From pre-start checks through vibration control, crabwalk, pressure sprinkling and towing, the 154-page Bomag BW 161 ADH-4, 202 AD-4 and 203 AD-4 operator manual PDF (OEM ID 008 063 01) covers the operating systems on these tandem vibratory rollers end to end, for serial numbers 861 920 80 1001, 861 920 81 1001 and 861 920 82 1001 and up. The maintenance chapter fills well over a third of the book, organised by interval from the 10-hour oil and coolant checks through the 2000-hour hydraulic oil and breather filter change to the 3000-hour injector replacement, with the as-required jobs (combustion air filter, water separator, scrapers) listed separately. Ahead of that, every indicator and control element on the dash gets its own description, so you can decode a warning lamp before it becomes a shutdown. Fill the engine with 9.5 litres of oil, plan around the 200-litre fuel tank, and pull the towing hitch to 578 Nm. A roller down mid-lift stalls the whole train. Bookmarked and text-searchable, this download hands you the correct fluid grades and intervals before you order a drop of anything.
What's Inside This Bomag BW 161 ADH-4, BW 202 AD-4, BW 203 AD-4 Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Data | 9-16 | Weights, Dimensions, Drive, Brakes, Steering, Vibration System |
| Safety Regulations | 17-30 | General Safety Instructions, Loading and Transport Safety, Maintenance Safety |
| Indicators and Controls | 31-50 | General Notes, Description of Indicators and Control Elements |
| Operation | 51-84 | Tests Before Taking Into Operation, Starting the Engine, Starting with Jump Wires, Driving the Machine, Stopping the Machine and Parking Brake, Switching the Vibration on and Off, Operating the Crabwalk, Pressure Sprinkling System, Emergency Stop Switch, Adjusting the Driver's Seat, Heating and Air Conditioning, Towing, Loading and Transport |
| Maintenance | 85-95 | General Notes on Maintenance, Fuels and Lubricants, Filling Capacities, Running-In Instructions |
| Maintenance Table | 96-146 | Every 10 Operating Hours, Every 250 Operating Hours, Every 500 Operating Hours, Every 1000 Operating Hours, Every 2000 Operating Hours, Every 3000 Operating Hours, As Required, Tightening Torques |
| Trouble Shooting | 147-150 | Engine Troubleshooting |
| Disposal | 151-154 | Final Shut-Down of Machine |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Towing hitch tightening torque | 578 Nm (426 ft.lb) | p. 77 |
| Fuel filter cartridge tightening torque | 10 - 12 Nm | p. 103 |
| Engine Oil Capacity | 9.5 litres | p. 94 |
| Fuel Tank Capacity | 200 litres | p. 94 |
| Water Tank Capacity | 1000 litres | p. 94 |
| Hydraulic Oil Capacity | 60 litres | p. 94 |
| Rated Power ISO 9249 | 98 kW | p. 11 |
| Rated Speed | 2300 min-1 | p. 11 |
| Fuel Filter Tightening Torque | 12 Nm | p. 103 |
| BW 161 ADH-4 | ||
| Operating Weight (Cece) with cabin, BW 161 ADH-4 | 10900 kg | p. 10 |
| BW 202 AD-4 | ||
| Operating Weight (Cece) with cabin, BW 202 AD-4 | 11500 kg | p. 13 |
| BW 203 AD-4 | ||
| Operating Weight (Cece) with cabin, BW 203 AD-4 | 13000 kg | p. 13 |
Bomag BW 161 ADH-4, BW 202 AD-4, BW 203 AD-4 Common Problems This Manual Covers
Bomag BW 161 ADH-4 won't crank, starter dead with travel lever in neutral
Verify the travel lever sits fully in the neutral notch; the start interlock blocks cranking if it rests even slightly off center. Check the main battery switch is on and battery terminals are tight and clean. Confirm fuel in the 200 litre tank, then work through the engine troubleshooting chart on page 149.
Manual Section: Engine Troubleshooting p. 149Engine loses power under load, black smoke on long passes, feels fuel starved
Replace the fuel filter element; a clogged cartridge starves the engine right when the drum needs full power. Wet the new seal with clean diesel, spin the cartridge on, and tighten to 12 Nm as shown on page 103. Bleed the fuel system, then check the maintenance schedule for the change interval.
Manual Section: Maintenance p. 103Travel drive gets weak after a few hours running, machine slows down mid pass
Check the hydraulic oil level with the machine parked level; the system holds approx. 60 litres of HV46 oil, listed in the capacities table on page 94. Blow out the hydraulic oil cooler fins with compressed air; a soiled cooler overheats the oil and robs travel power. Keep everything clean when opening the system.
Manual Section: Maintenance p. 94Oil pressure warning light comes on, engine running hot during vibration work
Shut the engine down immediately when the oil pressure light shows. Check the dipstick and top up; the engine holds 9.5 litres total, per the capacities table on page 94. Clean the radiator core and verify coolant level once cold. If the light returns at operating temperature, follow the engine troubleshooting table on page 149.
Manual Section: Engine Troubleshooting p. 149Water spray system not wetting the drums, asphalt sticking to the drum surface
Fill the water tank; it holds approx. 1000 litres, listed with the fill capacities on page 94. Pull and clean the spray nozzles and the filter screen so the drums wet evenly across the full width. In cold weather, drain the system after the shift or run an anti-freeze mixture per the manufacturer's instructions.
Manual Section: Maintenance p. 94Frequently Asked Questions
What are the replacement specs for the fuel filter element on the Bomag BW 161 ADH-4, BW 202 AD-4, BW 203 AD-4?
The fuel filter cartridge should be replaced every 250 operating hours. When installing, twist the new filter cartridge on by hand until the seal contacts, then tighten with 10 - 12 Nm. p. 103
What is the correct valve clearance for the Bomag BW 161 ADH-4, BW 202 AD-4, BW 203 AD-4 engine?
The intake valve clearance is 0.3 mm (0.012 in) and the exhaust valve clearance is 0.5 mm (0.020 in). These measurements must be checked and adjusted if the gap is too narrow or too wide. p. 124
What is the required tightening torque for the towing hitch on the Bomag BW 161 ADH-4, BW 202 AD-4, BW 203 AD-4?
The towing hitch must be fastened at the front or rear of the machine with a tightening torque of 578 Nm (426 ft.lb). p. 77
What is the correct 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, the tension should be retightened to approximately 300±50 N. p. 121
What is the engine oil capacity for the BW 161 ADH-4?
The engine oil capacity for the BW 161 ADH-4 is approximately 9.5 litres. p. 94
What do I get after purchasing this Bomag BW 161 ADH-4 manual?
All 154 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Can I print a copy of this Bomag BW 161 ADH-4 Operator Manual for the shop?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
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