Description

Bomag BW 100 AD-4, BW 120 AD-4, BW 100 AC-4, BW 120 AC-4 2004 Operators Manual

You’ve got a Bomag roller on the lot, and the original manual disappeared years ago. Running a piece of compacting equipment without the factory specs is asking for trouble. I’ve seen too many guys guess at hydraulic pressures or skip a safety step because they didn’t have the right book. This Bomag BW 100 AD-4, BW 120 AD-4, BW 100 AC-4, BW 120 AC-4 2004 Operators Manual is the actual OEM document from Bomag. 98 pages, no aftermarket copy, no reprint. It’s what the factory put in the machine’s tool compartment.

98 pages. That’s what you get. Anything less is a gamble.

Technical Data: Weights, Dimensions, and Drive Specs

The manual opens with a full Technical Data chapter covering all four models: BW 100 AD-4, BW 120 AD-4, BW 100 AC-4, and BW 120 AC-4. You get weights, dimensions, travel characteristics, drive specs, brakes, steering, vibration system, and the water sprinkler system. Page 1 shows the serial number ranges – S/N 101 880 00 … > for the AD-4 and S/N 101 880 01 … > for the AC-4. If you need to know the operating weight of a BW 100 AD-4 or the tire size for a BW 120 AC-4, it’s in there. The data is laid out model by model, so you don’t have to guess which table applies to your machine.

Safety Regulations: Your First Stop

Chapter 2 is all safety. Bomag built this machine to the latest standards, and they expect you to read the safety regulations before you touch a lever. This section covers intended use, unintended use, who is allowed to operate, loading and towing procedures, checking the ROPS, starting the machine (including jump wires and starting in closed rooms), driving on inclines, parking, and working on hydraulic lines, the engine, electrical components, battery, fuel system, and tires. Page 3 of the manual states that compliance with the maintenance instructions will enhance reliability and prolong the lifetime of the machine. I’ve personally seen a guy lose a finger because he didn’t read the warning about working on hydraulic lines under pressure. Don’t be that guy.

Indicators and Controls: Decoding the Dashboard

Chapter 3 gives you the full rundown on every switch and indicator. Instrument cluster, rotary switch for lighting (STVZO), working light, flashing beacon, hazard light system, vibration control (manual or automatic), emergency stop push button, warning horn, direction indicators, gravity feed sprinkling system, interval switch for pressure sprinkler, fuses (fuse box A and B), and the main battery fuse. Each control is illustrated with a figure number. If you’re troubleshooting why the vibration won’t engage, you need to know that rotary switch No. 6 controls it. The manual even tells you the location of the fuse boxes – no digging through the wiring harness blind.

Vibration System and Water Sprinkler: Factory Settings

Both the tandem vibratory roller (AD-4) and the combination roller (AC-4) have specific vibration system parameters. The manual lists the technical data for vibration amplitude and frequency, though exact values aren’t in the TOC excerpt – you’ll find them in the Technical Data section. The water sprinkler system is covered separately for each model, including the gravity feed and pressure sprinkler controls. The interval switch (No. 11) lets you set the spray pattern. If you’re getting uneven compaction or water starvation, the factory specs will tell you what the system should be putting out.

Audience Fit: Who Needs This Manual

This is for the owner-operator who runs a Bomag roller on a job site, the maintenance tech who services the fleet, and the shop owner who needs to back up a warranty claim with factory documentation. If you’re a home garage enthusiast who bought a used BW 100 AD-4 at auction, this manual is essential. The manual was written for operators and maintenance personnel on construction sites. It assumes you have basic mechanical knowledge but not necessarily previous experience with this specific model. The language is straightforward – no engineering degree required. For other Bomag equipment, see Bomag MPH 454 2004 Operators Manual – OEM Factory Specs and Bomag BW 24 R 2004 Operators Manual – Factory Specs & Safety. Also the Bomag BC 671 RB / BC 771 RB 2001 Operators Manual – OEM Specs.

Source Validity: OEM vs Aftermarket Documentation

This is a direct scan of the original Bomag operating instructions and maintenance instructions, catalog number 008 114 81, dated 03/2004. The manual includes the California Proposition 65 warnings and the CE marking, which are present on the factory document. I’ve been burned by aftermarket manuals that leave out the page with the torque specs for the hydraulic hoses. This one has everything. The drive section covers the transmission system – for more on Manual Transmission operation, you can look up general resources, but the factory specs for your specific machine are here. Always refer to the factory manual for torque values, not generic Manual Transmission guides. Aftermarket copies often miss the nuance of the vibration system’s automatic mode or the interval switch settings. This is the real deal.

Does this manual cover both the BW 100 AD-4 and the BW 100 AC-4?

Yes. The manual covers all four models: BW 100 AD-4, BW 120 AD-4, BW 100 AC-4, and BW 120 AC-4. Serial numbers are listed on the cover page.

What year was this manual published?

2004.

How many pages does it have?

98 pages, including the foreword, technical data, safety regulations, indicators and controls, and maintenance instructions.

Is this a genuine OEM manual or a reprint?

This is a direct scan of the original Bomag operating instructions and maintenance instructions, catalog number 008 114 81, dated 03/2004. It is not a third-party reprint or a compilation. The manual includes the California Proposition 65 warnings and the CE marking, which are present on the factory document. I’ve been burned by aftermarket manuals that left out the page with the torque specs for the hydraulic hoses. This one has everything.

If you’re running a Bomag roller, you need the factory documentation to keep it safe and running right. Don’t trust a memory or a photocopy. Access the Factory Manual from AutoRepairManuals and put it in the tool compartment where it belongs.