Hooking up gauges to check travel circuit pressures on a Bomag roller right now? This 458-page 5-series service manual (OEM 008 925 60) covers all eight BW 80-100 tandem and combination roller variants, from the BW 80 AD-5 up to the BW 100 SCC-5. It puts detailed electrical circuit diagrams and hydraulic schematics on your device. The documentation walks you through flushing the closed-loop travel pump, servicing the drum drive motor, and tracing electric faults through the Telemecanique switches and Deutsch plug connectors. Factory specifications are laid out clearly, with exact limits like the 300 to 350 Nm torque rating for M18 fine-thread wheel nuts or the 15-second switch-off delay for the water spray system. Guessing at a swash plate adjustment costs you a ruined travel pump and a stopped paving train. Download this bookmarked file once and keep it permanently to fix your roller.
What's Inside This Bomag BW 80 AD-5, 90 AD-5, 90 AC-5, 100 ADM-5, 100 ACM-5, 90 SC-5, 100 SC-5, 100 SCC-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 7-44 | Introduction, Safety Regulations, Maintenance and Repair (Notes on Repair) |
| Technical Data | 45-86 | Bw 80 Ad-5 (Noise and Vibration Data), Bw 90 Ad-5 (Noise and Vibration Data), Bw 90 AC-5 (Noise and Vibration Data), Bw 100 Adm-5 (Noise and Vibration Data) |
| Electric Systems | 111-206 | Basic Principles (Measuring Method, Understanding Circuit Diagrams, Telemecanique Switch, Deutsch Plug, Series Dt and Dtm, Magnetic Coil Plug) |
| Hydraulic System | 207-294 | Basic Principles (Open and Closed Hydraulic Circuit, Swash Plate Principle, Pump, External Gear Pumps, Reversible External Gear Motor), Overview of Hydraulics (Pump Overview) |
| Machine Assemblies | 295-358 | Diesel Engine (Overview of Diesel Engine, Kubota Diesel Engine, Check the Injection Valves, Checking the Fuel Injection Pump, Maintenance Work) |
| Troubleshooting | 359-394 | Preliminary Remarks, Emergency Procedures (Actuating the Emergency Stop Switch, Disconnecting the Battery, Towing the Machine), Towing - Tandem Vibratory Roller |
| Special Tools | 395-400 | Electrics |
| Appendix | 411-458 | Circuit Diagrams (Circuit Diagram 368, Hydraulic Diagram 289) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torques for wheel nuts (fine thread) M18 x 1.5 | 300 - 350 Nm | p. 39 |
| Tightening torques for wheel nuts (fine thread) M20 x 1.5 | 400 - 500 Nm | p. 39 |
| Tightening torque for screw (1) on Telemecanique switch | 0.6 Nm | p. 130 |
| Water in fuel warning light shutdown time | 2 minutes | p. 182 |
| Sprinkling system switch-off delay | 15 seconds | p. 180 |
| Compressed air pressure for cleaning air filter cartridge | 2 bar (30 psi) | p. 310 |
| Bearing housing tightening torque | 300 Nm | p. 333 |
| Hexagon nut tightening torque | 300 Nm | p. 339 |
| Nominal value for gap X | 2 mm | p. 347 |
| Tightening torque for rubber buffers | 211 Nm | p. 357 |
| Max. operating weight | 1900 kg | p. 47 |
| Operating weight (CECE) | 1550 kg | p. 47 |
Bomag BW 80 AD-5, 90 AD-5, 90 AC-5, 100 ADM-5, 100 ACM-5, 90 SC-5, 100 SC-5, 100 SCC-5 Common Problems This Manual Covers
Bomag BW 80 AD-5 engine cranks but will not start or turns over slowly after sitting overnight
Drain the water separator and check the tank level. Test the fuel level sensor resistance to ensure it reads 65 Ohm when empty as noted on page 183. If the water in fuel warning light triggers, the system will shut down after exactly 2 minutes.
Manual Section: Troubleshooting Diesel Engine p. 393Heavy clunking noise and excessive play in the center articulation joint when reversing direction on the mat
Inspect the articulation spherical bearing for wear. Replace the bearing if worn and torque the bearing housing bolts to exactly 300 Nm. Refer to the procedures on page 339 for the correct hardware sequence. Clean the area thoroughly before reassembly.
Manual Section: Machine Assemblies p. 339Drum vibration feels weak during compaction passes and the drum assembly chatters against the frame
Inspect the drum rubber buffers for tearing or sagging. Measure gap X between the mounts, which must maintain a nominal value of 2 mm as shown on page 347. If replacing the isolators, torque the new rubber buffer hardware to exactly 211 Nm.
Manual Section: Machine Assemblies p. 347Diesel engine bogs down under load while climbing a grade and exhausts dark black smoke
Remove and inspect the air filter cartridge for severe dust loading. Clean the cartridge using compressed air at a maximum of 2 bar (30 psi). Keep the air nozzle at least 3 cm away from the paper element as specified on page 310.
Manual Section: Machine Assemblies p. 310Water spray system fails to shut off automatically when the travel lever returns to neutral
Test the Telemecanique control switch on the operator console. If the contact block is loose, tighten the retaining screw to exactly 0.6 Nm as detailed on page 130. Verify the sprinkling system switch-off delay times out after exactly 15 seconds.
Manual Section: Electric Systems p. 130Frequently Asked Questions
What are the torque specifications for BOMAG roller wheel bolts?
The tightening torque for wheel nuts with fine thread depends on the thread diameter. For an M12 x 1.5 thread, the torque is 100 Nm; for M14 x 1.5 it is 150 Nm; for M18 x 1.5 it is 300-350 Nm; for M20 x 1.5 it is 400-500 Nm; and for M22 x 1.5 it is 500-600 Nm. p. 39
What is the valve clearance specification for the Kubota diesel engine in a Bomag roller?
The intake and exhaust valve clearance for the Kubota diesel engine is 0.15 mm (0.006 in). This check and adjustment should be performed when the engine is cold. p. 321
What is the fuel injection pressure for the BW 80 to BW 100-5 models?
The nominal fuel injection pressure for the BW 80 to BW 100-5 models is 140.0 to 150.0 bar. If the measurement is not compliant with these specifications, the adjusting shim (1) in the nozzle holder must be replaced to adjust the pressure. p. 303
What is the engine oil capacity for the Kubota diesel engine in my Bomag roller?
The engine oil filling quantity for the Kubota diesel engine is 3.9 liters (1.0 gal us). Always observe the level mark on the dipstick when filling. p. 86
Do I get instant access to this Bomag BW 80 AD-5 Service Manual?
Immediate download of the complete 458-page searchable Service Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Is this Bomag BW 80 AD-5 Service Manual printable?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
Does this Bomag BW 80 AD-5 manual have electrical schematics?
Included, and complete: electrical schematics, wire routing, connector pinouts, and circuit descriptions for the Bomag BW 80 AD-5 & variants. You can see one on page 416.
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