Bomag's factory BW 120 AC-5 operator manual PDF, document 008 201 31 EN, runs the combination roller from pre-start checks through travel and vibration operation to the full hour-based service schedule, 234 pages in all. The driver's stand takes a thick section by itself: every rotary switch, the instrument cluster, the ECONOMIZER display and both travel lever button assignments, identified and explained. Maintenance runs off the hour meter, from 50-hour water separator checks out to the 2000-hour hydraulic oil change, backed by fuse assignments and engine fault code tables for the day something quits mid-mat. Fill the hydraulic system with 46 mm²/s oil and change its filter every 500 operating hours. A roller sitting dead over a fuse burns paving hours nobody gave you. Pay once and this bookmarked, text-searchable PDF is yours for as long as you own the machine.
What's Inside This Bomag BW 120 AC-5 Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 11-14 | Foreword, Machine Type Plate and Engine Type Plate |
| Technical Data | 15-20 | Dimensions, Weights, Drive |
| Concerning Your Safety | 21-68 | Basic Prerequisites (General, Explanation of Signal Words Used, Personal Protective Equipment, Intended Use, Improper Use) |
| Indicators and Control Elements | 69-90 | Driver’s Stand (Overview, Instrument Cluster, Economizer Display, Rotary Switch for Direction Indicators, Rotary Switch for Working Lights, Rotary Switch for Lighting, Rotary Switch for Hazard Light System, Rotary Switch for Flashing Beacon, Rotary Switch for Push Button Assignment on Travel Lever, Rotary Switch for Vibration Pre-Selection, Rotary Switch for Engine Speed, Rotary Button for Regeneration, Emergency Stop Switch, Rotary Switch for Seat Heating, Rotary Switch for Water Spraying System, Starter Switch, V Din Socket, Travel Lever, Right, Left, Push Button Assignment Travel Lever, Foot Switch for Emulsion Spraying System) |
| Checks Prior to Start Up | 91-104 | Notes on Safety, Visual Inspections and Function Tests, Checking the Engine Oil Level, Checking the Fuel Level, Topping Up Fuel (Refuelling), Checking the Hydraulic Oil Level |
| Operation | 105-148 | Setting-Up the Work Place (Adjust the driver’s Seat, Sliding the driver’s Seat Sideways), Electronic Immobilizer, Starting the Engine |
| Loading / Transporting the Machine | 149-162 | Prepare for Transport, Loading the Machine (Fold Down the Foldable ROPS, Folding Down the Foldable ROPS with Protective Roof), Lashing the Machine to the Transport Vehicle |
| Maintenance | 163-218 | Preliminary Remarks and Safety Notes, Fuels and Lubricants (Engine Oil, Fuel, Coolant, Hydraulic Oil), List of Fuels and Lubricants |
| Troubleshooting | 219-230 | Preliminary Remarks, Starting the Engine with Jump Leads, Fuse Assignment (Notes on Safety, Fuses in Engine Compartment, Central Electrics), Fault Code Display, Engine Faults |
| Disposal | 231-234 | Final Shut-Down of Machine |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| tightening torque for counter nuts on high pressure relief valves | 22 Nm (16 ft·lbf) | p. 144 |
| Tightening torque for eye bolts (clamping plates) | 75 – 200 Nm (55 - 148 ft·lbs) | p. 160 |
| Hydraulic oil filter replacement interval | 500 operating hours | p. 171 |
| Hydraulic oil kinematic viscosity at 40 °C | 46 mm²/s | p. 170 |
| Hydraulic oil kinematic viscosity at 100 °C | 8 mm²/s | p. 170 |
| Engine oil filling quantity | 6.5 l (1.7 gal us) | p. 172 |
| Fuel filling quantity | 35 l (9.2 gal us) | p. 172 |
| Engine Rated Power | 25.0 kW | p. 18 |
| Rated engine speed | 2400 min-1 | p. 18 |
| Fuel tank capacity | 35 l | p. 19 |
| Water tank capacity | 160 l | p. 19 |
| Emulsion tank capacity | 45 l | p. 19 |
Bomag BW 120 AC-5 Common Problems This Manual Covers
Bomag BW 120 AC-5 engine cranks slowly or won't start on cold mornings
Check fuel level first; the tank holds only 35 l and runs down faster than you think on long shifts. Work through the engine fault tables starting on page 226 for no-start and slow-cranking conditions. If the battery is down, follow the jump lead procedure on page 219 before you call anyone.
Manual Section: Troubleshooting p. 226Drum vibration feels weak and the lift won't reach density at full throttle
Verify the vibration pre-selection rotary switch setting against the console layout on page 70, then run the engine at its rated 2400 min-1; low throttle drags exciter frequency down with it. Check hydraulic oil level during the start-up checks on page 91. If the hydraulic filter is past 500 operating hours, have it changed before the next mat.
Manual Section: Indicators and Control Elements p. 70Water spray system stops wetting the drum mid-pass and asphalt starts sticking
Check the water tank level; it holds 160 l and empties fast in hot weather with both bars running. Verify the rotary switch for the water spraying system is on, using the console layout on page 70. Clean the spray nozzles and confirm the scraper bars still ride the drum before you rejoin the pass.
Manual Section: Indicators and Control Elements p. 70Engine temperature climbs into the red during long vibration passes on hot days
Check coolant level with the engine cold; the system holds 6 l and even a small loss shows on a hot mat. Clean the radiator core of dust and chips. Measure V-belt deflection and correct anything outside 7 to 9 mm, shown on page 178, then follow the overheating table starting on page 226.
Manual Section: Troubleshooting p. 226Rubber tyres picking up fresh asphalt and tearing the mat on finish passes
Fill the emulsion tank before the mat goes down; it holds 45 l. Use the foot switch for the emulsion spraying system, shown on the console layout on page 70, through every finish pass. Check tyre pressure sits between 1.5 and 2.5 bar per the technical data on page 18; uneven tyres tear tender mix.
Manual Section: Indicators and Control Elements p. 70Frequently Asked Questions
What is the procedure to reset the electronic immobilizer?
To disarm the anti-theft protection, slowly enter the six-digit user code on the keypad. Once the code is entered, press the diamond button; the system is then disarmed and the engine can be started within the next 15 minutes. p. 108
How can I display and exit fault codes on the instrument cluster?
Press function key [F1] to display the first fault code on the display field. You can cycle through additional codes by pressing function key [F2]. To exit the fault code display, press function key [F1] again. p. 225
What is the tightening torque for the counter nuts on the travel pump after towing?
After completing the towing procedure and resetting the travel pump, tighten the counter nuts on the high pressure relief valves to a torque of 22 Nm (16 ft·lbf). p. 146
What is the required V-belt tension for the engine?
Check the V-belt tension by applying thumb pressure between the pulleys. The belt should be able to be depressed by 7 to 9 mm (0.28 – 0.35 inch). p. 178
What is the engine oil capacity for the BW 120 AC-5?
The engine oil filling quantity is 6.5 liters (1.7 gal us). Always ensure the oil level is between the MIN and MAX marks on the dipstick. p. 172
Do I get instant access to this Bomag BW 120 AC-5 Operator Manual?
Instant PDF download. You get the full 234-page searchable Operator Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Am I able to print pages from this Bomag BW 120 AC-5 manual?
Yes. No DRM, nothing blocks printing, so run off the pages you need on whatever printer you have.
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