Description

Bomag BW 141, BW 151, BW 154 2005 Training Manual

If you are wrenching on a Bomag tandem roller and you don’t have the factory training manual on your bench, you are guessing. Guessing on charge pressure costs you a pump. Guessing on valve clearance burns a valve. I have seen both. This 231-page document from Bomag (part number 008 097 16) is the real deal – the same binder they hand out in service training classes. No aftermarket translation, no missing pages. It covers the BW 141, BW 151, and BW 154 machines in AD and AC-4 variants built around 2005.

You need the stamped torque values for the travel pump high-pressure relief valves? They are in Section B 1 (Technical data and adjustment values). Need the procedure for checking and adjusting the valve clearance on the Deutz diesel engine? That is Section D 11. The manual breaks every subsystem into numbered sections with test points, troubleshooting charts, and hydraulic schematics. This is not a condensed operator’s handbook – it is a 231-page training document meant to be spilled on, dog-eared, and followed step by step.

Deutz Diesel Engine: Valve Clearance and Fuel Circuit

Chapter 5 runs from the control side of the Deutz engine to the exhaust, through the lubrication oil circuit, the fuel circuit, and the cooling package. The valve clearance adjustment procedure is laid out with exact feeler gauge specs and a sequence that keeps the pushrods from binding. The manual also covers assembling the plug-type injection pumps and the electrical connections on the engine. If you ever had a diesel that would not start after a pump swap, you want the injection pump assembly instructions on page D 14. The cooler package and fan are diagrammed with airflow direction and coolant routing – no guesswork on which hose goes where.

Travel Drive BW 141/151 AD – Charge Pressure and Relief Valve Specs

Chapter 6 is dedicated to the travel system on the BW 141 and BW 151. It covers the travel pump, control, charge pressure relief valve, high pressure relief valves (with bypass for towing), and pressure override. The test and adjustment points section tells you exactly where to tee in a pressure gauge and what reading to expect. The travel motors are A2FE 32 ccm fixed-displacement bent-axis units – the manual gives the exact torque for the flange bolts. Section E 9 has the charge pressure relief valve setting. If you adjust it by ear, you will either starve the pump or blow a seal. Don’t.

Vibration System: Pumps, Shut-off Valves, and Drum Details

Chapter 8 dives into the vibration pump, high pressure relief valves, control, vibration motors, and the vibration shut-off valve. It covers the exciter weights and drum layouts for the BW 141 AD-4 and BW 154 AD-4. The flushing valve section is critical – if the vibration system runs hot, the flushing valve could be stuck. The manual includes a troubleshooting chart that starts with the simplest checks (oil level) before moving to internal pump wear. That saves you from pulling a pump that only needed a filter change.

Is the Electrical System Covered?

Yes, and it is not an afterthought. Chapter 13 (Electrics with module description) runs from the instrument cluster warning lights to the seat contact switch, brake switch, angle sensor, and the electric junction box with modules A03, A04_AC, and A68. The module descriptions include pin assignments for digital and analog inputs, description of function (vibration control, water sprinkling control), and software version history. If you are chasing an intermittent vibration shutoff, the control logic in module A03 will tell you exactly what signal triggers the shut-off valve.

Get the Right Torque Data from Section B 1

Section B 1 (Technical data and adjustment values) is a single-page table that lists all the critical settings: charge pressure, high pressure relief settings, steering priority valve pressure, vibration system pressures, and torque values for drum mounting bolts. You cannot tune a Bomag roller without that table. The values are in imperial units as spec’d for North American machines. Keep a copy laminated in your toolbox because the factory decals on the machine fade after two seasons in the Texas sun.

This manual also covers the steering system (priority valve, steering valve, and the articulated joint – all maintenance-free bearings), the blower drive, the water sprinkler system, and the AC variant (travel motors in the AC wheel set, emulsion tank, and AC sprinkler control). The wiring diagram and hydraulic diagram are at the end – full-page foldouts in the original binder, but the PDF scans are clear enough to read on a tablet in the cab.

Do not confuse this training manual with a parts catalog or a generic repair guide. It was written by Bomag’s service training department for technicians who need to understand how the system works before they take a wrench to it. For example, the travel drive chapter includes a description of the pressure override function – if you do not know why the pump destrokes at a certain pressure, you will misdiagnose a loss of traction as a pump failure when it is actually a relief valve stuck open.

Related manuals you might need for other Bomag machines: Bomag BW 141, BW 142, BW 172, BW 172 D, BW 142 PD 1987 Repair Manual covers older rollers with different hydraulic layouts. If you work on the BC 670 RB, the Bomag BC 670 RB Training Manual – Factory Specs & Repair Docs has the same level of detail for that model. For compact rollers, check the Bomag BW 24 R 2001 Training Manual – Factory Specs & Repair.

One more thing – the travel drive on these rollers is hydrostatic, not a traditional Manual Transmission, so do not expect clutch or gear adjustment specs. But if you need to understand how the bent-axis motors interact with the flow divider, this manual explains it with cross-section diagrams. The Manual Transmission comparison ends here – this is hydraulic drive all the way.

FAQ

Does this manual include the AC-4 variant wiring?

Yes, the AC-4 variant has its own module A04_AC with pin assignments and sprinkler control logic.

How do I check and adjust the valve clearance on the Deutz engine?

Section D 11 walks you through removing the valve cover, rotating the engine to TDC on cylinder 1, checking clearance on intake and exhaust valves with a feeler gauge (specs are in the technical data table), and adjusting with the locknut and adjusting screw. It also covers the sequence for the remaining cylinders based on firing order. The manual includes a warning about not overtightening the locknut – torque is specified in inch-pounds. If you have never done a Deutz valve adjustment, start with this section before you touch the engine. A bent pushrod is expensive.

You need this training manual on your tablet or printed out before the next hydraulic leak turns into a three-day diagnostic nightmare. Access the Factory Manual now and keep the guesswork out of your Bay 3.