Tearing into the closed-loop vibration circuit takes exact hydraulic data, and that is exactly what anchors this 874-page Bomag BW 190 AD-5, BW 190 ADO-5, BW 202 AD-5, BW 202 ADO-5, BW 190/202 AD-5, BW 190/202 ADO-5 service manual pdf covering the complete tandem vibratory roller series (OEM ID 008 925 92). Extensive troubleshooting charts guide your diagnostics through everything from insufficient hydraulic power to CAN bus communication faults. Detailed water spraying diagrams and closed-circuit travel pump schematics let you trace pressure drops before a stalled machine holds up the entire paving train. Factory specifications give you the hard numbers required to verify the repair, like a brake releasing pressure of 30 bar and the MS05 drive motor tightening torque of 42 Nm. Guessing on these hydrostatic systems usually means buying the wrong travel motor or facing a second drum teardown, so grab this bookmarked digital file and jump straight to the exact diagnostic test you need right now.
What's Inside This Bomag BW 190/202 AD-5 and ADO-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 11-60 | Introduction |
| Fuels and Lubricants | 61-68 | Engine Oil, Fuel, Coolant, Hydraulic Oil, Gear Oil Sae 75W-90 |
| Technical Data | 69-88 | Bw 190 Ad-5, Bw 190 Ado-5, Bw 202 Ad-5, Bw 202 Ado-5, Additional Technical Data, Terms and Basis of Calculation |
| Electric Systems | 109-198 | Overview of Electric System, Table of Fuels and Lubricants (Table of Operating Means, Comparison Bomag Kubota), Wiring, CAN Bus Overview, Power Board, Control Console Cabin |
| Diesel Engine | 199-258 | Overview of Diesel Engine, Features, Cooling System (Removing and Installing the Thermostat), Intake Air Heating, Fuel Supply, Common-Rail System, Exhaust System |
| Hydraulic System | 259-378 | Overview of Hydraulics (Pump Overview), Open and Closed Hydraulic Circuit |
| Water Spraying System | 379-390 | Overview of Water Spraying System (Tandem Rollers, Pump Overview), Maintenance Work (Maintenance Table, Checks Prior to Start Up, As Required) |
| Air Conditioning | 391-426 | Overview of Air Conditioning System, Physical Principles, Refrigerant R134a, Compressor Oil / Refrigeration Oil, Working Principle of the Air Conditioning System |
| Drum | 427-536 | Ad Drum (Ad/Ap Removing, Assembling the Exciter Unit, Only Bw 190 and 202 Machines, Change Rubber Buffers of Ad Drum) |
| Chip Spreader | 537-546 | Mounting / Removing the Precision Spreader (Preliminary Remarks and Safety Notes), Maintenance Work (Maintenance Table, Checks Prior to Start Up, Every 1000 Operating Hours) |
| Cabin Assembly | 547-556 | Preparations, Final Function Tests, Checks |
| Troubleshooting | 557-744 | Preliminary Remarks, Emergency Procedures (Actuating the Emergency Stop Switch, Disconnecting the Battery, Towing the Machine) |
| Disposal | 745-746 | Final Shut-Down of Machine |
| Special Tools | 747-756 | Electrics, Special Tools for Ado Drum, List of Special Tools |
| Appendix | 773-874 | Circuit Diagrams (Water Spraying Diagram 921 133 28, Hydraulic Diagram 921 125 81c, Circuit Diagram 366) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Tightening torque for M22 x 1.5 wheel nut | 500 - 600 Nm | p. 49 |
| Brake releasing pressure | 30 bar | p. 280 |
| Tightening torque MS05 | 42 Nm | p. 281 |
| Engine Oil Capacity | 13L | p. 66 |
| Fuel Tank Capacity | 145L | p. 66 |
| Coolant Capacity | 18L | p. 66 |
| Hydraulic System Oil Capacity | 80L | p. 66 |
| V-belt Pulley Tightening Torque | 58.4-78.9 Nm | p. 180 |
| Starter Terminal B Fastening Torque | 9.8-11.0 Nm | p. 185 |
| BW 190/202 AD | ||
| Exciter Housing Oil Capacity (AD Drum) | 7.5L | p. 66 |
| BW 190 ADO | ||
| Exciter Housing Oil Capacity (Front Drum, ADO) | 7.5L | p. 67 |
| Exciter Housing Oil Capacity (Rear Drum, ADO) | 1.8L | p. 67 |
Bomag BW 190/202 AD-5 and ADO-5 Common Problems This Manual Covers
Bomag BW 190 AD-5 drum makes a harsh grinding noise when vibration is engaged
Inspect the exciter assembly as shown on page 457. Measure the exciter shaft axial clearance with a dial indicator. Adjust shims until clearance is between 1.2-2 mm. Drain the old fluid and fill the AD drum exciter housing with exactly 7.5L of fresh oil.
Manual Section: Drum p. 457Roller will not move forward or reverse and drive system logs a travel fault
Test the brake circuit at the travel motor test port. Verify the brake releasing pressure hits 12 bar to disengage the pads. If pressure spikes above the 30 bar maximum limit on page 280, replace the relief valve and torque the MS05 fittings to 42 Nm.
Manual Section: Hydraulic System p. 280Diesel engine cranks slowly or fails to turn over during cold morning shifts
Check the main power connections at the starter motor. Verify the cables are tight and free of corrosion. Torque the starter terminal B nut to 9.8-11.0 Nm as specified on page 185. If cranking remains slow, test the batteries and inspect the engine ground strap.
Manual Section: Electric Systems p. 185Alternator warning light illuminates on the dash and the cooling fan speed drops
Check the drive belt tension on the front of the engine block. Inspect the belt for cracking or glazing. Replace if worn and torque the V-belt pulley bolts to 58.4-78.9 Nm as outlined on page 180. Top off the coolant system with up to 18L if required.
Manual Section: Electric Systems p. 180Frequently Asked Questions
What is the procedure for resetting the operating hour meter on a -50 machine with a mechanically regulated diesel engine after replacing the control?
To restore the operating hour meter, first enter code 9999 to activate service mode. Then, enter code 8887 to release the memory operation, followed by code 8880 to restore the operating hour meter value. Successful completion is indicated by the display showing 'OK' or '11111'. p. 607
Torque specs for the multi-groove generator belt and AC compressor V-belt on a Bomag BW 190/202 AD-5 and ADO-5?
For the multi-groove generator belt, the nominal tension value during initial assembly is 300 N (67 lbf) (cold). For the air conditioning compressor V-belt, the nominal tension value during initial assembly is 400 N (90 lbf) (cold). p. 239
What is the procedure for bleeding the fuel system after replacing the fuel filter?
After replacing the fuel filter, open the bleeding screw on the fuel filter for one turn. Hold the ignition key in position 'I' until clean fuel starts to run out of the bleeding screw, then tighten the screw. A 5-minute test run in idle speed or low load is mandatory to ensure all air is removed. p. 247
What is the required oil capacity for the exciter housing on a BW 190 ADO machine?
The exciter housing for the front drum requires 7.5 liters (2 gal us) of oil, while the exciter housing for the rear drum requires 2 x 1.8 liters (0.48 gal us) of oil. p. 67
What is the valve clearance specification for the Bomag BW 190/202 AD-5 and ADO-5 engine?
The intake and exhaust valve clearance for the engine is 0.23 to 0.27 mm. p. 86
Is this Bomag BW 190 AD-5 manual a download or a disc?
Immediate download of the complete 874-page searchable Service Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Am I able to print pages from this Bomag BW 190 AD-5 manual?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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