Which rotary switch sets vibration amplitude, when the DPF calls for a standstill regeneration, how much oil each drum's exciter housing takes: the 208-page Bomag BW 202 AD-5 operator manual PDF, OEM 008 200 77 EN, is where those answers are settled for this tandem vibratory roller. The controls chapter maps every switch on your operator's stand, from travel ranges and drum pre-selection to the pressure sprinkler system, while maintenance, the largest block in the book, runs service tables from the 50-hour checks out to 3000 operating hours. Troubleshooting closes with fuse assignments for the central electrics, cabin and ROPS, plus an engine fault chart. Each drum exciter housing holds 7.5 litres of oil; the precision spreader has its own exciter housing that takes 0.2 litres, and its fastening screws torque to 10 Nm. A roller stopped mid-mat holds the whole paving train. Bookmarked and keyword-searchable, this PDF finds the right page before the asphalt cools, so your drum is back in the pass.
What's Inside This Bomag BW 202 AD-5 Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 9-12 | Foreword, Machine Type Plate and Engine Type Plate |
| Technical Data | 13-18 | Noise and Vibration Data |
| Concerning Your Safety | 19-48 | Terminological Definition of the Responsible Persons (Operating Company, Expert / Qualified Person, Driver / Operating Personnel) |
| Display and Control Elements | 49-70 | Operator’s Stand (Overview, Instrument Cluster, Economizer, Start Switch, Rotary Switch for Travel Lever Button Assignment, Travel Lever, Push Button Assignment in Travel Lever, Toggle Switch for Seat Heating, Rotary Switch for Sprinkling Pumps, Rotary Switch for Sprinkler System Pre-Selection, Rotary Switch for Pressure Sprinkler System, Rotary Switch for Working Lights, Rotary Switch for Direction Indicators, Rotary Switch for Hazard Light System, Rotary Switch for Lighting, Rotary Switch DPF-regeneration, Rotary Switch for Engine Speed, Emergency Stop Push Button, Rotary Switch for Travel Ranges, Rotary Switch for Vibration, Drum Pre-Selection, Manual / Automatic, Amplitude Selection) |
| Tests Before Taking Into Operation | 71-82 | Notes on Safety, Visual Inspections and Function Tests, Checking the Engine Oil Level, Checking the Fuel Level, Topping Up Fuel (Refuelling), Checking the Hydraulic Oil Level |
| Operation | 83-124 | Set-Up the Work Place (Adjust the driver’s Seat, Sliding the driver’s Seat Sideways, Swivelling the driver’s Seat), Electronic Immobilizer, Start the Engine, Travel Operation (Driving the Machine, Apply the Parking Brake, Notes on Travel Operation), Working with Vibration (Vibration in Manual Mode, Vibration in Automatic Mode), Operating the Crabwalk, Operating the Pressure Sprinkler System, Park the Machine in Secured Condition, Open the Engine Hood, Operating the Heating/Air Conditioning System, DPF-regeneration (Information Codes, Suppressing DPF-regeneration, Running Regeneration at Standstill), Edge Cutter (Changing the Compression Roller, Operating the Edge Cutter), Precision Spreader (Mounting / Removing the Precision Spreader, Filling the Precision Spreader, Emptying the Precision Spreader, Operating the Precision Spreader), What to Do in Events of Emergency (Actuate the Emergency Stop Switch, Disconnect the Battery, Towing the Machine, After Towing) |
| Loading/Transporting the Machine | 125-134 | Prepare for Transport, Load the Machine, Lashing the Machine to the Transport Vehicle, Loading by Crane, After Transport |
| Maintenance | 135-192 | Preliminary Remarks and Safety Notes (Lifting the Machine with a Jack), Fuels and Lubricants (Engine Oil, Fuel, Coolant, Hydraulic Oil, Exciter System), Table of Fuels and Lubricants, Running-In Instructions, Maintenance Table, Every 50 Operating Hours (Checking Radiator Hoses and Hose Clamps), Every 250 Operating Hours (Check the Air Intake Lines, Service the Belt Drive, Cleaning the Radiator Module), Every 500 Operating Hours (Change Engine Oil and Oil Filter Cartridge, Check the Hydraulic Lines, Checking the Oil Level in the Exciter Housing, Drain the Fuel Tank Sludge), Every 1000 Operating Hours (Adjusting the Valve Clearance, Replacing the Hydraulic Oil Filter, Change the Oil in the Exciter Housing, Checking the ROPS), Every 2000 Operating Hours (Changing the Hydraulic Oil, Change the Coolant, Replacing the Oil Separator Element), Every 3000 Operating Hours (Checking the Turbo Charger, Cleaning the DPF), As Required (Air Filter Maintenance, Cleaning Water Tank and Water Filter, Filling the Provision Tank for the Windscreen Washer System) |
