Rebuilding an A10VG travel pump is the hardest job in this book, and this Bomag BW 120 AD-3 repair manual PDF (OEM 008 193 71) walks it bolt by bolt across 220 pages covering four BW-3 machines, tandem vibratory and combination rollers both. Hydraulic schematics trace the travel, vibration and steering circuits, and the flushing section carries you from schematic through filter installation to a fully bled system. Troubleshooting diagrams take up a solid stretch of the middle, working drive power, steering and vibration faults down to a cause, while drum, vibrator shaft, articulated joint and MK04 motor repairs fill the back half. Verify charge pressure between 18 and 26 bar, and hold the travel pump at 390 to 440 bar before condemning either pump. A roller that quits vibrating mid-lift stalls the whole crew. Bookmarked and text-layered, the PDF is yours right after checkout, and the machine back in the pass soon after.
What's Inside This Bomag BW 100 AD-3, BW 120 AD-3, BW 100 AC-3, BW 120 AC-3 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety Regulations | 7-10 | General Safety, Hydraulic System Safety |
| General Notes on Repair | 11-12 | General Repair Procedures, Electrical System Repair |
| Tightening Torques | 13 | Metric Unified Threads |
| Travel Pump Connection Overview | 14-16 | Travel Pump Ports, Pressure Test Ports, Flushing Valve, Charge Pressure Relief Valve |
| Tests and Adjustments | 17-36 | Rotary Speed Checks, Travel Circuit Pressure Tests, Vibration Circuit Pressure Tests, Neutral Position Adjustment, Steering Circuit Pressure Tests |
| Flushing Procedures | 37-58 | Flushing Schematics, Travel Circuit Flushing, Vibration Circuit Flushing, Filter Installation, Bleeding Procedures |
| Trouble Shooting | 59-84 | Trouble Shooting Diagrams, Hydraulic System Faults, Steering Function Issues, Drive Power Issues, Vibration System Faults |
| Drum Repair | 85-104 | Drum Removal, Drum Installation, Vibration Motor Disassembly, Vibrator Shaft Disassembly, Bearing Cover Disassembly |
| Oscillating Articulated Joint Repair | 105-120 | Joint Removal, Joint Installation, Joint Disassembly, Joint Assembly, Tapered Roller Bearing Adjustment |
| Hydraulic Pump Repair (A10VG) | 121-168 | Pump Sectional View, Drive Shaft Sealing, Boost Pump Sealing, Control Unit Removal, Pump Disassembly, Tightening Torques |
| Hydraulic Motor Repair (MK04) | 169-220 | Motor Identification, Motor Replacement, Mechanical Brake Release, Sealing Ring Replacement, Brake Disc Replacement, Sensor Replacement |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Charge pressure | 18 ... 26 bar | p. 45 |
| Steering/charge pump nominal pressure | approx. 200 bar | p. 69 |
| Travel pump nominal pressure | 390 ... 440 bar | p. 72 |
| Control chamber pressure nominal value | approx. 15 bar | p. 71 |
| Vibration motor leakage rate nominal value | max. 0.5 l/min | p. 21 |
| Fuel tank capacity | 35L | p. 22 |
| Hydraulic oil tank capacity | 28L | p. 22 |
| Water tank capacity | 180L | p. 22 |
| Engine idle speed | 975 rpm | p. 21 |
| Engine high idle speed | 3010 rpm | p. 21 |
| Travel pump displacement | 28 cm3 | p. 21 |
| Vibration pump displacement | 11 cm3/rev | p. 21 |
Bomag BW 100 AD-3, BW 120 AD-3, BW 100 AC-3, BW 120 AC-3 Common Problems This Manual Covers
Bomag BW 100 AD-3 loses travel drive after hydraulic oil warms up, works fine cold
Connect a gauge to the charge pressure test port on the travel pump, connection overview on page 14, and work the machine until the fault shows. Charge pressure must hold 18 to 26 bar hot, spec on page 45. If it sags warm, inspect the charge pressure relief valve and flushing valve before condemning the pump.
Manual Section: Trouble shooting diagrams: Charge pressure relief valve and flushing valve p. 45Vibration will not switch on or drum amplitude feels weak at full throttle
Check the vibration solenoid first; verify the coil pulls in at the control block before pulling hoses. Run the vibration circuit pressure test from the procedures starting on page 17, then measure vibration motor case drain leakage: anything over 0.5 l/min, listed on page 21, means a worn motor. Confirm both before ordering parts.
Manual Section: Trouble shooting diagrams: Vibration system p. 79Roller creeps forward on the mat with travel lever sitting in neutral
Check the travel control cable for a sticking or kinked sheath first. Adjust the mechanical 0-position of the lever linkage, then set the hydraulic 0-position at the pump servo. Verify control chamber pressure sits near the 15 bar nominal value on page 71 while centering, so the pump truly destrokes in neutral.
Manual Section: Trouble shooting diagrams: The machine drives with travel lever in NEUTRAL p. 66Drive power drops on grades, engine revs fine but machine barely climbs the ramp
Verify engine speeds before touching hydraulics: 975 rpm at idle and 3010 rpm at high idle, specs on page 21. Check the travel control cable reaches full stroke, then gauge high pressure; the travel pump relief setting is 390 to 440 bar, listed on page 72. Test charge pressure hot, since low charge cuts pump displacement.
Manual Section: Trouble shooting diagrams: Insufficient drive power p. 73Hydraulic oil overheats halfway through the shift, travel and vibration both fade
Clean the cooler fins and replace the hydraulic filter and tank breather before anything else. Drain the tank if the oil smells burnt; it holds 28 liters, capacity on page 22. Flush the travel and vibration circuits following the procedures starting on page 37, because contaminated oil after an overheat takes the pump out next.
Manual Section: Flushing Procedures p. 37Brakes drag or will not release, drum scuffs the fresh asphalt when driving
Test brake release pressure at the travel motor; it takes approx. 12 bar to lift the brake, spec on page 22. Check magnetism at the brake valve coil with the travel lever out of neutral. If the coil is dead or pressure stays low, work through the brake release pressure diagram on page 63 before splitting the motor.
Manual Section: Trouble shooting diagrams: Brake release pressure p. 63Frequently Asked Questions
What are the tightening torque specifications for M10 bolts with 8.8 strength classification?
For bolts with metric unified threads and a strength classification of 8.8, the tightening torque for an M10 bolt is 50 Nm (37 ft-lb). p. 13
What is the nominal high idle speed for the diesel engine?
The nominal high idle speed for the diesel engine is 2950 to 3100 rpm. p. 27
What is the maximum leak oil rate for the vibration motor?
The maximum leak oil rate for the vibration motor is approximately 0.5 litres/min. p. 21
What is the nominal charge pressure for the travel circuit at high idle?
The nominal charge pressure for the travel circuit at high idle is 18 to 26 bar. p. 28
What is the required tightening torque for the drum drive motor rubber buffers?
The rubber buffers for the drum drive motor should be fastened with a torque of 211 Nm. p. 103
What exactly do I receive with this Bomag BW 100 AD-3 Repair Manual?
All 220 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Am I free to print this Bomag BW 100 AD-3 Repair Manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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