Bomag BW 120 AD-4 Combination Roller Service Manual 00891561

Factory Workshop Manual for Bomag BW 120 AD-4 Combination Rollers

The Bomag BW 120 AD-4 Combination Roller Repair & Service Manual (P/N: 00891561) is a professional-grade technical publication designed for the complete maintenance and overhaul of this specialized Dash-4 series compactor. As a combination model, this machine utilizes a 1200mm vibratory steel drum at the front and a set of four pneumatic tires at the rear, offering unique compaction characteristics that require specific technical oversight. This manual provides the OEM-verified data necessary to keep both the drum vibration and tire drive systems in peak condition.

Equipped with a robust diesel engine and a high-efficiency hydrostatic drive, the BW 120 AD-4 demands precise hydraulic calibration and electrical diagnostic accuracy. This manual covers every major system, from the interval-controlled water sprayers to the complex electrical logic of the operator console, ensuring your equipment meets factory performance standards on every paving project.

Essential for heavy equipment mechanics, site technicians, and fleet owners, this searchable PDF manual is the definitive resource for ensuring machine longevity and reducing operational downtime.

Technical Specifications & Maintenance Data

• Engine Systems: Complete service procedures for the liquid-cooled diesel powerplant, including fuel system priming, valve clearance settings, and cooling system pressure tests.
• Hydraulic Benchmarks: Precise factory pressure settings and flow testing instructions for the travel, vibration, and steering circuits.
• Fluid Capacities: Detailed charts for engine oil, hydraulic fluid, and cooling system capacities, including recommended viscosities for various operating temperatures.
• Torque Specifications: Accurate torque values for critical fasteners, including the center articulation joint, wheel hub bolts, and drum isolation mounts.

Comprehensive System & Service Coverage

• Dual-System Vibration: In-depth repair instructions for the front drum exciter system, including bearing replacement, shaft alignment, and frequency testing.
• Pneumatic Rear Drive: Specialized service routines for the rear tire assembly, focusing on the hydrostatic tire motors and scraper blade adjustments.
• Hydrostatic Transmission: Diagnostic workflows for drive power loss, travel pump rebuilding, and closed-loop hydraulic system decontamination.
• Electrical Infrastructure: High-resolution wiring diagrams covering the Dash-4 control logic, safety interlocks, fuse layouts, and dashboard instrumentation.
• Combination Spray System: Service instructions for the dual pressurized sprinkler system used to prevent asphalt pickup on both the steel drum and rubber tires.
• Steering & Articulation: Procedures for resealing steering cylinders and inspecting the pivot bearings for precise machine maneuverability.
• Braking Logic: Full testing and adjustment for the spring-applied hydraulic-release (SAHR) parking brake and emergency stop circuits.

Manual Specifications

• Machine Model: Bomag BW 120 AD-4 (Combination Roller)
• Part Number: 00891561
• Generation: Dash-4 Series
• Format: PDF Digital Download (Fully Searchable & Bookmarked)
• Language: English
• Total Pages: 740+
• File Size: Approximately 115 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

• Targeted Diagnostics: Quickly identify the root cause of hydraulic pressure drops or electrical circuit failures using factory troubleshooting trees.
• In-House Capabilities: Empower your shop team to perform advanced calibrations and major repairs, reducing the need for expensive dealer service calls.
• Safety Assurance: Verify the integrity of all operator safety systems, including seat switches and braking mechanisms, to protect your crew.
• Instant Keyword Access: The digital PDF format allows for rapid searching of specific terms like "fault codes" or "valve timing" for immediate results.

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Frequently Asked Questions

Does this cover the pneumatic tire drive system?

Yes, as a Combination (AD-4) manual, it includes full service and repair data for the rear pneumatic tire axle and drive motors.

Are wiring diagrams included?

Yes, the manual contains clear, high-resolution wiring diagrams that allow for 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.