| Trouble Shooting | 193-202 | Preliminary Remarks, Starting the Engine with Jump Leads, Fuse Assignment (Notes on Safety, Central Electrics, Main Fuses, Fuse, Cabin, Fuses ROPS), Engine Faults |
| Disposal | 203-204 | Final Shut-Down of Machine |
| List of Special Tools | 205-208 | Belt Tension Tester, Tool Kit Edge Cutter |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| fastening screws for precision spreader | 10 Nm (7.4 ft·lbf) | p. 82 |
| tightening torque for locking screws | 10 Nm (7.4 ft·lbf) | p. 111 |
| Maximum filling capacity of chip hopper | 900 l | p. 116 |
| Maximum specific weight of chipping material | 1.5 t/m3 | p. 116 |
| Exciter housing oil fill quantity (precision spreader) | 0.2 l (0.05 gal us) | p. 175 |
| Max. operating weight | 13300 kg | p. 14 |
| Rated power ISO 14396 | 85.0 kW | p. 15 |
| Fuel tank capacity | 145 l | p. 16 |
| Water tank capacity | 750 l | p. 16 |
| Engine oil capacity | 13 l | p. 144 |
| Hydraulic system oil capacity | 80 l | p. 144 |
| Exciter housing oil capacity (per drum) | 7.5 l | p. 144 |
Bomag BW 202 AD-5 Common Problems This Manual Covers
Bomag BW 202 AD-5 stops traveling after ten minutes of steady rolling, travel lever gets no response
Check the hydraulic oil level on the sight glass before the next pass; the system holds 80 l and a weeping hose drops it faster than you think. Clean asphalt spray and dust off the hydraulic oil cooler fins, then work through the troubleshooting procedure on page 194. If the loss repeats once the machine is hot, park it and call service.
Manual Section: Trouble Shooting p. 194Engine loses power then shuts off completely in the middle of a rolling pass
Check the fuel level and refill well before the 145 l tank runs dry; sucking the bottom pulls sediment in and makes restarting a fight. Run a DPF regeneration with the rotary switch if the machine has idled a lot between passes. Then verify the engine oil sits on the dipstick marks; the sump takes 13 l.
Manual Section: Trouble Shooting p. 194Smoke or burnt smell from the drum or axle area while vibrating on the lift
Stop the machine and let everything cool before putting a hand near the drum. Check the exciter housing oil level; each drum housing takes 7.5 l per the capacities table on page 144, and a low housing cooks the vibration shaft bearings. Inspect the scraper bars for hard contact against the drum and adjust them off before the next pass.
Manual Section: Maintenance p. 144Water spray system stops wetting the drum halfway through the mat, asphalt starts picking up
Check the water tank level first; it holds 750 l and empties faster than the fuel tank on a hot mat. Verify the rotary switch for the sprinkler pumps is set correctly at the operator's stand, laid out on page 50. Clean the spray nozzles and the line filter, then test both pumps before rolling back onto the mat.
Manual Section: Display and Control Elements p. 50Engine cranks slowly or will not start on cold mornings before the first pass
Check the battery terminals for corrosion and verify the electronic immobilizer is disarmed before cranking again. Confirm there is fuel on board; the tank holds 145 l and cold thickened fuel on a near-empty tank starts hard. Inspect the engine oil level while you are at it, then follow the troubleshooting procedures starting on page 194.
Manual Section: Trouble Shooting p. 194Frequently Asked Questions
What are the replacement specifications for hydraulic hoses?
Hydraulic hoses must be replaced if the outer layer is damaged down to the inlay, if there is embrittlement or cracking, or if the hose shows deformations in pressurized or depressurized conditions. Additionally, they must be replaced if there are leaks, if the hose has separated from the fitting, or if the shelf life and utilization period have been exceeded. Refer to page 162 for the complete list of replacement criteria. p. 162
What is the tightening torque for the precision spreader fastening screws?
The fastening screws on the right and left of the precision spreader must be tightened to a torque of 10 Nm (7.4 ft·lbf). p. 82
What is the nominal tension value for the multi-groove generator belt?
The nominal tension value for the multi-groove generator belt is 300 N (67 lbf) for both the initial assembly (new belt) and after a running-in time in case of reassembly. p. 151
What is the oil capacity for the exciter housing of the precision spreader?
The oil capacity for the exciter housing of the precision spreader is 0.2 liters (0.05 gal us). p. 144
What is the required oil viscosity for the exciter system?
For the exciter unit, you must use a fully synthetic gear oil with a viscosity of SAE 75W-90, meeting the API GL5 specification. p. 143
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