Four Bomag tandem vibratory rollers share this book: the BW 100 AD-3, BW 120 AD-3, BW 100 AC-3 and BW 120 AC-3, all four with the Deutz F2L 1011 engine. It runs 176 pages as an English PDF download, written for the mechanic doing the work rather than the operator.
The core of the book is hydraulic: pressure tests for the travel, vibration and steering circuits, flushing and bleeding procedures, and full disassembly and assembly of the travel pump, travel motor, drum with its vibrator shaft, and the oscillating articulated joint. Troubleshooting charts cover engine, electrical and hydraulic faults. Guessing a relief valve setting or a bearing end float on a machine like this ruins components fast; this manual gives you the factory figures. Bought once, it is yours to keep for the life of the roller.
What's Inside This Bomag BW 100–120 AD/AC-3 Series Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety Regulations | 9-12 | General, Hydraulic System |
| General Notes for Repairs | 13-14 | General, Seals and Gaskets |
| Tightening Torques | 15 | Torques for Bolts with Metric Unified Threads |
| Connecting Plan | 16-17 | Travel Pump, Control Lever, High Pressure Relief Valves, Servo Control |
| Tests and Adjustments | 18-40 | Technical Data, Rotary Speeds, Mechanical Neutral Position, Travel Circuit Pressure Tests, Vibration Circuit Pressure Tests, Steering System Pressure Tests |
| Flushing Procedures | 41-61 | Flushing Schematic, Travel Circuit Flushing, Vibration Circuit Flushing, Flushing Filter Installation, Bleeding Procedures |
| Trouble Shooting | 62-90 | Engine Faults, Electrical System, Monitoring Board, Hydraulic System, Steering System Faults |
| Drum Repair | 91-110 | Drum Removal, Drum Installation, Vibrator Shaft Disassembly, Bearing Cover, Rubber Buffers |
| Oscillating Articulated Joint Repair | 111-126 | Joint Removal, Joint Installation, Bearing Blocks, Rocker Bearing, Oscillation Axle |
| Travel Pump Repair | 127-142 | Pump Disassembly, High Pressure Relief Valves, Charge Pressure Relief Valve, Cylinder Block, Servo Control |
| Travel Motor Repair | 143-176 | Travel Motor Disassembly, Brake Discs, Brake Piston, Distributor Housing, Motor Sealing |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Steering charge pump displacement | 8 cm3/rev. | p. 27 |
| Steering valve displacement | 80 cm3/rev. | p. 27 |
| BW 100 AD-3, BW 120 AD-3 | ||
| Fuel tank capacity | 35L | p. 24 |
| Engine oil capacity | 6.5L | p. 24 |
| Hydraulic oil tank capacity | 28L | p. 24 |
| Water tank capacity | 180L | p. 24 |
| Travel pump high pressure setting | 385 bar | p. 23 |
| Steering valve pressure setting | 200 bar | p. 24 |
| Brake releasing pressure | 12 bar | p. 24 |
| BW 125 ADH, BW 135 AD | ||
| Fuel tank capacity (BW 125 ADH / BW 135 AD) | 55L | p. 30 |
| Hydraulic oil tank capacity (BW 125 ADH / BW 135 AD) | 32L | p. 30 |
| Water tank capacity (BW 125 ADH / BW 135 AD) | 230L | p. 30 |
Bomag BW 100–120 AD/AC-3 Series Common Problems This Manual Covers
Roller creeps with levers in neutral
A tandem roller that inches forward at idle usually needs the travel pump neutral position reset. The Tests and Adjustments section covers mechanical neutral position setting along with travel circuit pressure tests to confirm the pump is healthy.
Manual Section: Tests and Adjustments p. 18Weak or no travel drive
Low charge pressure or worn pump internals show up as sluggish travel on grades or no drive at all. Travel Pump Repair walks the teardown in order: high pressure relief valves, charge pressure relief valve, cylinder block and servo control.
Manual Section: Travel Pump Repair p. 127No vibration or noisy vibrator shaft
Vibrator shaft bearings run hot and fail, and a drum that rumbles or stops vibrating mid pass points there. The Drum Repair section walks through drum removal, vibrator shaft disassembly, bearing covers and the rubber buffers.
Manual Section: Drum Repair p. 91Play in the articulated joint
Worn bearing blocks in the center joint show up as clunking on direction changes and a rear drum that no longer tracks the front. Joint removal, bearing blocks, the rocker bearing and the oscillation axle all sit in Oscillating Articulated Joint Repair.
Manual Section: Oscillating Articulated Joint Repair p. 111Parking brake will not release
A dragging or locked drum often traces to the wet brake inside the travel motor rather than the drum itself. Travel Motor Repair breaks down the brake discs, brake piston, distributor housing and motor sealing.
Manual Section: Travel Motor Repair p. 143Contaminated oil after a component failure
When a pump or motor lets go, debris circulates through the whole closed loop and takes out the replacement if you skip flushing. The Flushing Procedures section gives the flushing schematic, travel and vibration circuit flushing, filter installation and bleeding.
Manual Section: Flushing Procedures p. 41Hard steering or steering drift
Steering complaints on these rollers call for pressure checks before parts get swapped. Steering system pressure tests are in Tests and Adjustments, and the Trouble Shooting section includes a dedicated chart for steering system faults.
Manual Section: Trouble Shooting p. 62Frequently Asked Questions
Which Bomag models does this repair manual cover?
It covers the BW 100 AD-3, BW 120 AD-3, BW 100 AC-3 and BW 120 AC-3 tandem vibratory rollers, all four with the Deutz F2L 1011 engine. The same file also carries the technical data of the BW 125 ADH, BW 135 AD and BW 138 AD with the F3L 1011 F. Check your type plate against this list before buying. p. 23
Does it include hydraulic pressure test values?
Yes. The Tests and Adjustments section gives test procedures and settings for the travel, vibration and steering circuits, including a 385 bar travel pump high pressure setting and a 200 bar steering valve setting for the BW 100 AD-3 and BW 120 AD-3. p. 18
Does it cover replacing the drum vibrator shaft bearings?
Yes. The Drum Repair section covers drum removal and installation, vibrator shaft disassembly, bearing covers and rubber buffers, and lists a vibrator shaft end float of 0.52 mm to 2.20 mm so you can shim it correctly on assembly. p. 91
What should I do to the hydraulic system after a pump or motor failure?
Flush it before running the new component. p. 41
Is this Bomag BW 100 AD-3 manual a PDF I download?
You download the Repair Manual yourself: 176 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Does this Bomag BW 100 AD-3 manual allow printing?
Yes. No DRM, nothing blocks printing, so run off the pages you need on whatever printer you have.
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