This Bomag BW 161 AD-4, BW 202 AD-4 Service Training PDF breaks both tandem rollers down system by system across 178 pages, filed under OEM number 008 099 81. Wiring diagrams trace the supply, starting unit, brake, seat contact and sprinkler circuits, while hydraulic schematics follow oil from the travel, vibration and steering pumps out to the drum drive and vibration motors. Troubleshooting tables for travel, vibration and steering sit beside factory test and adjustment points, so your gauge readings actually settle arguments. Check charge pressure against the 25 bar high idle figure before you condemn a travel pump, then gap the Deutz valves at 0.3 mm intake and 0.5 mm exhaust. A roller stopped mid-mat usually comes down to one missing pressure value. Print the section you need, let it collect grease on the bench, and keep the bookmarked file for the next job.
What's Inside This Bomag BW 161 AD-4, BW 202 AD-4 Manual
| System | Pages | Key Topics |
|---|---|---|
| Documentation | 5 | Index of related Bomag publications (each sold separately) |
| General | 6 | Machine Overview, Deutz BF4M 2012 Engines, Hydrostatic Drive Concept |
| Technical Data and Adjustment Values | 7-11 | Engine, Travel Pump, Reduction Gear, Drum Drive, Vibration Pump, Vibration Motor, Steering and Charge Pump, Steering Valve |
| Maintenance | 12-15 | Maintenance Schedule |
| Deutz Diesel Engine | 16-49 | Service Side, Starter Side, Lubrication Oil Circuit, Coolant Circuit |
| Travel System | 50-74 | Travel Pump, Control (Charge Pressure Relief Valve, High Pressure Relief Valve, Pressure Override), Travel Motor |
| Vibration | 75-96 | Vibration Pump (High Pressure Relief Valves, Control) |
| Steering | 97-111 | Steering/Charge Pump, Steering Valve (Priority Valve, Crab Walk, Articulated Joint, Measuring and Adjustment Points, Trouble Shooting Steering System) |
| Electrics, Module Descriptions | 112-148 | Hardware Description, Description of Function |
| Wiring Diagram | 149-176 | Supply, Starting Unit, Brake, Seat Contact, Monitoring Unit, Sprinkler System, Motor Speed, Illumination |
| Hydraulic Diagram | 177-178 | Travel Pump, Vibration Pump, Steering Pump, Steering Valve, Priority Valve, Crab-Walk Valve, Travel Motor, Vibration Motor |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Travel pump high pressure limitation | 455 bar | p. 8 |
| Travel pump pressure override | 420+/-15 bar | p. 8 |
| Intake valve clearance | 0.3 mm | p. 26 |
| Exhaust valve clearance | 0.5 mm | p. 26 |
| Cylinder head cover tightening torque | 9 +/- 1 Nm | p. 43 |
| Crankcase ventilation tightening torque | 9 +/- 1 Nm | p. 43 |
| Injection pump screws initial tightening torque | 5 Nm | p. 42 |
| Injection pump screws final tightening torque stages | 7 Nm, 10 Nm and 30 Nm | p. 43 |
| Solenoid for high amplitude | 0/12 V | p. 91 |
| Solenoid for low amplitude | 0/12 V | p. 91 |
| Engine Oil Capacity | 9.5L | p. 9 |
| Hydraulic Oil Capacity | 60L | p. 9 |
Bomag BW 161 AD-4, BW 202 AD-4 Common Problems This Manual Covers
Bomag BW 161 AD-4 tandem roller loses travel power, jerks, or will not move
Test charge pressure at the test port with the engine at high idle; you need 26 +/- 2 bar (page 69). A low reading points to the charge pump or charge pressure relief valve, not the travel motor. Then stroke the lever and confirm forward travel pressure at 420 +/- 10 bar before working through the travel troubleshooting chart on page 74.
Manual Section: Travel System p. 74Vibration will not start on either drum or cuts out intermittently during the pass
Check the vibration solenoid valves first; front and rear coils should switch cleanly between 0 and 12 V (page 92). A coil that reads 12 V but never shifts its spool is gummed up: pull it and clean it. Then gauge port MM between the vibration motors and confirm pressure stays under 380 bar before you condemn the pump.
Manual Section: Vibration p. 92Roller creeps in neutral or responds late and unevenly to travel lever movement
Verify the travel pump settings before blaming the lever: pressure override should hold 420 +/- 10 bar and the high pressure relief valves 455 bar (page 67). Test both directions at the pressure test ports. If the machine still creeps in neutral, run the neutral setting procedure for the travel lever monitoring module in the electrics section, page 112.
Manual Section: Travel System p. 67Engine loses power under load and fuel restriction shows up before the filter interval
Replace the fuel filter element and bleed the fuel system; a loaded element is the usual cause of early power loss, so find the contamination source in the tank before the next lift. If power stays down on clean fuel, check valve clearance cold, 0.3 mm intake and 0.5 mm exhaust, using the adjustment procedure that starts on page 26.
Manual Section: Deutz Diesel Engine p. 26Steering turns hard and the drums will not reach the end stops at full lock
Test steering pressure at the relief valve; it must hold 170 bar (page 99). Low pressure points to the steering/charge pump or a stuck priority valve, not the articulated joint. Check the crab-walk valve for internal leakage while the gauges are on, then work through the steering troubleshooting table in the steering section.
Manual Section: Steering p. 99Frequently Asked Questions
What are the replacement specifications for the fuel filter element on the Bomag BW 161 AD-4, BW 202 AD-4?
The main fuel filter is subjected to approximately 10 bar of fuel pre-pressure. Because this pressure is significantly higher than on other engines, only original filter elements specified in the operating and maintenance instructions must be used to prevent damage to the injection system. p. 25
What is the intake and exhaust valve clearance on the Bomag BW 161 AD-4, BW 202 AD-4 Deutz diesel engine?
The valve clearance must be checked and adjusted when the engine is cold. The intake valve clearance is 0.3 mm and the exhaust valve clearance is 0.5 mm. p. 26
What is the engine oil capacity for the BW 161 AD-4 and BW 202 AD-4?
The engine oil capacity for these machines is 9.5 liters. The required specification is SAE 15W-40, API CG-4. p. 9
What is the tightening torque for the cylinder head cover on the Bomag BW 161 AD-4, BW 202 AD-4?
When reinstalling the cylinder head cover, the tightening torque is 9 +/- 1 Nm. p. 43
What is the charge pressure relief valve setting for the travel pump on the Bomag BW 161 AD-4, BW 202 AD-4?
The charge pressure relief valve for the travel pump is set to 25 +3/-1 bar. p. 8
How quickly can I access this Bomag BW 161 AD-4 manual after buying?
A 178-page Service Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Am I free to print this Bomag BW 161 AD-4 Service Manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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