2004 BOMAG BW 100/120 AD/AC Series 4 Roller Service Training & Legacy Wiring Diagram Manual Set (P/N 008 099 86)

The training manual explains Series 4 systems, adjustments and troubleshooting. The separate electrical document provides circuit references for the earlier models listed in its title.

Coverage boundary: The earlier-model diagrams do not extend the Series 4 mechanical repair coverage to those machines.

Engine, Hydraulic Drive and Electrical Diagnosis

• Kubota engine: D 1703 MDI component views, compression testing, cold valve-clearance inspection and adjustment, troubleshooting charts, and energized-to-run shutoff-solenoid diagnosis.

• Travel drive and brakes: Hydromatik A10 VG 28 pump controls, charge and high-pressure protection, Poclain motors, brake-release arrangements, no-drive troubleshooting, travel-power checks and neutral adjustment.

• Vibration system: Bosch gear-pump operation, AD and AC motor arrangements, control and brake valves, pressure and leakage tests, exciter-shaft checks and no-vibration diagnosis.

• Steering: Bosch steering/charge pump, Danfoss OSPC 80 ON valve, steering cylinder and articulated-joint checks, with tests that isolate hydraulic component faults.

• Electrical controls and diagrams: Series 4 drawing set 880 100 51, module pin assignments, diagnostic LEDs, component-location views and separate AD/AC hydraulic schematics.

This BOMAG training publication was written for service engineers and suits technicians familiar with hydraulic pressure testing, electrical measurements and diesel-engine service equipment.

AD and AC Drive Configurations

AD rollers have two driven drums, each with a vibration motor. A rear-drum shutoff valve allows front-drum-only vibration. AC machines combine a vibrating front drum with two hydraulically driven rear wheels.

The Poclain MK04 drum motors use Hirth-type brakes; the AC-only MSE02 wheel motors have oil-immersed multi-disc brakes. The manual distinguishes their brake-release arrangements, helping technicians select the procedure for the fitted drive configuration.

Sprinkler systems: Coverage separates standard gravity-fed water sprinkling from the optional pressure system and the AC tire-emulsion circuit. The control descriptions explain how travel-lever position affects sprinkler operation and automatic shutoff.

Travel, Vibration and Steering Fault Isolation

Travel troubleshooting covers a machine that will not move, insufficient travel power, worn or misadjusted controls, and creeping with the lever in neutral. Electrical brake-valve checks are linked to charge-pressure, relief-valve, pump-control and individual motor tests.

Vibration diagnosis connects engine and exciter speed with circuit pressure, control-valve operation, pump output, motor leakage and exciter-shaft bearing condition. Steering tests distinguish cylinder leakage from a weak steering/charge pump or faulty Orbitrol, supporting component-level repair decisions.

Engine Testing and Repair Limits

The Kubota section provides testing, adjustment and fault-finding information, including troubleshooting for starting problems, smoke, low power, lubrication faults and overheating. It is not a complete internal engine-overhaul manual.

BOMAG identifies operating and maintenance instructions, the spare-parts catalog, separate repair instructions and Service Information as additional publications.

Control Modules and Circuit References

The travel-lever monitoring module, P/N 880 255 02, has connector assignments and LED diagnostic information covering automatic angle-sensor zero adjustment, sensor faults, manual and automatic vibration, and sprinkler timing.

The seat-contact module, P/N 88003042, is documented through its input/output assignments and operating logic. These sections explain the relationship between seat occupancy, brake interlocks and engine shutdown.

Diagram coverage: Series 4 sheets include supply/engine starting/emergency shutdown, vibration and sprinklers, brake/flow-divider/edge-cutter circuits, and seat contact. Lighting, weather-protection cab equipment and central-electrics layouts provide further circuit references.

The AD and AC hydraulic schematics show pumps, motors, valves, filters, the cooler, test ports, brakes and steering connections. Component-location views support identification alongside the circuit sheets.

Component-Specific Repair Cautions

The valve-clearance discussion identifies the flywheel TC mark as applying only to cylinder No. 1; using it indiscriminately for the other cylinders risks incorrect valve lash and valve-train damage. The travel-pump dead-head test has a strict duration limit to avoid overloading the pump and relief components.

Several procedures involve high-pressure hydraulics, released parking brakes or a disabled drive circuit. The roller must be secured, hydraulic pressure relieved where specified, and factory test limits observed.

A Preview of Compression and Exciter Checks

For the Kubota D 1703 MDI, the warm-engine compression test lists a factory range of 29.4–32.4 bar and a minimum permissible pressure of 23.5 bar.

The vibration troubleshooting section specifies 0.5–2.00 mm of exciter-shaft end float for the front and rear drums when investigating excessive operating pressure.

PDF Search, Bookmarks and Diagram Detail

Finding text and reading schematics: Text search is available through the main text and electrical diagrams, but not within the two full-machine hydraulic schematics. Embedded bookmarks provide working links to selected sections and circuit sheets; many travel-system and electrical-explanation entries lack working destinations. Small circuit labels require zooming, and some fine electrical lines appear light.

Supplied as one printable, 118-page PDF containing both publications listed above. The total includes the training cover, contents pages, component-location pages, both hydraulic schematic sheets and the separate earlier-model electrical document.