Straight from Bomag's own press, document number 008 127 21 is the factory operator manual for the BW 100 and 120 AD-3 and AC-3 series, four models spanning tandem vibratory and combination rollers, and this Bomag BW 120 AD-3 operator manual PDF gives you all 88 pages of it. Daily checks before starting, jump-wire starts, switching vibration and the three sprinkling systems, towing, transport tie-down, and the foldable ROPS each get their own procedure. Maintenance fills the largest part of the book: fuels, lubricants and filling capacities, the service chart, and jobs from adjusting scrapers to changing hydraulic oil. Torque the brake release screws to 35 Nm before you tow, and set V-belt deflection at 10 to 15 mm. Every hour a roller sits at the edge of the mat costs the whole train. Print what you need and let the pages take the grease; bookmarks keep the file itself in order.
What's Inside This Bomag BW 100 AD-3, BW 120 AD-3, BW 100 AC-3, BW 120 AC-3 Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Data | 7-12 | Dimensions, Weights, Engine, Brakes, Steering, Vibration System |
| Safety Regulations | 13-20 | General Notes |
| Indicators and Controls | 21-32 | Description of Indicators and Control Elements |
| Operation | 33-50 | Inspections Before Starting Operation, Starting the Engine, Starting with Jump Wires, Driving the Machine, Stopping the Machine / Applying the Brake |
| Maintenance | 51-82 | Fuels and Lubricants, Fuels, Lubricants and Filling Capacities, Running-In Instructions, Maintenance Chart, Check the Engine Oil Level, Checking the Dry Air Filter |
| Trouble Shooting | 83-88 | General Notes, Engine Problems |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Torque for brake release screws | 35 Nm | p. 45 |
| Torque for brake release plugs | 20 Nm | p. 46 |
| V-belt deflection | 10-15 mm | p. 70 |
| Acid level without control inserts | 10-15 mm | p. 65 |
| Engine Oil Capacity | 6.5L | p. 55 |
| Fuel Tank Capacity | 35L | p. 55 |
| Hydraulic System Oil Capacity | 28L | p. 55 |
| Water Tank Capacity | 180L | p. 55 |
| Emulsion Tank Capacity | 20L | p. 55 |
| Intake Valve Clearance | 0.3mm | p. 68 |
| Exhaust Valve Clearance | 0.5mm | p. 68 |
| Tire Pressure | 2.2 bar | p. 79 |
Bomag BW 100 AD-3, BW 120 AD-3, BW 100 AC-3, BW 120 AC-3 Common Problems This Manual Covers
Bomag BW 120 AD-3 engine oil pressure warning light comes on while the roller is working
Shut the engine down and check the oil level on the dipstick before anything else; do not restart until it reads between the marks. Top up with the grade listed on page 55; total capacity is 6.5 liters from dry. Inspect under the engine for fresh leaks, then work through the engine fault chart on page 85.
Manual Section: Engine Problems p. 85Engine loses power and blows dark exhaust smoke under load on the mat
Check the dry air filter cartridge and clean or replace it before chasing anything else. Inspect the V-belt next and adjust tension until deflection measures 10 to 15 mm at mid-span (page 70). Verify the crankcase is not overfilled and clear the cooling air intake of debris before the next pass.
Manual Section: Engine Problems p. 85Vibration will not switch on, drums roll but no amplitude at the mat
Verify the vibration switch and travel lever button engage with the engine at full throttle; low rpm will not drive the exciter. Check the fuse and the plug connector at the vibration control valve solenoid for corrosion. Nominal frequency is 55/66 Hz (page 9); if it never gets there, hand it to service and keep rolling static.
Manual Section: Trouble Shooting p. 83Engine cranks slowly or will not turn over on cold morning starts
Check the battery terminals for corrosion, then clean and grease the poles as shown on page 65. Verify the acid level sits 10 to 15 mm above the plates in each cell and top up with distilled water only. If the battery checks good, jump start with wires per the operation section rather than cranking it flat.
Manual Section: Battery Maintenance p. 65Rubber tires scrub or bounce on the combination roller during finish passes
Check tire pressure on all rubber tires before the shift while they are cold; the nominal value is approximately 2.2 bar (page 79). Inflate every tire to the same pressure, since one soft tire changes the kneading action across the mat. Inspect the valve stems and caps while you are down there.
Manual Section: Tire Pressure p. 79Water spray system stops misting and asphalt picks up on the drum
Check the water tank level first; it holds 180 liters (page 55) and runs dry faster than you think on a hot mat. Clean plugged spray nozzles and check the scraper bars for wear while the drum is wet. In freezing weather, drain the sprinkler system completely at shutdown so the lines do not split.
Manual Section: Water Sprinkler SystemFrequently Asked Questions
What are the replacement specifications for the air filter cartridge?
The dry air filter element must be changed after 5 times of cleaning, but at the latest after 1 year. Each cleaning interval must be marked with a cross on the cover of the filter element. p. 79
What are the replacement specifications for the fuel filter?
The fuel filter cartridge should be changed every 1000 operating hours. When changing, loosen and unscrew the cartridge using a suitable filter wrench, clean the sealing face, and apply some oil to the rubber seal of the new cartridge before tightening it hand tight. p. 72
What is the specified valve clearance for the engine?
The intake valve clearance is 0.3 mm and the exhaust valve clearance is 0.5 mm. These adjustments must be performed only when the engine is cold. p. 68
What is the engine oil capacity for the BW 100/120 AD/AC-3?
The engine oil capacity is approximately 6.5 litres (1.7 USgal). Always observe the level marks on the dipstick when filling. p. 55
What is the tightening torque for the plugs after towing?
After towing, the plugs must be tightened to 20 Nm. p. 46
What do I get after purchasing this Bomag BW 100 AD-3 manual?
An 88-page Operator Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Is printing allowed for this Bomag BW 100 AD-3 Operator Manual?
Print away. There is no DRM and no page limit. Many buyers print one chapter at a time and leave the rest on a tablet.
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