Most tandem roller trouble that stalls a mat starts small: a dry water tank, a clogged fuel pre-cleaner, a skipped 250-hour service, and catching those early is exactly what this 116-page factory operator manual (OEM 008 111 81) is for. Written for four BW-4 series machines, the Bomag BW 161 AD-4, BW 202 AD-4, BW 161 ADH-4 and BW 203 AD-4 operator manual PDF schedules every check on its maintenance chart, from the 10-hour walk-around to the 1500-hour service, and maintenance work fills roughly a third of the book. Operating sections walk you through starting on jump wires, crabwalk travel, the pressure sprinkling system and edge cutter, plus towing and frost protection for the water lines. Fill the crankcase with 10 litres of oil, filter included, and set intake valve clearance to 0.3 mm. Nobody hauls a paper binder up onto a roller. Bookmarked and text-searchable, your copy rides wherever the machine does.
What's Inside This Bomag BW 161 AD-4, BW 202 AD-4, BW 161 ADH-4, BW 203 AD-4 Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Data | 7-12 | Dimensions, Weights, Travel Characteristics, Drive System, Brakes, Steering System, Vibration System, Water Sprinkler System |
| Safety Regulations | 13-20 | General Notes |
| Indicators and Controls | 21-38 | Description of Indicators and Control Elements |
| Operation | 39-60 | Tests Before Taking Into Operation, Starting the Engine, Starting with Jump Wires, Driving the Machine, Stopping the Machine, Operating the Parking Brake, Shutting the Engine Down |
| Maintenance, Schedules, Fuels and Intervals | 62-85 | General Notes on Maintenance, Fuels and Lubricants, Fuels, Lubricants and Filling Capacities, Running-In Instructions, Maintenance Chart, Check the Engine Oil Level, Check the Fuel Level, Check the Hydraulic Oil Level |
| Maintenance, Service, Replacement and Lubrication | 86-108 | Changing the Oil in the Drum Drive Gear, Checking, Tensioning, Lubricating the Steering Chain, Check the Engine Mounts, Checking the V-Belt, Tighten, If Necessary Replace the V-Belt, Changing the Oil in the Vibrator Shaft Tube, Check, Adjust the Valve Clearance, Changing Hydraulic Oil and Breather Filter, Changing the Hydraulic Oil Filter |
| Trouble Shooting | 109-116 | General Notes, Engine |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Open-circuit voltage (fully charged) | 12.6 V | p. 81 |
| Open-circuit voltage (50% discharged) | 12.3 V | p. 81 |
| Engine Oil Capacity (with filter) | 10 litres | p. 66 |
| Towing Speed Limit | 1 km/h | p. 15 |
| Intake Valve Clearance | 0,3 mm | p. 94 |
| Exhaust Valve Clearance | 0,5 mm | p. 94 |
| Towing Hitch Tightening Torque | 578 Nm | p. 57 |
| BW 161 AD-4 | ||
| Operating Weight (Cece) | 9600 kg | p. 8 |
| BW 202 AD-4 | ||
| Operating Weight (Cece) | 11300 kg | p. 8 |
| BW 203 AD-4 | ||
| Operating Weight (Cece) | 12700 kg | p. 10 |
Bomag BW 161 AD-4, BW 202 AD-4, BW 161 ADH-4, BW 203 AD-4 Common Problems This Manual Covers
Bomag BW 161 AD-4 engine cranks slowly or won't start first thing on a cold morning
Check the emergency stop is released and the fuel gauge shows fuel; top up per page 70 if the tank ran dry. Test battery open-circuit voltage using the service steps on page 81: 12.6 V is fully charged, below 12.25 V recharge before cranking again. Clean and grease the pole clamps while the compartment is open.
Manual Section: Service the Battery p. 81Engine starts but loses power and smokes under load halfway through the lift
Drain the fuel pre-cleaner water separator and bleed the system per pages 72-73; water or air in the fuel kills power under load. Change the fuel filter cartridge (page 85) if the bowl shows dirt. Then check the combustion air filter per page 101; if power stays down, verify the 0.3 mm intake valve clearance on page 94.
Manual Section: Check / Empty the Fuel Pre-Cleaner (Water Separator) / Bleed p. 72Hydraulic oil filter warning light stays on after startup and during travel
Replace both hydraulic oil filter elements immediately; that light means the elements are clogged, so change them before the next pass. Follow the procedure on page 96 and renew the seal rings under the filter bowls. Verify the level in the inspection glass per page 71, and add that glance to the 10 operating hours checks on page 68.
Manual Section: Changing the Hydraulic Oil Filter p. 96Water sprinkler barely wetting the drums and asphalt sticking to the steel
Check the water tank level and the ventilation bore in the filler cap per page 74, then pull and clean the filling screens and water filter following page 104. Flush the tank per page 103 if sediment keeps coming back. When overnight temperatures drop toward 0 °C, drain the tank, pumps and lines as shown on page 105 before parking.
Manual Section: Clean the Water Filter p. 104Travel drive dead and machine stuck on the mat, needs towing clear
Follow the towing procedure in the operation section beginning on page 39 before hooking anything up. Torque the towing hitch fastening to 578 Nm per page 57, chock the drums before releasing the brakes, and keep the tow under the 1 km/h limit shown on page 15. Get the machine off the mat first, then troubleshoot.
Manual Section: Operation p. 57Frequently Asked Questions
What are the replacement specifications for the fuel filter?
The fuel filter cartridge should be changed every 1000 operating hours. When replacing, slightly oil the rubber seal on the new filter cartridge, fill it with clean diesel fuel, and tighten it hand-tight. p. 85
What are the replacement specifications for the hydraulic oil filter?
The hydraulic oil filter element must be replaced with every hydraulic oil change. After replacing the filter elements in the filter bowls, perform a test run and check the filters for leaks. p. 96
What is the correct valve clearance for the engine?
The intake valve clearance is 0.3 mm and the exhaust valve clearance is 0.5 mm. These measurements should be checked on a cold engine. p. 94
What is the required tightening torque for the towing hitch?
The towing hitch must be fastened at the front or rear of the machine using a tightening torque of 578 Nm (426 ft.lb). p. 57
What is the required V-belt tension for the generator?
For the first installation, the V-belt tension should be approximately 450±50 N. After 15 minutes of operation, it should be retightened to approximately 300±50 N. p. 90
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