When the paving train is waiting on density and the roller shuts down mid-mat, this 822-page Bomag BW 120 SL-5 service manual PDF (OEM 008 401 24 EN) provides the factory data to get your BW 100 and 120 AD-5, AC-5, and SL-5 tandem vibratory rollers moving again. Detailed hydraulic schematics trace the closed-loop travel and vibration circuits so you can accurately diagnose pressure losses. The troubleshooting chapters cover the entire electrical system, including CAN bus networks and central electrics, backed by clear wiring diagrams to pinpoint sensor faults. During reassembly, secure the drum drive motor using a mounting torque of 211 Nm and confirm the main battery fuse is rated at 80 A. There is nothing worse than being alone with a dead machine and no one on the crew to ask for help, but buying this searchable, bookmarked file means the exact answers are yours to keep for the life of the roller.
What's Inside This Bomag BW 100/120 AD-5, AC-5 and SL-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 9-56 | Introduction |
| Technical Data | 57-86 | Bw 100 Ad-5 (Technical Data), Bw 100 AC-5 (Technical Data), Technical Data Bw 100 Sl-5 (Noise and Vibration Data), Bw 120 Ad-5 (Technical Data), Bw 120 AC-5 (Technical Data) |
| Electric Systems | 103-176 | Overview of Electric System, Table of Fuels and Lubricants, Wiring, CAN Bus Overview, Central Electrics |
| Diesel Engine | 177-214 | Overview of Diesel Engine, Kubota Diesel Engine, Checking the Compression, Checking the Engine Oil Pressure, Checking the Thermostat in Disassembled State |
| Hydraulic System | 215-304 | Overview of Hydraulics, Open and Closed Hydraulic Circuit |
| Drum | 305-324 | Edge Cutter, Overview Drum, Removing and Installing the Drum, Dismantling the Drum, Assembling the Drum |
| Rubber Tires | 325-326 | Maintenance Work (Maintenance Table, Checks Prior to Start Up) |
| Scrapers | 327-330 | Maintenance Work (Scrapers, Checks Prior to Start Up) |
| Oscillating Articulated Joint | 331-340 | Overview Oscillating Articulated Joint, Disassembling the Oscillating Articulated Joint, Repairing the Oscillating Articulated Joint, Installing the Oscillating Articulated Joint |
| Troubleshooting | 341-394 | Preliminary Remarks |
| Disposal | 395-396 | Final Shut-Down of Machine |
| Special Tools | 397-402 | Electrics |
| Supplier Documentation: Travel Pump | 415-472 | Travel Pump Repair Instructions |
| Supplier Documentation: Drum Drive | 473-536 | Drum Drive Repair Instructions |
| Supplier Documentation: Wheel Drive | 537-753 | Wheel Drive Repair Instructions, General Repairs, Brake, Valving, Torque |
| Supplier Documentation: Steering Valve | 754-768 | Steering Valve Repair Instructions |
| Circuit Diagrams | 769-822 | Hydraulic Schematic, Electrical Wiring, CAN Bus, Fuse Assignment, Control Elements |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Drum drive motor mounting torque | 211 Nm | p. 97 |
| Main fuse | 80A | p. 109 |
| Main battery fuse | 80 A | p. 135 |
| Tightening torque for Telemecanique switch screw | 0.6 Nm | p. 171 |
| V-belt depression | 7 to 9 mm (0.28 – 0.35 inch) | p. 202 |
| Valve clearance (Intake / exhaust valve) | 0.18 mm to 0.22 mm (0.007 in to 0.009 in) | p. 206 |
| Maximum air pressure for cleaning | 2.1 bar (30 psi) | p. 212 |
| Engine Oil Capacity | 6.5L | p. 55 |
| Fuel Tank Capacity | 35L | p. 55 |
| Coolant Capacity | 6L | p. 55 |
| Hydraulic System Oil Capacity | 35L | p. 55 |
| Valve Clearance Intake | 0.18-0.22 mm | p. 84 |
Bomag BW 100/120 AD-5, AC-5 and SL-5 Common Problems This Manual Covers
Bomag BW 100 AD-5 engine won't start in cold weather or turns over very slowly
Check the main battery fuse on page 135 and verify it has an 80 A rating. Inspect the fuel system for paraffin separation. Drain any gelled diesel, replace the fuel filter, and top off the 35L fuel tank to get the roller back on the pass.
Manual Section: Electric Systems p. 135Economizer LED flashes after vibration engages and measured compaction values are implausible
Inspect the acceleration sensor mounting on the drum. Tighten the rubber buffer fastening screws to 211 Nm as shown on page 323. Check the sensor cable for breaks. Clear any dirt from the mount using a maximum air pressure of 2.1 bar (30 psi).
Manual Section: Drum p. 323Roller does not move forward or travel is blocked when shifting the drive lever
Verify the brake solenoid reaches its target value. Inspect the tandem gear pump and closed-loop travel motors. If replacing the drum drive motor, torque the mounting bolts to 211 Nm as specified on page 97. Confirm the hydraulic system oil capacity is at 35L before testing.
Manual Section: General p. 97Diesel engine shuts down during a heavy compaction pass or loses power under load
Measure the V-belt depression on page 202 to confirm it sits between 7 to 9 mm. Adjust the tension if slipping occurs under load. Check the intake and exhaust valve clearance, setting both to exactly 0.18 mm to 0.22 mm while the engine is cold.
Manual Section: Diesel Engine p. 202Frequently Asked Questions
What are the replacement specifications for the fuel filter?
The fuel pre-filter should be replaced every 500 operating hours. When installing the new filter, ensure the flow direction matches the arrow on the filter housing. p. 203
What is the recommended engine oil viscosity for ambient temperatures between -10 °C and 25 °C?
For ambient temperatures between -10 °C (14 °F) and 25 °C (77 °F), the recommended engine oil viscosity classes are SAE 10W-30 or SAE 15W-40. p. 51
What is the tightening torque for the M12 counter nut on the bypass valve?
The tightening torque for the counter nut on the bypass valve is 22 Nm. p. 225
What is the procedure for bleeding the travel circuit?
To bleed the travel circuit, install pressure test hoses to the charge pressure and high pressure test ports, hold the open ends in a container, and operate the starter for 30 seconds. Repeat this until oil runs out from the hoses, then remove the hoses and unlock the emergency stop switch. p. 296
What is the nominal injection valve opening pressure for the BW100 to BW138-5 models?
The nominal injection valve opening pressure for the BW100 to BW138-5 models is 137.3 to 147.0 bar. p. 189
What do I get after purchasing this Bomag BW 100 AD-5 manual?
One searchable PDF covering 822 pages, delivered instantly. No disc, no shipping, no waiting on the post.
Is printing allowed for this Bomag BW 100 AD-5 Service Manual?
Yes, printing is unrestricted: a single page, a chapter, or the lot, on letter or A4.
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