When a closed-loop travel pump fails to build charge pressure on a hot mat, this 904-page Bomag bw 202 ad-50, bw 206 ad-50, bw 202 ado-50 service manual pdf (OEM 008 400 30 EN) provides the factory test sequences to isolate the fault on your tandem vibratory roller. You can trace the CAN bus network through dedicated wiring schematics. Hydraulic diagrams track flow for the open and closed circuits, showing exactly where to tie in a gauge for the drum drive motor. Factory test data confirms whether the solenoid valves show 6 ohms of resistance, or if the fan pump displacement still hits 8 cubic centimeters per revolution. Standing alone on a night shift with a dead machine and no one to ask is a bad place to be. Download this searchable, bookmarked reference to get the roller running and back in the pass before the asphalt cools.
What's Inside This Bomag BW 202 AD-50, BW 206 AD-50, BW 202 ADO-50 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 9-68 | Introduction |
| Technical Data | 69-82 | Bw 202 Ad-50, Bw 202 Ado-50, Bw 206 Ad-50, Additional Technical Data, Terms and Basis of Calculation |
| Fuels and Lubricants | 83-92 | Engine Oil, Fuel, Coolant, Hydraulic Oil, Gear Oil Sae 75W-90 |
| Electric Systems | 115-204 | Overview of Electric System, Table of Fuels and Lubricants, Wiring, CAN Bus Overview, Power Board, Control Console Cabin |
| Diesel Engine | 205-264 | Overview of Diesel Engine, Service Side, Starter Side, Lubrication Oil Circuit, Coolant Circuit, Replacing the Thermostat, Fuel Supply, Injection System |
| Hydraulic System | 265-382 | Overview of Hydraulics (Pump Overview), Open and Closed Hydraulic Circuit |
| Water Spraying System | 383-394 | Overview of Water Spraying System (Tandem Rollers, Pump Overview), Maintenance Work (Maintenance Table, Checks Prior to Start Up, As Required) |
| Air Conditioning | 395-430 | Overview of Air Conditioning System, Physical Principles, Refrigerant R134a, Compressor Oil / Refrigeration Oil, Working Principle of the Air Conditioning System |
| Drum | 431-540 | Overview, Ad Drum (Ad/Ap Removing, Assembling the Exciter Unit, Only Bw 190 and 202 Machines, Change Rubber Buffers of Ad Drum) |
| Cabin Assembly | 541-550 | Seat Contact Switch, Cabin Wiring Loom, Bulkhead Seal, Function Tests |
| Troubleshooting | 551-734 | Preliminary Remarks, Emergency Procedures (Actuating the Emergency Stop Switch, Disconnecting the Battery, Towing the Machine) |
| Disposal | 735-736 | Final Shut-Down of Machine |
| Special Tools | 737-746 | Electrics, Special Tools for Ado Drum, List of Special Tools |
| Appendix | 761-904 | Circuit Diagrams, Water Spraying Diagram, Hydraulic Diagram, Electrical Circuit Diagrams |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for M12 x 1.5 hydraulic fitting (series L) | 15 Nm | p. 56 |
| Tightening torque for 7/16"-20 UNF hydraulic fitting | 15 Nm | p. 56 |
| Solenoid valves resistance | 6 Ω | p. 102 |
| Flushing valve flow rate | 4 l/min | p. 102 |
| Fan pump displacement | 8 cm³/rev | p. 102 |
| CAN terminating resistor | 120 Ohm | p. 129 |
| Brake solenoid valve | 1.8A | p. 131 |
| Telemecanique switch screw tightening torque | 0.6 Nm | p. 189 |
| Brake releasing pressure | 30 bar | p. 286 |
| Brake releasing pressure (completely open) | 12 bar | p. 287 |
| Hydraulic oil level in inspection glass | approx. 3 cm (1.2 in) below the top edge | p. 377 |
| Inner bearing race heating temperature | 120°C | p. 449 |
Bomag BW 202 AD-50, BW 206 AD-50, BW 202 ADO-50 Common Problems This Manual Covers
Bomag BW 202 AD-50 roller stops moving forward or reverse after ten minutes of paving.
Check charge pressure at the test port on page 298. Run the engine to operating temperature and verify the reading hits 25 bar. If pressure drops when the oil gets hot, inspect the charge circuit filter bypass valve to ensure it opens at 3.5 bar.
Manual Section: Trouble shooting, hydraulics p. 298Fault code 5120 displays on the console and diesel engine CAN communication cuts out entirely.
Inspect the main harness connectors for water ingress or loose pins. Test the CAN terminating resistor as shown on page 129. Verify the multimeter reads exactly 120 Ohm across the pins. Replace the damaged wiring segment if resistance is out of spec.
Manual Section: Troubleshooting, electrical systems p. 129Intermittent travel behavior under heavy load with the driving against brake warning remaining active.
Measure the brake solenoid valve current draw to ensure it pulls 1.8A as specified on page 131. Verify the hydraulic brake releasing pressure reaches 30 bar. Turn to page 286 to review the test port locations if the brake shoes fail to disengage.
Manual Section: Trouble shooting, hydraulics p. 131Drum vibration frequency drops off significantly when rolling a stiff asphalt mat.
Test the front and rear vibration pump start-up pressure to confirm it reaches 380 bar under load. Check the solenoid valves resistance on page 102 to verify they read exactly 6 Ω. Replace the affected valve cartridge immediately if the coil is shorted out.
Manual Section: Trouble shooting, hydraulics p. 102Grinding noise and heavy vibration coming from the drum drive side during static rolling.
Remove the sealed bearing assembly and inspect for metal shavings. Heat the new inner bearing race to 120°C before installation as instructed on page 449. Cool the cylinder roller bearing to -20°C using page 451 as a guide to shrink the outer race for proper fitment.
Manual Section: Drum p. 449Frequently Asked Questions
How do I clear a fault code on the BOMAG BW 202 AD-50?
To delete all stored faults, ensure the engine is not running, enter code number 0710 (without service code 9999), and then switch the ignition off and on again. All stored faults will be deleted. p. 612
What is the procedure for replacing the hydraulic oil filter on the BW 202 AD-50?
Bomag calls for checking the hydraulic oil filter for leaks after the test run and disposing of the old filter and oil according to environmental regulations. p. 379
What is the tightening torque for the injection line cap nuts on the Bomag BW 202 AD-50, BW 206 AD-50, BW 202 ADO-50?
When replacing injection lines, pre-tension the cap nuts on the injection pump and injection valve with a torque of approximately 5 Nm using a claw spanner 8018, then tighten the cap nut to 25 ± 3.5 Nm. p. 228
What is the required valve clearance on the Bomag BW 202 AD-50, BW 206 AD-50, BW 202 ADO-50 diesel engine?
The intake valve clearance should be 0.3 mm (0.012 in) and the exhaust valve clearance should be 0.5 mm (0.020 in). p. 252
What is the filling capacity for the fuel tank on the BW 202 AD-50?
The fuel tank capacity for the BW 202 AD-50 is 145 liters (38 gal us). p. 90
How will I receive this Bomag BW 202 AD-50 Service Manual?
Instant PDF download. You get the full 904-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Can I print a copy of this Bomag BW 202 AD-50 Service Manual for the shop?
Printing is allowed without restriction. Pull the pages you need for the job and bin them when they get greasy.
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