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.
Complete the set for your BW 100 AD-4, BW 100 AC-4, BW 120 AD-4…
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 |
