Charge pressure, vibration leakage rates, drum bearings: questions that stall a roller repair get settled in the Bomag BW 120 AD-4 service manual PDF, a 546-page factory Service Manual (OEM 008 915 61) covering four tandem and combination variants in the BW 100 and 120 series. Hydraulic and wiring diagrams fill the final section, tracing the travel, vibration and steering circuits down to individual connectors. Troubleshooting tables walk you through vibration, steering and axial piston pump faults, and flushing schematics show the hookup for each drum drive and vibration loop before you bleed the travel circuit. Set the relief valve downstream of the flushing valve to 16 bar; torque the engine oil pressure switch to between 15 and 19 Nm. No foreman, no hotline, just you and the machine. A bookmarked, text-searchable PDF gets you to the right page and the roller back in the pass; grab the download and finish the job.
What's Inside This Bomag BW 100 AD-4, BW 100 AC-4, BW 120 AD-4, BW 120 AC-4 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 7-26 | Introduction, Safety Regulations, General Repair Instructions |
| Technical Data | 27-34 | Weights, Dimensions, Travel Characteristics, Drive, Engine, Brake, Steering |
| Maintenance | 35-42 | Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Table |
| Overall View of Machine | 43-46 | Overview |
| Electrics | 47-78 | Battery Service, Starting with Jump Wires, Generator Repair, Repair of Starter, Glow Plugs, Engine Shut-Down Solenoid, Engine Oil Pressure Monitoring |
| Description of the Modules | 79-96 | Electric Modules |
| Engine | 97-126 | Kubota Diesel Engine, Checking the Injection Valves |
| Hydraulics | 127-166 | Hydraulic Circuit, Pump Overview, Travel Pump, 42R 028, Drum Drive Motor MK04, Wheel Motor MSE02, External Gear Motors, External Gear Pumps |
| Tests and Adjustments | 167-178 | Special Tools, Checking the Rotation Speeds, Pressure Tests in the Travel Circuit, Pressure Test in the Vibration Circuit, Checking the Leakage Rate of the Vibration Motor |
| Trouble Shooting | 179-194 | Perform Trouble Shooting, Engine Problems, Troubleshooting Axial Piston Pumps, Trouble Shooting Vibration, Trouble Shooting Steering |
| Flushing and Bleeding | 195-224 | Special Tools for Flushing |
| Drum | 225-248 | Special Tools, Repair Overview for Drum, Removing and Installing the Drum, Dismantling the Drum, Assembling the Drum |
| Oscillating Articulated Joint | 249-264 | Special Tools, Repair Overview (Oscillating Articulated Joint), Removing and Installing the Oscillating Articulated Joint, Dismantling the Oscillating Articulated Joint |
| Suppliers Documentation | 265-460 | Steering Valve, Travel Pump, Drum Drive, Wheel Drive |
| Circuit Diagrams | 461-546 | Hydraulic Diagram 880 100 50, Hydraulic Diagram 880 100 52, Hydraulic Diagram 920 100 61, Hydraulic Diagram 880 100 62, Wiring Diagram 880 100 58, Wiring Diagram 880 100 63 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for M4 screw (8.8) | 3 Nm | p. 23 |
| Tightening torque for M5 screw (8.8) | 6 Nm | p. 23 |
| Flushing valve downstream pressure relief valve | 16 bar | p. 146 |
| Charge oil filter bypass valve pressure differential | 3.5 bar | p. 146 |
| Charge oil filter contamination indicator pressure differential | 2.5 bar | p. 146 |
| Travel pump high-pressure relief valve | 405 bar | p. 148 |
| Steering pressure relief valve limit | 140 bar | p. 160 |
| Vibration circuit high pressure (starting pressure) limit | 210 bar | p. 159 |
| End float of the exciter shafts | 0.5 mm - 2.00 mm | p. 191 |
| Engine Oil Capacity | 6.5L | p. 39 |
| Fuel Tank Capacity | 40L | p. 39 |
| Water Tank Capacity | 220L | p. 39 |
Bomag BW 100 AD-4, BW 100 AC-4, BW 120 AD-4, BW 120 AC-4 Common Problems This Manual Covers
Bomag BW 100 AD-4 loses travel drive once hydraulics warm up, barely creeps on grades
Test charge pressure with the oil warm and the engine at full throttle. The flushing valve downstream relief on page 146 is set at 16 bar; if warm pressure sags well below that, suspect internal travel pump wear. Check the charge oil filter first, since a 2.5 bar differential trips the contamination indicator.
