This is the factory service manual for the Bomag BW 100 AD-5, BW 120 AD-5, BW 100 AC-5 and BW 120 AC-5, the 5-series light tandem rollers (AD) and combination rollers with rear tires (AC). It covers the Kubota D1803 engine (25.0 kW at 2400 rpm), the CAN BUS electrics with J1939 SPN fault codes on the instrument cluster (fault code display p.185, full engine diagnostics chapter from p.413), the hydrostatic travel circuit with the A10VG28 pump, drum removal and rebuild, the oscillating articulated joint, and the water sprinkler system (205 l on AD, 160 l plus 45 l emulsion on AC). Wiring and hydraulic diagrams are in the appendix, including circuit diagram 317 and hydraulic diagram 362.
What's Inside This Bomag BW 100 AD-5, BW 120 AD-5, BW 120 AC-5, BW 100 AC-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 9-58 | Concerning Your Safety, General Prerequisites, Definition of Responsible Persons, Fundamentals for Safe Operation, Handling Fuels and Lubricants, Parking the Machine in Secured Condition, What to Do in Events of Emergency |
| Technical Data | 59-78 | Bw 100 Ad-5, Bw 100 AC-5, Bw 120 Ad-5, Bw 120 AC-5, Additional Technical Data |
| Overview of Machine | 79-94 | - |
| Electric Systems | 95-164 | Overview of Electric System, Table of Fuels and Lubricants, Wiring, CAN BUS Overview, Central Electrics, Fuse Assignment, Notes on Safety |
| Diesel Engine | 165-234 | Overview of Diesel Engine, CAN BUS Overview, Features, Cooling System, Fuel System, Engine Control, Fault Code Display |
| Hydraulic System | 235-324 | Overview of Hydraulics, Open and Closed Hydraulic Circuit, Hydraulic Units, Travel Pump, A10VG28 Hw, Swash Plate Principle, Pump, Drum Drive Motor MK 04, Wheel Drive Motor, Ms/Mse |
| Drum | 325-344 | Edge Cutter, Overview Drum, Removing and Installing the Drum, Dismantling the Drum, Assembling the Drum |
| Rubber Tires and Scrapers | 345-350 | Inspection and Maintenance Work, Maintenance Table, Checks Prior to Start Up |
| Oscillating Articulated Joint | 351-360 | Overview Oscillating Articulated Joint, Disassembling the Oscillating Articulated Joint, Repairing the Oscillating Articulated Joint, Installing the Oscillating Articulated Joint |
| Troubleshooting - Emergencies | 361-370 | What to Do in Events of Emergency, Actuating the Emergency Stop Switch, Disconnecting the Battery, Towing the Machine, After Towing, AD-machine, AC-machine |
| Troubleshooting - Electrical Systems | 371-402 | Troubleshooting, Electrical Systems, Starting the Engine with Jump Leads, Fuse Assignment, Trouble Shooting "Starter", Instrument Cluster (A15), Trouble Shooting Economizer, The Machine Does Not Drive |
| Troubleshooting - Hydraulics | 403-412 | Trouble Shooting, Hydraulics, Insufficient Hydraulic Power, Trouble Shooting Axial Piston Pumps, The Machine Does Not Drive, Insufficient Travel Power, Check the Parking Brake |
| Troubleshooting - Diesel Engine | 413-732 | Trouble Shooting, Diesel Engine, Fault Code Display, Diagnostics Manual |
| Disposal and Special Tools | 733-740 | Final Shut-Down of Machine, Special Tools, Hydraulic System, Tests and Adjustments, Special Tools for Flushing, Electrics |
| Index | 741-750 | - |
| Appendix - Travel Pump | 751-810 | A Supplier Documentation |
| Appendix - Drum Drive | 811-874 | - |
| Appendix - Wheel Drive | 875-1091 | - |
| Appendix - Steering Valve | 1092-1106 | - |
| Appendix - Circuit Diagrams | 1107-1158 | B Circuit Diagrams, Hydraulic Diagram 362, Circuit Diagram 317 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Kubota D1803, 25.0 kW (33.5 hp) at 2400 rpm | p. 61 |
| Operating weight with ROPS (CECE), BW 100 AD-5 | 2500 kg (5512 lbs) | p. 61 |
| Operating weight with ROPS (CECE), BW 100 AC-5 | 2300 kg (5071 lbs) | p. 65 |
| Operating weight with ROPS (CECE), BW 120 AD-5 | 2700 kg (5953 lbs) | p. 69 |
| Travel speed | 0-10 km/h | p. 61 |
| Amplitude, BW 100 AD-5 | 0.5 mm | p. 62 |
| Fuel capacity | 35 litres | p. 62 |
| Water capacity, BW 100 AD-5 | 205 litres | p. 62 |
| Water + emulsion capacity, BW 100 AC-5 | 160 litres + 45 litres emulsion | p. 67 |
| Charge pressure relief valve (troubleshooting example) | 30 bar | p. 403 |
Bomag BW 100 AD-5, BW 120 AD-5, BW 120 AC-5, BW 100 AC-5 Common Problems This Manual Covers
Engine will not start or starts poorly, especially in cold weather
Work the fuel side first: filter, lines, water separator and winter fuel, all covered in the fuel system section of the Diesel Engine chapter. The electrical troubleshooting chapter then covers starter diagnosis, fuse assignment and starting with jump leads when the battery is down.
