Description

Bomag BW 100 AD-3, BW 120 AD-3, BW 100 AC-3, BW 120 AC-3 2000 Repair Manual

You get a Bomag BW 100 AD-3, BW 120 AD-3, BW 100 AC-3, BW 120 AC-3 2000 Repair Manual on your bench. No service history, customer waiting, and you’re staring at a tandem vibratory roller that won’t move. Pulling specs from memory or a third-party copy is how you end up with stripped threads and a come-back. This factory OEM manual from 2000 runs 220 pages and covers the AD-3 and AC-3 variants. It’s the only documentation that matches the production tolerances of these machines. I carry a paper copy in my toolbox for the 100 AD-3 jobs that roll through my San Antonio shop.

Safety Regulations and General Notes on Repair

Section 1.02 “Safety regulations” is not optional reading. It spells out lockout/tagout procedures for the hydraulic system and drum drive. Section 1.03 “General notes on repair” tells you which seals need replacing when you split the gearbox, and the exact cleaning procedure before reassembly. Skip these and you’re risking a 2,000‑lb drum dropping on your foot or contamination that kills a bearing in 50 hours.

What the Table of Contents Covers

The manual opens with a foreword (1.01), then goes straight into safety and repair notes. Section 1.04 “Tightening torques” gives you the factory numbers for every fastener on the vibration system and travel drive. Section 1.05 “Connection overview” is the wiring and hydraulic line routing that saves you an hour of tracing. These five sections (1.01–1.05) are the core of the whole manual. You get the same structure Bomag ships to its dealer network.

Audience Fit – Who Works on These Rollers?

If you own a BW 100 AC-3 or BW 120 AD-3, you are the audience. Home-garage enthusiasts who maintain their own compactors need this manual because the aftermarket stuff leaves out the safety lockout steps. Professional shops that see a Bomag twice a year need it to avoid billing the customer for guesswork. The manual assumes you know which end of a wrench to use, but it holds your hand through unfamiliar assemblies like the Manual Transmission on the AD‑3 models. Manual transmission tear-downs are rare on rollers – this manual makes them predictable.

Source Authenticity – OEM vs Aftermarket Reprints

Bomag printed this manual in August 2000 (part number 008 193 71). It is not a scan of a scan. Every page is from the original digital file – the same file used to print dealer copies. Aftermarket binders often omit section 1.04 “Tightening torques” or rewrite the safety warnings to reduce liability. This manual has the full torque table in Nm, the hydraulic connection diagrams, and the serial number ranges that tell you whether your machine is covered (S/N 101 150 51 33 47 > for the BW 100 AD‑3; S/N 101 150 61 10 51 > for the BW 120 AD‑3, etc.). You don’t get that from a $9 access on a third‑party site.

3 Sections That Keep You Out of Trouble

First, the tightening torque table. Second, the safety regulations that cover hydraulic accumulator depressurization. Third, the connection overview (section 1.05) – it shows the routing of the hydrostatic hoses so you don’t cross‑thread a fitting. Go through these three before you touch a bolt. One of my techs ignored the torque spec on a drum motor mount and cracked the casting. That repair cost more than a hundred copies of this manual.

Does this manual include wiring diagrams for the vibratory system?

No. The connection overview (1.05) covers hydraulic and electrical routing but not full schematics. For wiring, you need the separate Bomag electrical manual. This repair manual focuses on mechanical disassembly, reassembly, and torque specs.

How do I know this manual matches my specific machine?

The cover lists four models: BW 100 AD‑3, BW 120 AD‑3, BW 100 AC‑3, BW 120 AC‑3. Inside, the serial number ranges are printed on page 1 of the manual. If your machine’s S/N falls within the ranges listed (e.g., S/N 101 170 51 49 67 > for the BW 100 AC‑3), you’re covered. The manual is dated 08/2000 and applies to those production runs. Later production may have changes not reflected here.

Access the factory manual and get the same document Bomag dealers use. You will find the torque specs, safety steps, and connection diagrams that keep your roller running without comebacks. Pair it with the Bomag MPH 100 R/S 1999 Repair Manual – Factory OEM Shop Manual or the Bomag BC 571/671/771 RB 1998 Repair Manual – OEM Factory Specs if you have other Bomag equipment. The Bomag BW177, DH, PDH, 40 2010 Repair Manual – OEM Specs is newer but follows the same format. For the Manual Transmission specifics on the AD‑3 models, refer to the external article linked above.