This Bomag BW 161, BW 202, BW 164 Service Training PDF pulls the hydrostatic drivetrain of five tandem vibratory roller variants apart on paper: 176 pages under OEM ID 008 098 47, spanning the AD, AC, and ADH-2 designations. Wiring diagrams map the supply and starting circuits down to individual component codes, while hydraulic schematics for the BW 161 AD and BW 202 ADH-2 trace pressure lines from travel pump to drum drive motor. When a roller creeps with the travel lever in neutral or vibration drops out at one drum, troubleshooting trees walk you from symptom to test port. Set charge pressure to 22 bar and verify the pressure override responds at 410 bar before you condemn a pump. Guess wrong on that call and you eat a rebuild the machine never needed. Bookmarks drop you from symptom chart to schematic in seconds, and the text layer speeds up spec lookups.
What's Inside This Bomag BW 161–202 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| About This Training | 3 | Quality Obligation, Qualification of Employees, Training Objectives |
| General Information | 4 | Compaction Tasks, Sprinkler Systems, Emergency Brake Release System |
| List of Components | 5 | Position of Components and Test Ports, Front and Rear Travel Motors, Steering and Vibration Pumps |
| Travel System | 6-14 | Travel Pump, Travel Motors, Connecting Hoses, Control Piston, High Pressure Relief Valves, Pressure Override Valve |
| Technical Data and Adjustment Values | 15-18 | Bw 202 Adh-2 Specifications, Filling Capacities, Bw 202 Ad-2 Specifications |
| Maintenance | 19-22 | Maintenance Importance, Maintenance Intervals, Maintenance Table |
| Travel System Description | 23-41 | Travel Pump, Hydraulic Schematic, Overview of Ports and Connections, Servo Control, Charge Pressure Relief Valve, High Pressure Relief Valves |
| Trouble Shooting Travel System | 42-70 | Machine Moves with the Travel Lever in Neutral, Machine Does Not Move, Poor Travel Power, Max. Speed Not Reached |
| Vibration System | 71-85 | Vibration Pump, Vibration Motors, Vibration Shut-Off Valve, Flushing Valve, Pressure Relief Valve, Anti-Cavitation Valve |
| Trouble Shooting Vibration System | 86-109 | No Vibration at Front and Rear, Front or Rear Vibration Cannot Be Switched on, Too Low Vibrator Shaft Speed at Front and Rear |
| Steering System | 110-118 | Steering Pump, Steering Valves, Priority Valve, Steering Cylinders, Shock Valves, Load Sensing Line |
| Trouble Shooting Steering System | 119-122 | No Steering Function, Checking Steering Pressure, Checking Steering Cylinders |
| Circuit Diagrams | 123-142 | Table of Contents, Supply Circuit Diagram, Starting Unit Circuit Diagram |
| Component Listing | 143-172 | Component List A-E, Component List F-H, Component List K-X |
| Hydraulic Schematics | 173-176 | Hydraulic Schematic Bw 161 Ad, Component Legend, Hydraulic Schematic Bw 202 Adh-2 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| High pressure (Pressure override responding) | 410 bar | p. 6 |
| Charge pressure | 22 bar | p. 6 |
| Change interval | min. every 2 years | p. 22 |
| Current consumption on both solenoids | approx. 2 Ampere | p. 86 |
| Current consumption on the vibration shut-off valve | approx. 2.4 Ampere | p. 91 |
| Battery capacity | 102Ah | p. 149 |
| Magnetventil Bremse (Solenoid valve, brake) | 2,5A | p. 162 |
| Hydraulic oil capacity | 60 L | p. 16 |
| BW 202 ADH-2 | ||
| Engine Power (ISO 9249), BW 202 ADH-2 | 70 kW | p. 15 |
| High pressure (Travel pump), BW 202 ADH-2 | 450 bar | p. 15 |
| BW 202 AD-2 | ||
| Engine Power (ISO 9249), BW 202 AD-2 | 70 kW | p. 17 |
| High pressure (Travel pump), BW 202 AD-2 | 440 bar | p. 17 |
Bomag BW 161–202 Series Common Problems This Manual Covers
Bomag BW 202 tandem roller loses travel power after warming up, then stops moving mid-pass
Check charge pressure at the travel pump test port before anything else; a healthy charge circuit holds about 22 bar, listed with the adjustment values on page 6. If charge falls off as the oil warms, suspect the charge pressure relief valve or a plugged filter, then work through the travel troubleshooting procedure starting on page 42.
Manual Section: Trouble Shooting Travel System p. 42Vibration will not switch on at front or rear drum, or cuts out intermittently while rolling
Test the solenoids with a clamp meter before pulling the vibration pump. Front and rear vibration solenoid valves should draw about 3 A per the component listing on pages 162 and 163, and the vibration shut-off valve about 2.4 A per page 91. No current means wiring or switch trouble; follow the vibration troubleshooting steps beginning on page 86.
Manual Section: Trouble Shooting Vibration System p. 86Hydraulic oil runs hot during long shifts and travel power fades as temperature climbs
Verify hydraulic oil level first; the system holds 60 L per the technical data on page 16. Clean the cooler fins with compressed air and check for crushed or kinked suction lines. Replace the hydraulic oil filter element if it is past its interval, minimum every 2 years per the maintenance table on page 22, then recheck temperature under load.
Manual Section: Trouble Shooting Travel System p. 42Steering feels sticky and slow, drums will not articulate all the way to the end stops
Measure steering pressure at the test port with the wheel held against a stop. The steering pressure relief valve is set to 140 bar per page 111; a low reading points to the relief valve or a worn steering pump. Work through the steering troubleshooting on page 119 before condemning the cylinders, and bleed the circuit after any line is opened.
Manual Section: Trouble Shooting Steering System p. 119Machine will not move at all, brake never releases, no click from the brake solenoid
Check current draw at the brake solenoid valve with the brake switch released; it should pull about 2.5 A per the component listing on page 162. Zero current means a switch or wiring fault, so trace the circuit against the wiring diagram on page 124 before replacing the valve, then confirm the brake releases and the roller creeps in both directions.
Manual Section: Circuit Diagrams p. 124Frequently Asked Questions
What are the replacement specifications for the fuel filter?
The fuel filter cartridge should be changed at the 1000 operating hour interval. The system must be bled after the filter is replaced. p. 21
What is the valve clearance specification for the engine?
The valve clearance for the inlet valve is 0.15 mm and the outlet valve is 0.145 mm on the BW 202 ADH-2 engine when the engine is cold. p. 15
What is the engine oil capacity for the BW 202 ADH-2?
The engine oil filling capacity is 13.5 liters, using SAE 15W-40 oil (API SJ/CF). p. 16
What is the nominal charge pressure for the travel system?
The nominal charge pressure for the travel system is 22 bar. p. 6
What is the high pressure relief valve setting for the travel system?
The high pressure relief valve for the travel system is set to 440 + 10 bar. p. 6
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Are there any print restrictions on this Bomag BW 161 AD manual?
Printing is allowed without restriction. Pull the pages you need for the job and bin them when they get greasy.
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