Within the hour you could be tracing charge pressure on a BW 120 AD-4 with this Bomag BW 120 AD-4 Service Training PDF open beside the test port: 107 pages, OEM ID 008 099 86, covering four BW 100 and BW 120 tandem vibratory roller variants of Series 4. Wiring diagrams take up the last third of the book, laid out in function groups with potential and relay cross references, next to hydraulic schematics for the closed-loop travel circuit and troubleshooting tables for travel, vibration and steering. The Kubota engine section walks through valve clearance adjustment and pump installation on the flywheel side. Check charge pressure against the 24 bar spec, and confirm the high pressure relief valves open at 380 bar before you condemn a travel pump. When it is just you and a dead roller, there is no one to ask; this book answers. Print the pages you need and let them take grease on the bench, or work the bookmarks on screen.
What's Inside This Bomag BW 100–120 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| List of Components | 2-8 | Engine, Travel Pump, Travel Motor, Vibration Pump, Vibration Motor, Steering Valve |
| Kubota Diesel Engine | 9-19 | View of Engine, Pump Installation on Diesel Engine, View of Diesel Engine, Flywheel Side, Tests and Adjustments, Valve Clearance, Trouble Shooting |
| Travel System | 20-52 | Travel Pump, Travel Pump Control, Charge Pressure Relief Valve, High Pressure Relief Valves, Drum Drive Motor, Wheel Drive Motors on AC-machines, Trouble Shooting Travel System |
| Vibration | 53-64 | Vibration Pump, Vibration Control Valve, Vibration Motor, Trouble Shooting Vibration |
| Steering | 65-70 | Steering Valve Maintenance, Steering Troubleshooting |
| Electric Circuit Diagrams | 71-107 | Table of Contents, Function Groups, Reference Lines, Frames, Potential Cross References, Relay Cross References, Electric System |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Displacement | 28 cm³/rev. | p. 6 |
| High pressure limitation | 380 bar | p. 6 |
| Displacement (drums) | 408 cm³/rev. | p. 7 |
| Displacement (wheels) | 255 cm³/rev. | p. 7 |
| Starting pressure | 210 bar | p. 7 |
| Operating pressure | 100 +/-60 bar | p. 7 |
| Frequency stage 1 | 55 Hz | p. 8 |
| Frequency stage 2 | 70 Hz | p. 8 |
| Engine Power | 25.2 kW | p. 6 |
| Fixed Engine Speed Stage 1 | 2250 rpm | p. 6 |
| Fixed Engine Speed Stage 2 | 2700 rpm | p. 6 |
| Valve Clearance (Cold) | 0.20 mm | p. 6 |
Bomag BW 100–120 Series Common Problems This Manual Covers
Bomag BW 100 AD-4 roller stops traveling after warming up, travel lever gives no response
Test charge pressure at the marked test port with the hydraulic oil at operating temperature. The charge pressure relief valve is set at 24 bar (page 21); a reading well below that hot points to charge pump wear or a clogged hydraulic oil filter. Replace the filter first, retest hot, and pull the travel pump only if pressure still falls.
Manual Section: Travel System Troubleshooting p. 21Roller creeps forward or backward with travel lever in neutral position on flat ground
Block the drums, then adjust the neutral position on the travel pump control until the machine holds still with the lever released. Tee gauges into both high pressure ports; standing pressures must be equal. The high pressure relief valves are set at 380 bar (page 29), so unequal readings at neutral mean the pump is off center, not a relief valve fault.
Manual Section: Travel System Troubleshooting p. 29Drum vibration weak or not starting, frequency drops off under load on second stage
Check vibration frequency at full engine speed with a reed tachometer: 55 Hz on stage 1 and 70 Hz on stage 2 (page 8). If frequency runs low, gauge the vibration circuit; one vibrating drum should hold about 60 bar operating pressure (page 59). High pressure with low frequency means a worn vibration motor or a dragging exciter bearing.
Manual Section: Vibration Troubleshooting p. 59Engine cranks but will not start, or loses power and smokes heavily under load
Check fuel level, fuel filter, and air filter element before touching the injection system. Set valve clearance to 0.20 mm cold, then run a compression test; the factory setting is 29.4 to 32.4 bar (page 13). Low compression with heavy smoke means rings or valves. Drain overfilled engine oil, it smokes and drags the engine down between passes.
Manual Section: Engine Troubleshooting p. 16Travel drive sluggish or machine will not move at all, park brake stays applied
Measure current draw at the brake valve solenoid; it should pull 2.7 A (page 36). No current means an electrical fault, so trace the brake circuit through the wiring diagrams. With current present but no release, check charge pressure feeding the brake. On AD machines only, release the brake mechanically at no more than 35 Nm (page 46) to tow clear.
Manual Section: Travel System Troubleshooting p. 36Frequently Asked Questions
What is the valve clearance specification for the Kubota diesel engine?
The valve clearance for both intake and exhaust valves must be set to 0.20 mm when the engine is cold. This adjustment should be performed by aligning the '1TC' mark on the flywheel with the notched part on the plate to ensure the piston is at top dead center. p. 14
What is the compression pressure specification for the engine?
The factory setting for compression pressure is 29.4 to 32.4 bar. If the measured compression is below the permissible limit value of 23.5 bar, you should check the cylinder, piston, valve, and cylinder head. p. 13
What is the nominal charge pressure for the travel system?
The nominal charge pressure for the travel system is 24 bar. This pressure is maintained by the charge pressure relief valve integrated into the travel pump. p. 6
What is the maximum torque for the brake release screws?
When mechanically releasing the brakes on the travel motors, you must tighten the two screws alternately and in steps until they bottom, with a maximum torque of 35 Nm. p. 34
What is the nominal current consumption for the brake valve solenoid?
The nominal current consumption for the brake valve solenoid is a maximum of 2.7 A. If no current consumption is detected during testing, the solenoid coil should be replaced. p. 36
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Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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