Tracing closed-circuit travel pump faults down to the vibration motor requires the end-to-end system data found in the 580-page Bomag BW 100 AD, BW 120 AD, BW 130 AD repair manual PDF (OEM 008 191 20). The diagnostic sections walk you through the tandem pump and vibration control block, backed by dedicated hydraulic schematics and electrical circuit diagrams. For heavy repairs, the text details how to dismantle the drum, exchange rubber buffers, and overhaul the pendulum center joint. Exact factory numbers anchor the work, providing measurements like a 13.0 kg/cm front static linear load and a standard M4 bolt torque of 3 Nm. A paving train grinds to a halt when you lack one single charge pressure value. Download this digital text, jump straight to the spec with the bookmarks, and print the pages for the bench where they can get covered in grease.
What's Inside This Bomag BW 100 AD, BW 120 AD, BW 130 AD Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| General Notes on Repair | 23-26 | Hydraulic System, Electric System, Seals, Torques, General |
| Safety | 27-28 | Articulated Joints, Protective Clothing, Maintenance, Fuel and Oils, Battery Electrolyte |
| Hydraulic Symbols | 29-44 | Flow Line, Pump, Measuring Instrument, Valve, Cylinder, Filter |
| Electric Symbols | 45-60 | Enclosure, Trunk Bundle, Connection, Ground, Variability, Resistor |
| Torques | 61-64 | Metric Unified Threads, Metric Fine Threads, Bolt Yield Strength, Lubricants |
| Conversion Table of Some Metric and English Measures | 65-70 | Length, Area, Volume, Weight, Pressure, Torque |
| Technical Data | 71-78 | Weights, Dimensions, Driving Characteristics, Drive System, Roller Drums, Brakes |
| System Description of Hydraulics | 79-86 | Variable Displacement Pump, Swash-Plate Pump, Closed Circuit, Hydraulic Control, Auxiliary Gear Pump |
| Connection Survey and Test Points | 87-90 | Travel Pump, Tandem Pump, Steering Valve, Solenoid Valve Vibration |
| Special Tools | 91-98 | Filling and Flushing Unit, Rubber Buffer Mounting Device, Mounting Pin for Sealing Rings, Puller for Coupling Half, Centering Plate for Vibration Motor |
| General Description of Diesel Engine | 99-142 | Trouble Shooting for Diesel Engine F2L 511, Measuring the Diesel Engine Speed |
| Instruction for Repair | 143 | Disassembling and Installing the Starter, Exchanging the Alternator, Exchanging the Solenoid Switch, Disassembling and Installing the Engine, Making the Engine Ready for Travel |
| Travel System | 144-182 | Travel Motor, Brake Discs, Sealing Ring for Brake Shaft, Distributor Gaskets, Cylinder Block, Bearing Cups, Piston Rings, Travel Pump |
| Important Points for Trouble Shooting and Repair Work | 183-318 | Trouble Shooting Chart, Exchanging the Travel Motor, Exchanging the Travel Pump, Variable Displacement Pump, Flushing the Travel Circuit, Filling the Hydraulic System |
| System Description of Vibration | 319-356 | Tandem Pump, Vibration Control Block, Vibration Motor, Vibration Circuit Flushing |
| Vibration Drive | 357-432 | Instructions for Repair (Disassembling and Mounting the Drum, Exchanging the Rubber Buffers, Dismantling and Reassembling the Drum, Exchanging the Vibration Motor, Exchanging the Vibration Motor Seals, Exchanging the Tandem Pump, Exchanging the Vibration Control Block) |
| Steering Cylinder | 433-467 | Removing and Installing the Steering Cylinder, Repairing the Steering Cylinder |
| Removing and Installing the Steering Unit | 468-473 | Instrument Panel Cap, Cover Plate, Hydraulic Connections |
| Steering Unit BW T30-Ad, Repair | 474-511 | Disassembling the Steering Unit, Spacer Ring and Loop Rings, Assembly |
| Steering Unit TEW 160/720, Repair | 512-562 | Disassembling and Assembling the Steering Unit, Removing the Double Shock Valve |
| Hydraulic Circuit Diagram | 563-570 | Hydraulic Circuit Diagram Bw 100/120 Ad |
| Electrical Circuit Diagram | 571-580 | Battery, Alternator, Starter, Horn, Oil Pressure Switch, Brake Switch |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Torque for M4 bolt (8.8 grade) | 3 Nm | p. 61 |
| Battery acid density (full) | 1.28 kg/l | p. 107 |
| Battery acid density (half) | 1.21 kg/l | p. 107 |
| V-belt tension | 10...15 mm | p. 148 |
| Static linear load, front | 13.0 kg/cm | p. 75 |
| Static linear load, rear | 13.15 kg/cm | p. 75 |
| Engine rated power DIN 6271 IFN | 23.5 kW | p. 75 |
| Steering angle | 25 degree | p. 72 |
| Water tank capacity | 165 L | p. 72 |
Bomag BW 100 AD, BW 120 AD, BW 130 AD Common Problems This Manual Covers
Bomag BW 100 AD tandem roller cranks slowly and engine will not start on the morning shift.
Check the battery acid density using the procedures on page 107. Verify the cells read a full 1.28 kg/l and clean off any oxidation on the clamps. If the reading drops to 1.14 kg/l, replace the battery immediately to get the machine back on the mat.
Manual Section: General Description of Diesel Engine p. 107Drum drive roller engine overheats quickly and shuts down abruptly while compacting hot asphalt.
Inspect the cooling fins for asphalt dust buildup and check the V-belt tension. Adjust the belt deflection to 10..15 mm as detailed on page 148. Tighten the mounting hardware securely, replacing the belt if cracked to keep the paving train moving without interruption.
Manual Section: Travel System p. 148Articulated joint binds during operation and the tandem roller fails to reach maximum steering angle.
Measure the articulation travel and verify against page 72 that it reaches the maximum steering angle of 25 degree. Inspect the pendulum center joint and steering cylinder for physical binding, then grease all pivot points thoroughly to restore full maneuverability for the next pass.
Manual Section: Technical Data p. 72Roller drives normally when cold but suddenly stops traveling after the hydraulic system warms up.
Verify the park brake solenoid wiring integrity near the travel motor. If replacing the solenoid coil or securing ground wires, torque any M4 bolt (8.8 grade) fasteners to exactly 3 Nm as specified on page 61. Test the travel circuit at operating temperature before returning to work.
Manual Section: Torques p. 61Frequently Asked Questions
What is the torque specification for an M10 bolt with a strength classification of 8.8?
For an M10 bolt with a strength classification of 8.8, the torque specification is 50 Nm (37 ft-lb). p. 62
What is the correct tension for the V-belt on the engine?
The V-belt tension should be checked at the longest unsupported section of the belt, where it must be in the range of 10 to 15 mm. p. 148
What is the nominal charge pressure for the travel circuit?
The nominal charge pressure for the travel circuit is 17 to 19 bar. p. 187
What is the required oil capacity for the hydraulic tank?
The hydraulic tank has a capacity of 42 liters (11.1 gallons). p. 71
What is the procedure for bleeding the steering cylinder?
To bleed the steering cylinder, let the engine idle and turn the steering several times to the left and right. p. 145
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