Bomag BW 120 AC-5 Roller Pdf Repair Service Manual 00840124EN

Professional Workshop Manual for Bomag BW 120 AC-5 Combination Rollers

The Bomag BW 120 AC-5 Repair & Service Manual (P/N: 00840124EN) is the authoritative factory-level technical guide for maintaining, diagnosing, and overhauling this 5th Generation (Dash-5) combination roller. Designed for precision paving, the BW 120 AC-5 utilizes a 1200mm vibratory steel drum at the front and four pneumatic tires at the rear. This manual provides the high-fidelity technical data required to service both the steel drum vibration systems and the specialized pneumatic tire drive assembly.

As part of the modern Dash-5 series, this machine features updated electronic control modules and Tier 4/Stage V compliant engine technology. This manual delivers the specific technical depth required to service the redesigned operator station, high-efficiency hydraulic circuits, and integrated sensor networks unique to this generation.

Whether you are addressing a hydraulic leak in the field or conducting a total engine rebuild in the shop, this OEM-structured documentation ensures your equipment meets factory safety and performance standards.

Advanced Technical Specifications & Setup

• Next-Gen Engine Integration: Comprehensive data for the latest diesel powerplants, including fuel system priming, cooling system thermal management, and exhaust aftertreatment diagnostics.
• Hydraulic Performance Testing: Detailed flow rates and pressure benchmarks for the travel, vibration, and steering pumps, including port locations for gauge attachment.
• Combination Drive Dynamics: Factory-verified procedures for the synchronized drive between the front drum motor and the rear tire traction motors.
• Fluid & Lubrication Data: Updated specifications for engine oil, hydraulic fluid grades, and articulation joint grease points.

System-Specific Repair Modules

• Vibration Control: Specialized procedures for the Dash-5 exciter system, focusing on frequency optimization, bearing replacement, and vibration isolation mount service.
• Rear Pneumatic Axle: Comprehensive maintenance routines for the rear tire assembly, including hydraulic motor rebuilding and tire scraper adjustment.
• Electronic Control Unit (ECU): Full coverage of the machine's digital architecture, including sensor inputs, controller outputs, and wiring harness routing.
• Intelligent Water Management: Service guides for the multi-stage filtration spray system used to prevent asphalt pickup on both the drum and tires.
• Steering & Articulation: Procedures for resealing steering cylinders, inspecting articulation pins, and servicing pivot bearings.
• Safety & Braking: Maintenance for the spring-applied hydraulic-release (SAHR) parking brake and integrated emergency stop logic.

Manual Specifications

• Machine Model: Bomag BW 120 AC-5 (Combination Roller)
• Part Number: 00840124EN
• Generation: Dash-5 Series
• Format: PDF Digital Download (Fully Searchable & Bookmarked)
• Language: English
• Total Pages: 820+
• File Size: Approximately 105 MB
• Illustrations: High-definition wiring diagrams, hydraulic flow schematics, and exploded assembly views
• Compatibility: Windows, macOS, Android, iOS, and Tablets

Why This Service Manual Is Essential for Repairs

• Precision Troubleshooting: Move beyond guesswork with logic-based fault-finding trees for electrical and hydraulic failures.
• Reduced Downtime: Perform advanced in-house calibrations and repairs without relying on expensive dealer service calls.
• Safety Compliance: Verify correct operation of seat safety switches, emergency braking systems, and operator safety circuits.
• Instant Access: Digital PDF format allows fast keyword searching for terms such as fault codes, wiring, or fuse locations.

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Frequently Asked Questions

Does this cover the pneumatic tires?

Yes, as a "Combination" manual, it includes full service and repair data for the rear pneumatic tire drive system.

Are wiring diagrams included?

Yes, the manual contains clear, high-resolution wiring diagrams that allow accurate tracing of electrical circuits and fault diagnosis.

Can I access this manual on my smartphone?

Absolutely. The PDF format is universally compatible with all mobile devices, allowing you to reference technical data directly at the machine.

How is the manual delivered?

You will receive an instant download link immediately after purchase, allowing you to save the PDF to any computer or tablet.