Startup checks, sprinkler operation, chip spreader handling, towing and the full maintenance schedule: this 126-page Bomag operator manual (OEM 008 053 01) walks all of it end to end for the BW 100, 120 and 125 series, six models in AD-4 tandem vibratory and AC-4 combination roller form. Service tables run from the ten-hour daily checks through the 3000-hour injection pump inspection, and the maintenance chapter fills roughly a third of the book. Indicator and control descriptions decode every switch on the panel, from the electronic immobilizer to the pressure sprinkling system. Set valve clearance to 0.20 mm at the 1000-hour service, and top the water tank to its full 220 liters before the shift's first pass. On a small crew there is nobody down the yard to ask, so the book has to answer. Bookmarked and text-searchable, the PDF rides on whatever screen you carry out to the machine.
What's Inside This Bomag BW 100-125 AD/AC-4 Series Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Data | 9-16 | Weights, Dimensions, Travel Characteristics, Drive System, Brake System, Exciter System |
| Safety Regulations | 17-30 | Loading and Transport, Towing, Roll Over Protective Structure, Maintenance, Hydraulic Lines, Fuel System |
| Indicators and Controls | 31-44 | Indicators and Control Elements |
| Operation | 45-70 | General, Tests Before Taking Into Operation, Electronic Immobilizer, Operator's Seat, Starting the Engine, Starting with Jump Wires, Driving the Machine, Stopping the Machine |
| Maintenance | 71-118 | Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Table |
| Trouble Shooting | 119-122 | Engine |
| Disposal | 123-126 | Final Shut-Down of Machine |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Maximum compressed air pressure for cleaning | 2.1 bar | p. 93 |
| valve clearance | 0.20 mm | p. 103 |
| Engine Oil Capacity | 6.5L | p. 11 |
| Fuel Tank Capacity | 40L | p. 11 |
| Water Tank Capacity | 220L | p. 11 |
| Valve Clearance (Intake and Exhaust) | 0.20 mm | p. 103 |
| Tightening Torque (Eye Bolts for ROPS) | 75-200 Nm | p. 70 |
| Engine Oil Change Interval | 250 hours | p. 74 |
| BW 100 AD-4 | ||
| Hydraulic Oil Capacity | 28L | p. 11 |
| BW 120 AD-4, BW 125 AD-4 | ||
| Hydraulic Oil Capacity | 32L | p. 11 |
| BW 100 AD-4, BW 120 AD-4, BW 125 AD-4 | ||
| Tightening Torque (Brake Release Screws) | 35 Nm | p. 65 |
| Tightening Torque (Brake Release Plugs) | 20 Nm | p. 66 |
Bomag BW 100-125 AD/AC-4 Series Common Problems This Manual Covers
Bomag BW 120 AD-4 travel drive cuts out after hydraulic oil warms up, lever gives no response
Check the hydraulic oil level in the sight glass before restarting; the BW 120 AD-4 circuit holds 32 L per the technical data on page 11. Replace the hydraulic oil filter element if it is past the 500 hour interval on page 75. If drive still drops out warm, park it and call service before the next lift.
Manual Section: Maintenance p. 75Engine cranks but will not start, runs rough and loses power under load
Check the engine troubleshooting table starting on page 121 first. Verify fuel level in the 40 L tank, drain the water separator, and replace the fuel prefilter if it is dirty. Pull the air filter element and clean it with compressed air held below 2.1 bar, as noted on page 93; replace it if the paper is torn.
Manual Section: Engine Troubleshooting p. 121Water spray stops misting mid pass, asphalt picking up on the drum
Verify the water tank is full; it holds 220 L per the technical data on page 11. Remove the spray nozzles and rinse the filter screens, then flush the lines until every nozzle mists evenly across the drum. Add nozzle cleaning to the daily checks in the maintenance schedule on page 78 so the mat keeps rolling clean.
Manual Section: Maintenance p. 78Engine running hot on long shifts, temperature gauge climbing and power fading
Stop compacting and let the engine cool at idle. Check the coolant level in the expansion tank once it is cool, then clean debris from the radiator and oil cooler fins. Verify engine oil is at the full mark; capacity is 6.5 L per page 11. If the gauge still climbs, follow the overheating steps on page 121.
Manual Section: Trouble Shooting p. 121Engine oil level dropping between daily dipstick checks during the first weeks
Check the dipstick on level ground before each shift and log every top-up. Higher consumption is normal during running-in; follow the running-in instructions in the maintenance section starting on page 71. Change the oil and filter cartridge at the 250 hour interval on page 74, and inspect the drain plug and filter seal for leaks.
Manual Section: Maintenance p. 74Frequently Asked Questions
What are the replacement specifications for the hydraulic oil filter element?
The hydraulic oil filter element should be replaced every 500 operating hours. During maintenance, ensure the area around the filter is clean, and do not reuse the filter element or the oil in the filter bowl. p. 75
What are the replacement specifications for the engine oil filter cartridge?
The engine oil filter cartridge should be changed every 250 operating hours. When installing a new cartridge, slightly oil the rubber seal and tighten the filter element by hand until the seal contacts, then tighten for another half turn. p. 90
What is the correct valve clearance for the engine?
The intake and exhaust valve clearance for the engine is 0.20 mm when the engine is cold. p. 103
What is the tightening torque for the foldable ROPS eye bolts?
Turn the clamping plates to the horizontal position, then tighten the eye bolts to a torque of 75 to 200 Nm. Page 70 walks the foldable ROPS through the whole sequence. p. 70
What is the required tire pressure for the AC-machines?
The nominal tire pressure for the AC-machines is approximately 2.2 bar (32 psi). It is important to ensure equal pressure in all rubber tires. p. 113
Is this Bomag BW 100 AD-4 manual a download or a disc?
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