Manual Section: Diesel Engine, Fuel system / Troubleshooting - Electrical Systems p. 413Engine overheats or shuts down after a short run
The cooling system section of the Diesel Engine chapter covers the radiator, coolant circuit and belt drive on the Kubota D1803. On these small rollers packed fins and a slipping V-belt cause most overheating, so start there before condemning the thermostat or the engine.
Manual Section: Diesel Engine, Cooling system p. 178Machine does not drive, or travel power fades
Follow 'The machine does not drive' in the hydraulics troubleshooting chapter: run the travel circuit pressure tests from section 6.11.2 (p.287), verify charge pressure against the 30 bar relief value, and check the parking brake, since correct pressure with no motion points at the brake, not the pump.
Manual Section: Troubleshooting - Hydraulics p. 403Vibration will not engage or the ECONOMIZER acts up
The electrical troubleshooting chapter has a dedicated ECONOMIZER section plus instrument cluster (A15) diagnosis. A loose acceleration sensor or jumpy running on hard ground triggers most of these complaints, so check sensor mounting before chasing wiring or replacing control parts.
Manual Section: Troubleshooting - Electrical Systems, ECONOMIZER p. 371Frequently Asked Questions
The instrument cluster is showing a fault code. Does this manual tell me what it means?
Yes. These 5-series machines report engine faults as J1939 SPN codes on the cluster. Section 5.6.1 (p.185) explains the fault code display, and the engine diagnostics chapter starting at p.413 walks each code through to a cause. That chapter alone runs over 300 pages, which is most of what a dealer tech would be reading off the same code. p. 185
My roller drives fine cold, then loses travel after it warms up. Will this manual help?
This exact complaint shows up on these machines and it is usually electrical or a travel control fault, not a worn pump. The manual has 'The machine does not drive' worked through twice, once in the electrical troubleshooting chapter (starter, instrument cluster A15, fuse assignment) and once in the hydraulics chapter, so you can split the problem between wiring and the hydrostatic circuit instead of guessing. p. 403
Can I actually test the hydrostatic drive, or does it just say replace the pump?
You can test it. Section 6.11.2 (p.287) gives the pressure tests in the travel circuit, and the troubleshooting chapter uses real numbers, for example the charge pressure relief valve at 30 bar (p.403). With a gauge and those values you can tell a tired charge pump from a stuck brake before spending pump money. p. 287
Does it cover the AC combination rollers with tires, or only the tandem drum machines?
Both. The AC variants (front drum, rear rubber tires, emulsion sprinkler) get their own technical data, the MS/MSE wheel drive motor section, tire and scraper maintenance, and separate towing procedures, since freewheeling an AC machine after towing is not the same job as on an AD. p. 65
Is drum removal and the articulated joint rebuild actually documented, or just exploded views?
Documented as procedures. The drum chapter covers removing, dismantling and reassembling the drum, plus the edge cutter (section 7.1, p.326). The oscillating articulated joint gets its own chapter with disassembly, repair and installation, which matters because a sloppy joint on these small tandems shows up as wander and mat marks. p. 325
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