From daily inspections through cold starts, sprinkler operation, towing and transport, this 98-page Bomag BW 120 AD-4 operator manual PDF (OEM 008 114 81) walks the full working routine of four rollers in the BW 100/120 line: two AD-4 tandem vibratory machines and two AC-4 combination models. Maintenance takes up more than a third of the book, running the whole service chart from checking the water separator to changing the hydraulic oil and bleeding the fuel system after a filter swap. Indicators and controls get their own illustrated section, so you know what every lamp on the dash means before it costs you a shift. Fill the engine with 6.5 liters of oil, the hydraulic tank with 28, and keep cleaning air under 5 bar at the combustion air filter. Small crew, no dealer on the phone; that is when this book earns its keep. One download, bookmarked and text-indexed, yours for the life of the machine.
What's Inside This Bomag BW 100 AD-4, BW 120 AD-4, BW 100 AC-4, BW 120 AC-4 Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Data | 7-12 | Weights, Dimensions, Drive System, Vibration System, Steering System, Brakes |
| Safety Regulations | 13-20 | General Notes |
| Indicators and Controls | 21-32 | Description of Indicators and Control Elements |
| Operation | 33-54 | Inspections Before Starting Operation, Starting the Engine, Starting with Jump Wires, Driving the Machine, Stopping the Machine / Operating the Parking Brake |
| Maintenance | 55-92 | Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Chart, Check the Engine Oil Level, Check the Coolant Level, Check the Water Separator |
| Trouble Shooting | 93-98 | Engine |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Safety cartridge replacement interval | at least every 2 years | p. 62 |
| Compressed air pressure for cleaning | max. 5 bar | p. 88 |
| Engine Oil Capacity | 6.5L | p. 59 |
| Fuel Tank Capacity | 40L | p. 59 |
| Hydraulic Oil Tank Capacity | 28L | p. 59 |
| Water Tank Capacity | 220L | p. 59 |
| Emulsion Tank Capacity | 20L | p. 59 |
| Valve Clearance | 0.18-0.22mm | p. 78 |
| V-belt Deflection | 7-9 mm | p. 68 |
| Engine Oil Change Interval | 250 hours | p. 57 |
| Hydraulic Oil Filter Change Interval | 2000 hours | p. 62 |
Bomag BW 100 AD-4, BW 120 AD-4, BW 100 AC-4, BW 120 AC-4 Common Problems This Manual Covers
Bomag BW 100 AD-4 engine cranks slowly and will not start after winter storage
Drain the water separator and check for water or sludge before cranking again. If the fuel is stale, drain the 40 L tank, refill with fresh diesel, and bleed the system. Work through the engine troubleshooting steps on page 95 before calling service; most storage no-starts clear up at the fuel side.
Manual Section: Trouble Shooting p. 95Machine travels sluggishly and drum vibration feels weak, hydraulic oil level dropping in sight glass
Check the hydraulic oil level in the sight glass before the first pass each day; the tank holds 28 L per the technical data on page 59. If the level keeps falling, shut down and inspect every hose and fitting for leaks. Keep the 2000 hour filter change on schedule and never top up with dirty oil.
Manual Section: Maintenance p. 59Engine oil level drops noticeably between daily checks during first weeks of operation
Pull the dipstick twice a day during the running-in period and daily after that, always on level ground with the engine stopped. Top up to the upper mark; total fill is 6.5 L. Keep the 250 hour oil change interval from page 57 and watch for external leaks under the engine tray.
Manual Section: Maintenance p. 57Engine loses power during compaction passes and exhaust smokes black under load
Remove the air filter dry element and blow it out from the inside with compressed air at a maximum of 5 bar, following the procedure on page 88. Replace the safety cartridge at the latest after 2 years. Fit a new main element if the paper is oily or torn, then recheck power under load.
Manual Section: Maintenance p. 88Coolant temperature climbs mid-shift and the charge warning light flickers on
Start with the V-belt: deflection should be 7-9 mm under thumb pressure, adjusted per page 68. Clean debris from the radiator fins, verify coolant sits at the mark, and let the engine idle before shutoff. If the charge light stays on, follow the engine troubleshooting table on page 95 before the next lift goes down.
Manual Section: Maintenance p. 68Frequently Asked Questions
What are the replacement specifications for the hydraulic oil filter element?
The hydraulic oil filter element should be replaced at every hydraulic oil change, which is every 2000 operating hours. Additionally, if the service indicator pin pops out during operation at maximum speed and operating temperature, the filter element must be replaced. p. 82
What are the replacement specifications for the fuel pre-filter?
The fuel pre-filter cartridge should be changed every 500 operating hours. When installing a new filter, ensure the flow direction matches the arrow on the filter housing. p. 76
What is the correct valve clearance for the engine?
The intake and exhaust valve clearance for the engine is 0.18 to 0.22 mm, and this adjustment must be performed only when the engine is cold. p. 78
What is the tightening torque for M10 bolts with a strength class of 8.8?
For an M10 bolt with a strength class of 8.8, the specified tightening torque is 37 Nm. p. 92
How often should the engine oil be changed?
The engine oil change interval is 250 operating hours (page 57). The manual ties that 250 hour interval to oil of quality class API CF, CF-4 or CG-4 and a fuel sulphur content of less than 0.5%, so check the fuels and lubricants section before running a different oil grade or a higher sulphur fuel. p. 72
How quickly can I access this Bomag BW 100 AD-4 manual after buying?
Straight to your device: 98 pages of searchable Operator Manual, downloadable the moment payment goes through.
Is this Bomag BW 100 AD-4 manual print-friendly?
Zero restrictions. The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
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