Bomag put its own part number on this book: 008 191 32, the 318-page factory repair manual for the BW 161 AD and 202 AD tandem vibratory rollers. Hydraulic schematics trace the closed-loop travel and vibration circuits, wiring diagrams map the relay board and monitoring module, and troubleshooting charts walk travel, vibration, and steering faults back to a testable cause. Sealing procedures take the travel and vibration pump apart valve by valve, so you can reseal a leaking control unit instead of replacing the whole pump, then flush the circuit afterward. Set charge pressure inside the 18 to 22 bar window, confirm 390 to 410 bar on the high pressure test, and torque the coupling screws to 90 Nm. A guessed relief pressure can cook a pump in one shift. Bookmarked and text-searchable, it rides on whatever screen you carry to the machine.
What's Inside This Bomag BW 161 AD, BW 202 AD Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 9-26 | Safety Regulations, Technical Data, Torques, Connecting Points, Special Tools |
| Engine | 27-42 | Checking Diesel Engine Speed, Dismounting and Installing the Engine, Preparing the Engine for Operation |
| Travel System | 43-134 | Pressure Tests in the Travel System, Travel Pump High Pressure Test, Trouble Shooting Chart, Dismounting and Installing the Travel Motor, Repair Survey, Repairing the Travel Motor |
| Vibration | 135-230 | Checking the Speed of the Exciter Shaft, Trouble Shooting Chart, Dismounting and Installing the Vibration Pump for the Front Drum, Exchanging the Coupling for the Vibration Pump |
| Steering | 231-266 | Checking, Adjusting the Steering Pressure, Trouble Shooting Chart, Dismounting and Installing the Steering Cylinders, Repairing the Steering Cylinder |
| Electric System | 267-304 | Important Electric Symbols and Designations, Overall View of Instrument Panel, Current Supply, Fuses, Starting, Charge and Start Control, Brake, Brake Control |
| Circuit Diagrams | 305-318 | Wiring Diagramme, Hydraulic Schematic |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Solenoid coil current consumption | 1.23 A | p. 49 |
| Charge pressure | 18 ... 22 bar | p. 45 |
| High pressure | 390 ... 410 bar | p. 45 |
| Pressing force for brake assembly (Bomag-part-no. 058 152 38) | 35000 N (3.5 t) | p. 72 |
| Mounting screws for coupling | 90 Nm | p. 152 |
| Mounting nuts for drive disc | 420 Nm | p. 153 |
| Constant pressure for bleeding | 20-22 bar | p. 221 |
| Maximum pressure during bleeding | 100 bar | p. 222 |
| Terminal #6 voltage (seat contact switch closed) | Approx. +6.7V | p. 299 |
| Terminal #7 voltage (left hand seat contact switch closed) | Approx. +6.7V | p. 299 |
| BW 161 AD | ||
| Operating weight (Cece), BW 161 AD | 9087 kg | p. 15 |
| BW 202 AD | ||
| Operating weight (Cece), BW 202 AD | 10077 kg | p. 15 |
Bomag BW 161 AD, BW 202 AD Common Problems This Manual Covers
Bomag BW 161 AD tandem roller will not travel, drive response weak in both directions
Check the hydraulic oil level first; the tank holds 60 l (page 17) and a low level starves the charge circuit. Then tee a gauge into the travel pump and confirm charge pressure of 18 to 22 bar at full throttle, per the spec on page 45. If pressure is low, work through the travel troubleshooting chart starting on page 49.
Manual Section: Travel System p. 49No vibration at front drum, rear drum still shakes normal with both selected
Verify the switch selection first, then measure the exciter shaft speed as described in the vibration section starting on page 135. If the front vibration pump coupling has sheared, replace it and torque the coupling mounting screws to 90 Nm per page 152. Bleed the circuit afterward and keep pressure below 100 bar during bleeding, page 222.
Manual Section: Vibration p. 135Engine cranks but won't start, no warning lights, starter sometimes completely dead
Check the seat contact switch and relay board before condemning the starter. With the operator seated, test relay board terminal 6: it should read approximately 6.7 V with the seat contact switch closed, per page 299. No voltage means the safety circuit is blocking the start; check fuses and current supply in the electric section from page 267.
Manual Section: Electric System p. 267Steering stiff or slow to respond, drums barely articulate at full engine speed
Connect a pressure gauge to the steering circuit and verify 140 to 180 bar with the wheel held against the stop, per page 50. Adjust the relief valve if low. If pressure is good but steering stays stiff, inspect the articulated center joint and torque its mounting screws to 580 Nm per page 263.
Manual Section: Steering p. 231Brake warning light stays on, machine locked up and won't propel either direction
Check charge pressure before pulling the brake apart; the brakes release hydraulically and snap closed when the charge circuit fails. Verify 18 to 22 bar at the test port per page 45, then inspect the brake line for a break or leak. Work through the brake control tests in the electric section from page 267.
Manual Section: Electric System p. 267Frequently Asked Questions
What is the nominal engine speed for the BW 161 AD and BW 202 AD?
The nominal engine speed for both the BW 161 AD and BW 202 AD models is 2150 rpm. p. 16
What is the tightening torque for the travel motor mounting nuts?
When installing the travel motor, the mounting nuts on the drive disc must be tightened to 420 Nm. p. 55
What is the required tightening torque for the vibration motor coupling screws?
The mounting screws for the vibration pump coupling must be tightened to 90 Nm. p. 152
What is the nominal charge pressure for the travel system?
The nominal charge pressure for the travel system is 18 to 22 bar at operating temperature. p. 45
What is the tightening torque for the oscillating articulated center joint hexagon screws?
The hexagon screws for the oscillating articulated center joint must be tightened to 580 Nm. p. 263
Is this Bomag BW 161 AD manual a PDF I download?
All 318 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Can I print specific sections of this Bomag BW 161 AD Repair Manual?
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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