Manual Section: Troubleshooting (Travel Pump)Machine creeps forward at idle with the travel lever in neutral, won't sit still
Set the machine on blocks, then adjust the travel pump neutral position with the oil at operating temperature. Torque the MDC control screws to 15-18 Nm once the adjustment holds (page 337). If creep returns, test the travel lever itself: a stored fault code will point to a lever-position fault that no pump adjustment can cure.
Manual Section: Suppliers Documentation p. 337No vibration on either drum, or vibration cuts out halfway through the pass
Gauge vibration circuit pressure at the test point with the drum clear of the ground. The pump relief valve is set at 200 bar (page 189); pressure spiking to relief with no drum motion means a seized exciter, so pull the drum and measure exciter shaft end float against the 0.5 mm to 2.00 mm limit on page 191.
Manual Section: Trouble Shooting Vibration p. 189Parking brake will not release, drum drags and machine shudders when trying to move off
Pull the stored fault code first; it will flag a brake valve cable break or bad ground connection before you blame the hydraulics. Test the solenoid coil and its ground against the wiring diagram. Then verify warm charge pressure, comparing your reading with the 16 bar flushing valve downstream relief setting on page 146.
Manual Section: Circuit DiagramsEngine starts then shuts down after about ten seconds, red oil pressure light flashing
Verify engine oil level before anything else; the sump holds 6.5 liters (page 39). Connect a gauge at the oil pressure switch port and compare readings with page 117: 0.98 bar minimum at idle, 3 to 4.4 bar at nominal speed. If pressure is good, replace the switch and torque it to 15 to 19 Nm.
Manual Section: Engine p. 117Steering feels heavy and rear drum wanders off line during the pass
Test steering pressure at the steering valve; the relief is set at 140 bar (page 160). If pressure checks out, get under the machine and lever the oscillating articulated joint to feel for play in the bearing blocks; worn blocks let the rear drum wander no matter how healthy the hydraulics are. Repair procedure starts on page 249.
Manual Section: Trouble Shooting SteeringFrequently Asked Questions
What are the torque specifications for the wheel nuts on the BOMAG BW 100 AD-4?
The tightening torque for wheel nuts (fine thread) on the BW 100 AD-4 depends on the thread diameter. For an M12x1.5 thread, the torque is 100 Nm; for M14x1.5, it is 150 Nm; for M18x1.5, it is 300-350 Nm; for M20x1.5, it is 400-500 Nm; and for M22x1.5, it is 500-600 Nm. p. 24
What are the fuel prefilter replacement specifications for Bomag BW 100 AD-4, BW 100 AC-4, BW 120 AD-4, BW 120 AC-4?
To change the fuel pre-cleaner, you must loosen the hose clamps, pull the filter out of the hoses, and install the new fuel pre-filter while observing the flow direction indicated by the arrow. Finally, fasten the hose clamps securely. p. 114
What is the valve clearance for the Kubota diesel engine on Bomag BW 100 AD-4, BW 100 AC-4, BW 120 AD-4, BW 120 AC-4?
Intake and exhaust valve clearance on the Kubota diesel engine is 0.20 mm; the manual walks through the full check-and-adjust procedure in section 7.23. p. 123
What is the Kubota diesel engine oil capacity for the Bomag BW 100 AD-4, BW 100 AC-4, BW 120 AD-4, BW 120 AC-4?
The engine oil capacity for the Kubota diesel engine is approximately 6.5 litres. p. 29
What is the M12 bolt tightening torque on the Bomag BW 100 AD-4, BW 100 AC-4, BW 120 AD-4, BW 120 AC-4?
For screws with a metric unified thread and a strength class of 8.8, the tightening torque for an M12 bolt is 88 Nm. For strength class 10.9, it is 123 Nm, and for strength class 12.9, it is 147 Nm. p. 23
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