Within the hour you could have gauges teed into the travel circuit, running the pressure tests this Bomag BW 80 AD-2 service manual PDF lays out across 388 pages of factory repair data (OEM 008 914 60) for five rollers in the BW tandem and combination family. Full wiring diagrams and hydraulic schematics close out the book, while troubleshooting charts trace faults from a machine that refuses to drive to vibration that never starts, one check at a time. Drum teardown, the oscillating articulated joint, and flushing the travel circuit each get their own repair sections. Set the M12x1.5 wheel nuts to 100 Nm and verify the travel pump against its 18 cm3/rev maximum displacement. When the vibration quits mid-pass, there's nobody to ask. This bookmarked, text-layered PDF rides on whatever screen you carry out to the machine.
What's Inside This Bomag BW 80 AD-2, 90 AD-2, 100 ADM-2, 90 AC-2, 80 ADS Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 7-26 | Introduction, Safety Regulations, General Repair Instructions |
| Technical Data | 27-36 | Engine, Travel Pump, Drum Drive Motor, Steering Valve, Vibration System, Brakes |
| Maintenance | 37-44 | Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Chart |
| Tests and Adjustments | 45-58 | Special Tools, Checking the Rotation Speeds, Pressure Tests in the Travel Circuit, Travel Pump High Pressure Test, Pressure Tests in the Vibration Circuit |
| Trouble Shooting | 59-74 | Trouble Shooting Chart, Diesel Engine, Machine Does Not Drive, Insufficient Travel Power, Machine Drives with the Travel Lever in "Neutral", Vibration Frequency Too Low |
| Electrics | 75-146 | Understanding Circuit Diagrams, Designation of Components in the Wiring Diagram, Terminal Designations in Wiring Diagram, Circuit Symbols in the Circuit Diagram |
| Special Tools, Electrics | 147-156 | Special Tools |
| Electronic Modules | 157-162 | Electric Module K04 |
| Engine | 163-182 | Kubota Diesel Engine, Checking the Coolant Level, Changing the Coolant, Checking, Cleaning, Changing the Dry Air Filter Cartridge, Replacing the Dry Air Filter Cartridge |
| Hydraulics | 183-200 | Travel Hydraulics, Vibration Hydraulics, Steering Hydraulics, Check the Hydraulic Oil Level, Changing the Hydraulic Oil, Checking the Hydraulic Oil Filter Element |
| Flushing and Bleeding | 201-216 | Special Tools for Flushing, Flushing - General, Flushing Schematic for Travel System, Flashing the Travel Circuit, Bleeding the Travel Circuit |
| Drum | 217-234 | Repair Overview for Drum, Removing and Installing the Drum, Dismantling the Drum, Assembling the Drum |
| Oscillating Articulated Joint | 235-248 | Repair Overview Oscillating Articulated Joint, Removing and Installing the Oscillating Articulated Joint, Repairing the Oscillating Articulated Joint |
| Suppliers Documentation | 249-320 | Steering Valve, Wheel Drive, Drum Drive |
| Circuit Diagrams | 321-388 | Wiring Diagram, Hydraulic Diagram |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for M12x1.5 wheel nuts | 100 Nm | p. 23 |
| Tightening torque for M14x1.5 wheel nuts | 150 Nm | p. 23 |
| Travel pump Max. displacement | 18 cm3/rev. | p. 34 |
| Travel pump Max. flow capacity | 65,8 l/min | p. 34 |
| Drum drive motor Displacement stage 1 | 500 cm3/rev. | p. 34 |
| Drum drive motor Perm. leak oil rate | 1,5 l/min | p. 34 |
| Solenoid valve current consumption | 2.75 A | p. 63 |
| Charge pressure | 18 to 20 bar | p. 63 |
| End float of the exciter shafts (min.) | 0.52 mm | p. 73 |
| End float of the exciter shafts (max.) | 2.00 mm | p. 73 |
| Fine particle contamination | 5 – 15 µm | p. 207 |
| Extra fine particle contamination | < 2 – 5 µm | p. 207 |
Bomag BW 80 AD-2, 90 AD-2, 100 ADM-2, 90 AC-2, 80 ADS Common Problems This Manual Covers
Bomag BW 80 AD-2 creeps forward at idle with travel lever centered in neutral
Check the neutral setting of the travel pump before condemning it. Verify charge pressure reads 18 to 20 bar using the spec on page 63, then adjust the travel cable and end stops until the drum sits still at full throttle. A stretched cable causes most creep complaints on these machines.
