An hour from now you could have the travel pump loop traced: this 85-page Bomag BW 80 AD-2 Service Training PDF, factory number 008 099 27, is the workshop book for that roller and three more tandem vibratory rollers in the same AD-2 and AC-2 family. The wiring diagrams fill the last quarter of the book, laid out by function group with potential and relay cross references, and hydraulic schematics map the closed-loop travel circuit from pump through drum drive motor. Troubleshooting tables walk poor travel power and a machine that creeps with the lever in neutral back to a testable cause, with the Kubota engine, vibration and steering sections handled the same way. Verify brake release at a 12 bar minimum opening pressure and hold the brake line at 18 to 20 bar before you condemn anything. Guess wrong on a travel pump and you pay for the part and the second teardown. Bookmarks drop you on the right section in two taps.
What's Inside This Bomag BW 80–100 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| List of Components | 8-10 | - |
| Kubota Diesel Engine | 11-23 | Cylinder Block, Cylinder Head, Combustion System, Crankshaft, Piston and Pistons Ring, Conrod, Camshaft and Fuel Camshaft, Flywheel |
| Travel System | 24-45 | Travel Pump, Control, Charge Pressure Relief Valve, High Pressure Relief Valves, Drum Drive Motor, Brake Control, Flushing the Travel System, Trouble Shooting Travel System |
| Vibration | 46-58 | Vibration Pump, Vibration Control, Vibration Motor, Trouble Shooting Vibration |
| Steering | 59-64 | Steering Valve, Trouble Shooting Steering |
| Wiring Diagrams | 65-85 | Table of Contents, Function Groups, Line Thicknesses, Reference Lines, Frames, Potential Cross Reference, Releay Cross-References, Electric System |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| current draw of the solenoid valve | 2.75 A | p. 32 |
| minimum opening pressure for brake | 12 bar | p. 30 |
| Battery capacity | 55AH | p. 75 |
| Battery | 55AH | p. 81 |
| Generator | 40A | p. 81 |
| Engine Power (DIN 6271 IFN/SAE at 3000 min-1) | 11.9 kW | p. 8 |
| Engine Displacement | 719 cm³ | p. 8 |
| Engine Valve Clearance (cold) | 0.15 mm | p. 22 |
| Travel Pump High Pressure Limitation | 300 bar | p. 8 |
| Travel Pump Charge Pressure | 20 bar | p. 8 |
| Vibration Motor Frequency | 60 Hz | p. 10 |
| Engine Oil Capacity (15W/40) | 3.9 L | p. 10 |
Bomag BW 80–100 Series Common Problems This Manual Covers
Bomag BW 90 AD-2 engine won't start or cranks slow, no smoke from exhaust in cold weather
Check fuel level and swap the fuel filter first; winter paraffin gelling plugs it fast on these Kubotas. Work the no-start chart starting page 18, then verify compression against the 28.4 to 32.4 bar factory figure on page 21. Check valve clearance, 0.15 mm cold, per page 22 while you are in there.
Manual Section: Kubota Diesel Engine p. 18Roller starts fine but won't move in either direction, drive cuts out when operator shifts on seat
Test the brake solenoid first; it should draw 2.75 A, per page 32. Tee a gauge into the brake line and confirm 18 to 20 bar nominal pressure, noted on page 33; the brake needs roughly 12 bar minimum to release. Then chase the seat switch and park-position switch through the wiring diagram on page 75.
Manual Section: Travel System p. 32Vibration weak or won't kick in on either drum, mat not hitting density in normal pass count
Test the vibration circuit with a gauge before pulling anything apart. Starting pressure should hit 210 bar and operating pressure should settle near 125 bar, both on page 52. Low readings point to exciter bearing drag or a worn vibration pump; run the pressure test and leakage-rate check in the vibration section, page 46 onward.
Manual Section: Vibration p. 52Charge warning light stays on above idle and battery goes flat overnight
Check V-belt tension first; a loose belt kills charging output before the generator does. Measure voltage across the battery at working rpm; the system runs a 40 A generator with a 55 Ah battery, listed on page 81. If output is dead with a good belt, replace the regulator and trace the charge circuit on the wiring diagram, page 75.
Manual Section: Wiring Diagrams p. 81Engine shuts down seconds after start, low oil pressure warning on a warm machine
Check oil level on level ground before condemning anything; the sump only holds 3.9 L of 15W/40, listed on page 10, so a small leak drains it fast. Verify the grade matches ambient temperature, then work the oil pressure branch of the engine troubleshooting chart starting page 18. Inspect the pickup screen if pressure stays low on fresh oil.
Manual Section: Kubota Diesel Engine p. 18Frequently Asked Questions
What is the valve clearance specification for the engine?
The valve clearance for both intake and exhaust valves must be checked and adjusted when the engine is cold. The factory setting for the valve clearance is 0.15 mm. p. 22
What is the engine oil capacity for the machine?
The engine oil capacity is 3.9 liters, which should be filled to the maximum mark on the dipstick. p. 10
What is the nominal charge pressure for the travel system?
The nominal charge pressure for the travel system is 20 bar. p. 8
What is the high pressure relief valve setting for the travel system?
The high pressure relief valves limit the maximum pressure in the travel system to 300 bar. p. 28
What is the coolant capacity for the engine?
The cooling system capacity for the engine is 1.9 liters of water and anti-freeze mixture. p. 10
What format is this Bomag BW 80 AD-2 manual in?
Delivery is instant: an 85-page searchable PDF is yours the second checkout clears. Laptop, tablet, or phone, all fine.
Can I print a copy of this Bomag BW 80 AD-2 Service Manual for the shop?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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