Before the paving train stalls waiting on a dead Series 5 compactor, you need the repair data found in this 420-page factory reference (OEM 008 917 37) covering seven tandem and combination roller variants. Your Bomag bw 80 ad-5, bw 90 ad-5, bw 100 adm-5, bw 90 sc-5, bw 100 sc-5, bw 100 acm-5, bw 100 scc-5 service manual pdf maps out the entire travel and vibration systems through detailed hydraulic schematics and complete teardown instructions for the oscillating articulated joint. Electrical troubleshooting charts trace faults directly from the A15 instrument cluster down to the seat contact switch and travel control lever. Workshop procedures include hard tolerances, like setting the V-belt deflection between 7 and 9 mm or verifying the Kubota engine thermostat stroke begins at 69.5°C. Guessing at travel pump neutral positions usually results in a ruined component and a forced second teardown. Download this bookmarked digital file once, and the specifications belong to your shop permanently.
What's Inside This Bomag BW 80/90/100-5 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 7-26 | Introduction, Safety Regulations, Tightening Torques |
| The Series 5 | 27-30 | Drive Technology, Operator's Stand, Vibration Control, Articulated Joint, Water Sprinkling System, Braking System |
| Technical Data | 31-48 | Engine Data, Travel Pump, Drum Drive Motor, Wheel Motor, Vibration Motor, Steering Valve |
| Maintenance | 49-60 | Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Table |
| Overall View of Machine | 61-66 | Overview |
| Electrics | 67-108 | Battery Service, Starting with Jump Wires, Main Battery Switch, Generator Repair, Repair of Starter, Instrument Cluster, Overview, Seat Contact Switch |
| Engine | 109-134 | Fuel Supply, Kubota Diesel Engine, Checking the Engine Oil Level, Changing Engine Oil and Oil Filter, Checking the Coolant Level, Changing the Coolant |
| Hydraulics | 135-184 | Hydraulic Circuit, Travel Pump, A10VG18 Hw, Drum Drive Motor MK04, Wheel Motor MSE02, External Gear Motors, External Gear Pumps, Pump Assembly |
| Tests and Adjustments | 185-200 | Special Tools, Checking the Rotation Speeds, Pressure Tests in the Travel Circuit, Checking / Adjusting the Neutral Positions of the Travel Pump |
| Trouble Shooting | 201-212 | Perform Trouble Shooting, Trouble Shooting Chart, Diesel Engine, Troubleshooting Axial Piston Pumps, Fault Detection Via Instrument Cluster, A15, Machine Does Not Drive |
| Flushing and Bleeding | 213-232 | Special Tools for Flushing, Flushing - General, Flushing Schematic for Travel System, Ad/SC-machine, Travel System, Flushing Ad/SC-machine |
| Drum | 233-254 | Repair Overview for Drums, Removing and Installing the AD-drum, Dismantling the AD-drum, Assembling the AD-drum |
| Oscillating Articulated Joint | 255-264 | Repair Overview Oscillating Articulated Joint, Removing and Installing the Oscillating Articulated Joint, Repairing the Oscillating Articulated Joint |
| Suppliers Documentation | 265-376 | Drum Drive, Wheel Drive, Steering Valve |
| Circuit Diagrams | 377-420 | Hydraulic Diagram 121, Wiring Diagram 76 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| V-belt pulley tightening torque | 58.4 to 78.9 Nm | p. 71 |
| Pickup winding (AW) nominal current | 32 A | p. 90 |
| Holding winding (HW) nominal current | 0.8 A | p. 90 |
| V-belt deflection | 7 to 9 mm | p. 120 |
| Thermostat beginning of stroke | 69.5°C to 72.5°C | p. 125 |
| Thermostat end of stroke | 85°C | p. 125 |
| Nozzle holder (upper/lower part) tightening torque | 35 to 39 Nm | p. 128 |
| Leak oil line retaining nut tightening torque | 20 to 24 Nm | p. 128 |
| Current consumption of the solenoid valve | 2.75 Amp | p. 209 |
| Charge pressure, high idle | 20 bar | p. 209 |
| Engine Oil Capacity | 3.9L | p. 55 |
| Fuel Tank Capacity | 30.0L | p. 33 |
Bomag BW 80/90/100-5 Series Common Problems This Manual Covers
Bomag BW 80 AD-5 will not move in either direction and travel drive feels intermittently weak
Check charge pressure at high idle to ensure it reaches 20 bar. Verify the brake solenoid current consumption is exactly 2.75 Amp on page 209. If the travel drive remains weak, inspect the travel pump connections and verify the hydraulic oil capacity is at 14L.
Manual Section: Fault detection via instrument cluster, A15 p. 209Engine keeps running after turning the key switch off and stop solenoid fails to engage
Inspect the stop solenoid wiring and measure the pickup winding nominal current. Verify it draws exactly 32 A on page 90. Check the terminal resistance for the pick-up winding to ensure it reads 0.38 Ω on page 91. Replace the solenoid if readings fail.
Manual Section: Electrics p. 90Diesel engine temperature spikes quickly under heavy compaction load and the entire cooling system overheats
Measure the V-belt deflection by applying pressure midway between the pulleys. Adjust tension to achieve a deflection of 7 to 9 mm as shown on page 120. Inspect the thermostat to ensure the beginning of stroke occurs between 69.5°C to 72.5°C on page 125.
Manual Section: Engine p. 120Diesel engine loses power, runs irregularly during compaction passes, and stalls under heavy vibration load
Remove and test the injection valves for proper opening pressure. Verify the fuel injection pressure reaches 140.0 to 150.0 bar on page 127. Reinstall the components and torque the nozzle holder assembly to 49 to 68 Nm as instructed on page 128.
Manual Section: Engine p. 127Frequently Asked Questions
What is the torque specification for the rubber buffers on the AD-drum of the Bomag BW 80/90/100-5 Series?
Torque spec for the rubber buffers on the AD-drum is 211 Nm. p. 241
What are the replacement specifications for the fuel filter on a Bomag BW 80/90/100-5 Series?
Replace the fuel filter cartridge according to the maintenance table. When changing it, clean the sealing face on the filter carrier, apply a thin film of fuel to the seals, screw the new cartridge on hand-tight, then tighten another half turn. p. 123
What is the engine oil and oil filter change interval on the Bomag BW 80/90/100-5 Series?
Change the engine oil and oil filter every 250 operating hours. For new machines or overhauled engines, the first change comes at 50 operating hours. p. 58
What is the valve clearance spec for the Kubota diesel engine in the Bomag BW 80/90/100-5 Series?
Valve clearance for both intake and exhaust valves on the Kubota diesel engine runs 0.145 to 0.185 mm, checked cold. p. 132
What is the engine oil capacity for the Bomag BW 80/90/100-5 Series?
Engine oil capacity for the motor is approximately 3.9 liters (1.0 gal us). p. 55
What do I get after purchasing this Bomag BW 80 AD-5 manual?
All 420 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Can I print this Bomag BW 80 AD-5 manual?
Yes, printing is unrestricted: a single page, a chapter, or the lot, on letter or A4.
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