Manual Section: Machine Drives in NeutralMachine sluggish climbing grades or no drive at all, gets worse as hydraulic oil warms
Start with the hydraulic oil level; the tank only holds about 9 litres and a small leak drains it fast. Test charge pressure against the 18 to 20 bar spec on page 63, then run the travel pump high pressure test and confirm 300 to 340 bar per page 66 before ordering a pump.
Manual Section: Travel System Troubleshooting p. 63Vibration cuts out mid-pass or drum rumbles loudly with frequency dropping below normal
Verify diesel engine speed against its rated spec first; a lazy engine drops frequency and mimics bad bearings. Then measure end float on the exciter shafts before splitting the drum. Anything outside 0.52 mm to 2.00 mm on page 73 means the vibrator bearings are done and the drum comes apart.
Manual Section: Vibration Frequency Too Low p. 73Drum drags or locks up while rolling, parking brake will not fully release
Test brake release pressure at the travel motor; the wet brake needs a minimum 12 bar opening pressure per page 187 to pull off the discs. If pressure is low, check the solenoid valve draws its rated 2.75 A and trace charge pressure back through the circuit before pulling the drum drive.
Manual Section: Hydraulics p. 187Rear drum wanders and machine no longer tracks straight through directional changes
Inspect the oscillating articulated joint for play with the machine on stands and the steering worked lock to lock. Replace worn bearings rather than shimming them, and torque the clamping nut to a maximum of 300 Nm per page 238 on reassembly. Sloppy bearing blocks ruin mat finish on every pass.
Manual Section: Oscillating Articulated Joint p. 238Frequently Asked Questions
What are the travel pump replacement specs for the Bomag BW 80 AD-2, BW 90 AD-2, BW 100 ADM-2, BW 90 AC-2, BW 80 ADS?
The travel pump is a Bosch-Rexroth A10VG18 axial piston pump with a maximum displacement of 18 cm³/rev. The high pressure limitation is set to 300 ± 5 bar, and the charge pressure at high idle is 20 ± 1 bar. p. 34
What is the valve clearance spec for the Bomag BW 80 AD-2, BW 90 AD-2, BW 100 ADM-2, BW 90 AC-2, BW 80 ADS engine?
Intake and exhaust valve clearance is 0.14 to 0.18 mm, measured on a cold engine. p. 43
Tightening torque for drum rubber buffers on Bomag BW 80 AD-2, BW 90 AD-2, BW 100 ADM-2, BW 90 AC-2, BW 80 ADS?
Rubber buffers on the drum must be tightened to a torque of 211 Nm. p. 221
What is the required frequency for the toothed belt on the pump drive?
Required frequency for the pump drive toothed belt is 100-130 Hz. Confirm it can be depressed 6 to 8 mm when applying a pressing force of 70 N. p. 199
What is the nominal engine compression pressure on Bomag BW 80 AD-2, BW 90 AD-2, BW 100 ADM-2, BW 90 AC-2, BW 80 ADS?
Factory data puts compression pressure at 29.0 to 33.0 bar, with a permissible limit of 23.0 bar. p. 181
How quickly can I access this Bomag BW 80 AD-2 manual after buying?
You download the Service Manual yourself: 388 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Can I print a copy of this Bomag BW 80 AD-2 Service Manual for the shop?
Absolutely: the PDF carries no copy protection, so print whatever sections the shop needs and keep the file as backup.
Reviews
There are no reviews yet.