Drum, oscillating articulated joint, travel pump, vibration motor, drum drive motors: the Bomag BW 161 AD-2, BW 202 AD-2 repair manual PDF (OEM 008 193 64) walks each system end to end across its 196 pages, covering both tandem vibratory rollers. Much of the front section is one long trouble shooting diagram, tracing travel and vibration faults to hard values like the 1.23 A draw on a magnetic coil. Supplier documentation on the A4VG travel pump, A4FM28 vibration motor and MS/MSE 02 to 18 drive motors fills the back half, down to rotary group and brake piston level. Torque the rubber buffers to 300 Nm and set the high pressure relief valve at 440 bar before you condemn a pump. Bookmarked and carrying a proper text layer, the PDF goes wherever the roller is parked; download it and keep the numbers in your pocket.
What's Inside This Bomag BW 161 AD-2, BW 202 AD-2 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 5-14 | Foreword, Safety Regulations, General Repair Instructions |
| Trouble Shooting | 15-36 | Trouble Shooting Diagram |
| Drum | 37-62 | Special Tools, Repair Overview for Drum, Removing and Installing the Drum, Changing the Rubber Buffers, Repairing the Drum, Dismantling, Assembling the Change-Over Weights |
| Oscillating Articulated Joint | 63-74 | Repair Overview Oscillating Articulated Joint, Removing and Assembling the Crabwalk Cylinder, Removing and Installing the Oscillating Articulated Joint |
| A4Vg | 77-122 | Drive Shaft, Boost Pump, Control Piston Cover, Valves, Control Module, Rotary Group |
| A4Fm28 | 123-144 | Vibration Motor, Drive Shaft, Port Block, Rotary Group |
| Ms/Mse 02 to 18 | 145-196 | Motor, Brake Piston, Bearing Support, Brake Shoes, Cam, Cylinders Block Assembly |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| High pressure relief valve | 440 bar | p. 13 |
| Charge pressure relief valve | 22 bar | p. 13 |
| Power draw on the magnetic coil | 1.23 A | p. 20 |
| Pressure cut-off valve nominal value | 410 bar | p. 33 |
| Tightening torque for rubber buffers | 300 Nm | p. 46 |
| Tightening torque M4 (8.8) | 3 Nm | p. 11 |
| Pressure override | 410 bar | p. 13 |
| Support leg fastening nut torque | 300 Nm | p. 42 |
| Oscillating articulated joint screw torque | 580 Nm | p. 68 |
| BW 161 AD-2 | ||
| Oil capacity for BW 161 | 3.0 L | p. 57 |
| Drum oil capacity (BW 161) | 3.0 L | p. 57 |
| BW 202 AD-2 | ||
| Drum oil capacity (BW 202) | 4.8 L | p. 57 |
Bomag BW 161 AD-2, BW 202 AD-2 Common Problems This Manual Covers
Bomag BW 161 AD-2 roller randomly stops traveling after ten minutes of rolling, then drives again
Check the seat and brake switch circuits before condemning the pump; an intermittent contact drops the travel solenoid exactly this way. Measure power draw on the magnetic coil, 1.23 A nominal per page 20, and wiggle-test the harness while the machine is hot. Then gauge charge pressure against the 22 bar spec while the fault is active.
Manual Section: Trouble Shooting p. 20No vibration on either drum, control lever vibration button seems completely dead
Verify the vibration solenoid gets current when the button is pressed, and check the 3/2-way valve while you are in that circuit. Then gauge the vibration circuit: starting pressure around 410 bar, operating pressure 80 to 120 bar in double vibration, values on page 30. No pressure rise at all points to the vibration pump, not the switch.
Manual Section: Trouble Shooting p. 30Insufficient travel power on grades, roller barely climbs the trailer ramp under its own power
Measure boost pressure at the A4VG travel pump first: 18 bar nominal and 40 bar peak, with the adjustment procedure on page 118. If boost checks out, test the high pressure relief valves against the 440 bar nominal value on page 33. Worn HP valves and a tired boost pump cost climbing power, so rule both out before you open the rotary group.
Manual Section: A4Vg p. 118Knocking and rumbling from the drum during vibration, rubber buffers cracked or loose
Pull the drum following the service procedure starting on page 41 and inspect the exciter bearings and rubber buffers. Replace any cracked buffers and torque them to 300 Nm as specified on page 46. Set bearing end float between 0.5 mm and 1.9 mm per page 56, then refill the drum: 3.0 L for the BW 161, 4.8 L for the BW 202.
Manual Section: Drum p. 41Machine creeps in neutral, travel lever centered but drums keep rolling slowly
Adjust the mechanical and hydraulic zero position on the A4VG travel pump; the fault tree for a machine moving in neutral starts on page 17. Inspect the travel lever linkage for binding and a worn centering spring before touching the pump. Confirm charge pressure holds 22 bar during the test so the servo has clean pressure to center on.
Manual Section: Trouble Shooting p. 17Frequently Asked Questions
What is the tightening torque for M12 screws with a strength class of 8.8?
The tightening torque for screws with a metric unified thread of M12 and a strength class of 8.8 is 88 Nm (65 ft-lb). p. 11
What is the nominal speed for the diesel engine?
The nominal speed for the diesel engine is 2150 rpm. p. 19
What is the nominal charge pressure for the vibration pump?
The nominal charge pressure for the vibration pump is approximately 22 bar. p. 21
What is the oil capacity for the BW 161 drum bearing housing?
The oil capacity for the BW 161 drum bearing housing is 3.0 liters of SAE 15W/40 oil. p. 57
What is the tightening torque for the oscillating articulated joint hexagon screws?
The tightening torque for the hexagon screws on the oscillating articulated joint is 580 Nm. p. 68
What exactly do I receive with this Bomag BW 161 AD-2 Repair Manual?
Delivery is instant: a 196-page searchable PDF is yours the second checkout clears. Laptop, tablet, or phone, all fine.
Is this Bomag BW 161 AD-2 Repair Manual printable?
Printing is allowed without restriction. Pull the pages you need for the job and bin them when they get greasy.
Reviews
There are no reviews yet.