Document 008 098 04 is Bomag's own factory Service Training for the BW 100 and BW 120 tandem vibratory rollers, and this Bomag BW 120 AD-3 Service Training PDF runs 89 pages across four AD-3 and AC-3 variants. Electric circuit diagrams fill the last fifth of the book, laid out by function groups with potential and relay cross references so you can follow a wire across sheets. Hydraulic circuits trace the closed-loop travel system from the Hydromatik A10 VG 28 pump through the drum drive motor and the wheel motors on AC machines, backed by troubleshooting trees for weak travel, vibration and steering faults. Verify 20 bar charge pressure before condemning a travel pump, and expect 55 Hz from the exciter in stage one, 66 in stage two. Sometimes it's just you, the roller and a fault nobody nearby can name. This bookmarked, text-layer PDF and its component list give you the pump maker and type before you order.
What's Inside This Bomag BW 100 AD-3, BW 100 AC-3, BW 120 AD-3, BW 120 AC-3 Manual
| System | Pages | Key Topics |
|---|---|---|
| List of Additional Documentation | 4 | Index of Related Bomag Publications (Each Sold Separately) |
| General | 5 | |
| Maintenance | 6 | |
| List of Components | 7-9 | Engine, Travel Pump, Travel Motor, Vibration Pump, Vibration Motor, Steering Valve |
| Deutz Diesel Engine | 10-17 | External Engine Parts, Lubrication Oil Circuit, Fuel Circuit, Valve Clearance |
| Travel System | 18-49 | Hydromatik Travel Pump A10 Vg 28, Function of Travel Pump, Charge Pressure Relief Valve, High Pressure Relief Valves, Drum Drive Motor, Wheel Drive Motors on AC-machines |
| Vibration | 50-62 | Vibration Pump, Vibration Control Valve, Vibration Motor, Trouble Shooting Vibration |
| Steering | 63-69 | Steering Valve, Trouble Shooting Steering |
| Electric Circuit Diagrams | 70-89 | Table of Contents, Function Groups, Line Thicknesses, Reference Lines, Frames, Potential Cross References, Relay Cross References, Electric System |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Displacement | 408 cm³/rev. | p. 8 |
| Frequency stage 1 | 55 Hz | p. 9 |
| Frequency stage 2 | 66 Hz | p. 9 |
| High pressure limitation | 385 bar | p. 7 |
| Charge pressure | 20 bar | p. 7 |
| Starting pressure | 220 bar | p. 8 |
| Operating pressure | 80..100 bar | p. 8 |
| Mechanical brake release screw torque | 35 Nm | p. 27 |
| Engine Power | 22 kW | p. 7 |
| Fixed Engine Speed Stage 1 | 2500 rpm | p. 7 |
| Fixed Engine Speed Stage 2 | 3000 rpm | p. 7 |
| Intake Valve Clearance | 0.3 mm | p. 16 |
Bomag BW 100 AD-3, BW 100 AC-3, BW 120 AD-3, BW 120 AC-3 Common Problems This Manual Covers
Bomag BW 100 AD-3 roller will not travel, drums barely turn under load at full throttle
Check charge pressure first with the engine running; it should hold a steady 20 bar. If it reads low, inspect the charge pressure relief valve and hydraulic oil filter before condemning the travel pump. Work through the travel system fault tree starting on page 30, then verify high pressure reaches the 385 bar limitation under stall.
Manual Section: Travel System Troubleshooting p. 30Roller creeps forward or backward with the travel lever in neutral position
Verify the travel lever and ball socket linkage are seated and aligned before touching the pump. Block the machine, lift the drums clear, and set the travel pump neutral position per the procedure starting on page 30. Confirm charge pressure holds 20 bar during adjustment, then test both directions before the next pass.
Manual Section: Travel System Troubleshooting p. 30Vibration will not switch on at either drum, no exciter response from the switch
Check the seat contact switch and the magnetic coil on the vibration control valve before pulling any hoses. Then tee a gauge into the vibration circuit; starting pressure should hit 210+10 bar per the check on page 50 before settling into the 80 to 100 bar operating range. No pressure spike points to the vibration pump or control valve.
Manual Section: Vibration Troubleshooting p. 53Vibration weak or uneven on one drum, mat not reaching density behind the machine
Measure the leak oil rate at the suspect vibration motor with vibration running; the procedure on page 59 allows a maximum of 1.5 l/min. Anything higher, replace the motor. If leak oil is within spec, check exciter shaft end float and bearing mobility, and confirm frequency reaches 55 Hz in stage 1 before sending the roller back onto the lift.
Manual Section: Vibration Troubleshooting p. 59Parking brake will not release, machine stays locked with engine running and lever engaged
Check brake relieving pressure at the travel motor; it must reach 12 bar per the spec on page 26 to lift the brake. Test the brake solenoid valve for 1.2 A draw at 12 V. To get a dead machine off the mat, release the brakes mechanically, torquing the release screws to 35 Nm as shown on page 27.
Manual Section: Brake Mechanical Release p. 27Frequently Asked Questions
How do I reset the parking brake on a BOMAG BW 100 AD-3 or BW 120 AD-3?
To mechanically release the parking brake, unscrew the two plugs (191), press the screws (192) against the springs (193), and tighten both screws alternately in steps until they bottom, with a maximum torque of 35 Nm. p. 27
Why is my BOMAG BW 100/120 AD-3 showing a low hydraulic pressure fault?
A low hydraulic pressure fault may be caused by an incorrect charge pressure, which should be between 18-22 bar. You should check the steering/charge pump by connecting a 600 bar pressure gauge to test port M1; the nominal value is approximately 170 bar. p. 33
What are the replacement specifications for the travel motor?
The travel motors for the drums are Poclain type MK 04 with a displacement of 408 cm³/rev. The travel motors for the wheels on AC-machines are Poclain type MSE 02, also with a displacement of 408 cm³/rev. p. 8
What is the correct valve clearance for the Deutz F2L 1011 F engine?
The valve clearance for the intake valve is 0.3 mm and for the exhaust valve is 0.5 mm. These must be checked and adjusted only when the engine is cold. p. 16
What is the nominal charge pressure for the travel pump?
The nominal charge pressure for the travel pump is approximately 18-22 bar. This value is measured at the charge pressure test port (PS) on the travel pump. p. 32
What exactly do I receive with this Bomag BW 100 AD-3 Service Manual?
You download the Service Manual yourself: 89 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Is printing allowed for this Bomag BW 100 AD-3 Service Manual?
Printing is allowed without restriction. Pull the pages you need for the job and bin them when they get greasy.
Reviews
There are no reviews yet.