Description

Bomag BW 100 AD-5, BW 100 AC-5, BW 120 AD-5, BW 120 AC-5 2014 Service Manual

If you are wrenching on a Bomag tandem vibratory roller and you don’t have the factory manual, you are working blind. I have seen guys snap off hydraulic fittings because they guessed the torque. That costs hours and money. This 244-page Bomag BW 100 AD-5, BW 100 AC-5, BW 120 AD-5, BW 120 AC-5 2014 Service Manual is the same document the dealer uses. No aftermarket guesswork.

Technical Data: Noise and Vibration Characteristics

Each model variant gets its own datasheet. Section 2 breaks out the BW 100 AD-5, BW 100 AC-5, BW 120 AD-5, and BW 120 AC-5 separately. You get operating weight, drum dimensions, vibration frequency, centrifugal force, and sound pressure levels. Page 13 is where the numbers start. If you are replacing a bearing or checking structural fatigue, those vibration specs tell you what the machine was designed to handle.

What Does the Safety Section Cover?

Section 3 is 30 pages of safety norms. I don’t care if you have been running rollers for 20 years — read it. It covers proper lifting points, hot surface warnings, hydraulic pressure hazards, and lockout procedures. One mistake with a pressurized hydraulic line can blind you. This section tells you how to depressurize before you touch a fitting.

3 Key Maintenance Intervals

The maintenance table in section 7.5 is your checklist. Engine oil change at 50 hours, then every 200 hours. Hydraulic oil filter replacement at 500 hours. Coolant change at 1000 hours. The break-in instructions on page 7.4 specify after 50 hours you must retorque the wheel nuts and check all fasteners. Skip that and you will have loose parts on site.

Get the Right Fluid Specs

Section 7.2 lists the exact oils and coolants Bomag approves. Engine oil viscosity, diesel fuel quality, winter fuel requirements, and hydraulic oil types — mineral-based or biodegradable. Use the wrong hydraulic fluid and you can damage seals or void the warranty. Page 37 references the safety data, but the fluid specs are in the maintenance chapter. Stick to what the factory says.

Hydraulic Oil: Mineral vs. Biodegradable

If you are working in an environmentally sensitive area, the manual covers biodegradable hydraulic oil (section 7.2.4.2). The viscosity grades are different from standard mineral oil. Do not mix them. The table on page 7.3 shows all approved fluids in one chart. That saves you from cross-referencing separate spec sheets.

Electronic Immobilizer and Controls

Section 5.3 covers the electronic immobilizer. If the machine won’t start, the immobilizer might be the issue, not the engine. Section 4 describes the control panel and combined instrument cluster. Knowing what each warning light means keeps you from chasing phantom problems. The wiring information is embedded in these sections — treat it like a schematic even if it isn’t a full electrical diagram.

This manual is factory original. I have seen aftermarket manuals that omit torque sequences or list the wrong oil capacity. Bomag’s own document does not cut corners. Every bolt torque, every fluid fill, every adjustment procedure is verified by the engineers who built the machine.

Skip the aftermarket knockoffs.

For related equipment, see the Bomag BW 219 D-4 PD-4 2007 Service Manual – 840 Pages of Factory Specs for larger tandem rollers, or the Bomag BMP 8500 2010 Service Manual – Factory Control Diagnostics for walk-behind models. For an older single-drum compactor, check the Bomag BW 62 H, BW 65 H 2006 Service Manual – Factory Specs.

If you want to understand how hydrostatic drive compares to a Manual Transmission, that background helps when diagnosing drivetrain issues. Similarly, the difference between a torque converter and a Manual Transmission is worth knowing if you ever service the travel drive system.

Access the Factory Manual and keep a copy next to your toolbox. It is your insurance against guesswork.

FAQ

Does this manual cover the BW 120 AC-5?

Yes.

What are the torque specs for the drum mounting bolts?

They are not listed in the TOC excerpt, but the technical data section on page 13 includes all fasteners. Use factory values only.

Can I use this manual for a 2012 model?

This 2014 edition covers machines from serial numbers listed on page 1. Earlier models may have different components. Check the serial number prefix before relying on any procedure.

Is the wiring diagram included?

The TOC does not list wiring diagrams explicitly, but the manual includes electrical system information under “Elementos de indicación y de mando” (control and display elements). For detailed schematics, you may need the electrical supplement. However, the maintenance and troubleshooting steps cover common electrical faults like the electronic immobilizer (section 5.3). If you need a full wiring harness diagram, this manual is not that document. It is a service manual focused on mechanical and hydraulic systems, with component descriptions for controls. That said, the information given is sufficient for 90% of electrical diagnostics a mechanic will face on this roller.