer Module |
| Speedometer Module | 306-310 | Description of Function, Teaching the Module |
| Service Training | 311-429 | - |
| Engine | 430-499 | General Information on Diesel Engine, Operation Side, Exhaust Side, Lubrication Oil Circuit, Coolant Temperature Switch, Three-Phase Generator, Fuel Circuit |
| Air Conditioning System | 500-544 | Physical Basics, Pressure and Boiling Point, Refrigerant R134a, Environmental Aspects, Compressor Oil / Refrigeration Oil, Working Principle of the Air Conditioning System, Monitoring Devices |
| Special Tools and Frame Welding | 545-561 | Locking Handle for Fastening Element, Suction Lifter, Auxiliary Materials, Cutter, Window Glass Bonding Agent, Activator, Silicone Sealant |
| Travel Control Cable | 562-567 | Replacing the Travel Control Cable, Removing the Driver's Seat, Disassembling the Travel Control Cable |
| Drum | 568-621 | Special Tools, Drum (BW 141/151-4), Lifting Device for Vibrator Unit, Guide Bolts M16 X 270, Guide Bolts M12 X 270, Screw Bolt for Vibrator Unit Lifting Device, Puller for Coupling Half, Drum Shell |
| Oscillating Articulated Joint | 622-650 | Repair Overview Oscillating Articulated Joint, Crab Walk Cylinder, Steering Cylinder, Cross Member, Disconnect the Main Battery Switch (Fig. 1)., Drain the Water Tank, Remove the Left and Right Hand Sraps 1 (Fig. 5). |
| Suppliers Documentation - Travel Pump and Motors | 651-828 | Vibration Pump, Travel Motor, Drum Reduction Gear |
| Suppliers Documentation - Vibration Motor | 829-902 | - |
| Circuit Diagrams | 903-1060 | Hydraulic Diagram 920 100 51, Hydraulic Diagram 920 100 63, Hydraulic Diagram 920 100 57, Wiring Diagram 920 100 04, Wiring Diagram 920 100 05, Wiring Diagram 920 100 06, Wiring Diagram 920 100 07 |
| Supplement - Monitoring Modules | 1061-1078 | Monitoring Module A15, Old Design, New Design, Machine |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Deutz BF4M 2011, 60 kW at 2500 rpm | p. 38 |
| Operating weight (CECE), BW 141 AD-4 | 7500 kg | p. 38 |
| Operating weight (CECE), BW 151 AD-4 | 7900 kg | p. 38 |
| Operating weight (CECE), BW 151 AC-4 | 8300 kg | p. 40 |
| Operating weight (CECE), BW 161 ADCV | 7900 kg | p. 40 |
| Travel speed | 0-10,5 km/h | p. 38 |
| Max. steering pressure | 200 ± 5 bar | p. 43 |
| Travel pump charge pressure (high idle) | 25 +3/-1 bar | p. 42 |
| Fuel capacity | 160 litres | p. 39 |
| Water capacity (sprinkler) | 800 litres | p. 39 |
| Valve clearance (intake / exhaust) | 0,3 mm / 0,5 mm | p. 42 |
Bomag BW 141 AD-4, BW 151 AD-4, BW 151 AC-4, BW 161 ADCV Common Problems This Manual Covers
Engine cranks strongly but will not start
Work the fuel side first: tank level, line leaks and loose connections before blaming injectors or the injection pump. The Engine chapter lays out the complete fuel circuit and lubrication oil circuit so you can trace supply from tank to injectors in order instead of guessing.
Manual Section: Engine - Fuel circuit p. 441Charge warning lamp stays on after startup
Usually a loose or worn V-belt dropping alternator speed, or the regulator itself. The Engine chapter covers the three-phase generator, and the Electrics chapter teaches you to follow current paths and component cross references in the wiring diagrams to isolate whether the fault is belt, alternator or wiring.
Manual Section: Engine - Three-phase generator / Electrics p. 459Runs hot and loses power in dusty paving conditions
Dust packs the cooling fins on these machines fast when you are running the sprinkler over hot asphalt all day. The Maintenance chapter gives the general maintenance notes plus notes on engine performance, fuels and lubricants, and correct oil viscosity so the cooling package and oil spec both stay inside Deutz limits.
Manual Section: Maintenance - Notes on the engine performance p. 29Weak or dead travel drive, drums barely turn
Before pulling a pump, run the pressure tests in the travel circuit from Tests and Adjustments and verify charge pressure against the 25 +3/-1 bar high idle spec on p.42. Check the mechanical neutral position too. If a component did fail, the Flushing and Bleeding chapter keeps debris out of the replacement.
Manual Section: Tests and Adjustments - Pressure tests in the travel circuit p. 59Frequently Asked Questions
The machine creeps or barely moves after startup. Does this manual actually help me trace that?
Yes, and this is where it earns its money. The Tests and Adjustments chapter walks you through pressure tests in the travel circuit and setting the mechanical neutral position. Charge pressure at high idle should sit at 25 +3/-1 bar (p.42); if it is low you know to look at the charge circuit before condemning a pump. Flushing and Bleeding covers getting air out afterwards. p. 59
Are fault codes for the electronic control documented?
Yes. Fault codes of the ESX control are listed starting on p.176 in the Electronic Modules chapter, alongside the descriptions of modules A03, A04, A68 and A71, the BEM Evib-meter, and the speedometer module including how to teach it. The Electrics chapter also explains how to read the wiring diagrams so you can chase a code to an actual wire. p. 176
What engine is in these rollers and does the manual cover engine service?
All four models run the Deutz BF4M 2011 rated 60 kW at 2500 rpm (p.38). The Engine chapter covers the lubrication oil circuit, fuel circuit, coolant temperature switch and the three-phase generator. Valve clearance is 0,3 mm intake / 0,5 mm exhaust (p.42), with the adjustment procedure in section 12.30 on p.480. p. 430
Does it cover the BW 151 AC-4 combination roller and the ADCV crab walk?
Yes. The AC-4 with rear tires and the BW 161 ADCV are covered throughout, with their own weights (8300 kg and 7900 kg CECE) and vibration data: amplitude 0,60/0,31 mm on the AC versus 0,64/0,28 mm on the AD, both at 40/60 Hz. The Oscillating Articulated Joint chapter includes the crab walk cylinder and steering cylinder, with steering pressure spec at 200 +/- 5 bar. p. 40
I need to flush the hydraulic system after a component failure. Is the procedure in here?
Yes, there is a dedicated Flushing and Bleeding chapter with the special tools listed by name: filling and filtering unit with oil bag, flushing filter with S connection, 1 micron filter elements, 20S-25S flushing hoses and R1 inch screw sockets. The system holds 60 l of hydraulic oil (p.39-41), so plan your fresh oil and disposal before you open anything. p. 73
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