BOMAG BW 161 AD-4 ADH-4 AC-4 BW 190 AD-4 BW 202 AD-4 BW 203 AD-4 Tandem Vibratory Roller Service Manual

BOMAG BW 161 AD-4 ADH-4 AC-4 BW 190 AD-4 BW 202 AD-4 BW 203 Tandem Vibratory Roller Service Manual

The BOMAG BW 161 AD-4 ADH-4 AC-4 BW 190 AD-4 BW 202 AD-4 BW 203 AD-4 Tandem Vibratory Roller Service Manual is a detailed workshop reference for the BW 161, BW 190, BW 202 and BW 203 roller variants identified in the manual. Catalogue number 008 910 96, dated 11/2006, it combines machine technical data with repair procedures, hydraulic tests and adjustments, electrical and electronic diagnostics, engine service information, component overhaul material and extensive circuit documentation. The manual is written for expert mechanics and describes removal, dismantling, inspection, adjustment, assembly and testing work across the major systems of these machines.

Models and Service Coverage

This BOMAG roller service manual specifically covers BW 161 AD-4, BW 202 AD-4, BW 161 ADH-4, BW 203 AD-4, BW 190 AD-4 and BW 161 AC-4. The cover identifies serial-number series beginning S/N 101 920 02, S/N 101 920 03, S/N 101 920 04, S/N 101 920 05, S/N 101 920 06 and S/N 101 920 11. Technical-data sections include Deutz BF4M 2012 and BF4M 2012 C engine applications as shown for the individual machine variants.

The scope goes well beyond routine maintenance. The manual includes machine specifications and filling capacities, hydraulic connection identification, pressure testing, pump neutral adjustment, vibration-system checking, circuit flushing and bleeding, electrical fundamentals and diagnostic methods, electronic-control module descriptions, engine service, air-conditioning work, structural and drum repairs, articulated-joint overhaul, hydraulic component supplier documentation and complete electrical and hydraulic diagram sections.

File Details

• Manual type: Service Manual
• Brand: BOMAG
• Models: BW 161 AD-4, BW 161 ADH-4, BW 161 AC-4, BW 190 AD-4, BW 202 AD-4, BW 203 AD-4
• Equipment: Tandem Vibratory Roller
• Language: English
• Page count: 1,174 pages
• File format: PDF
• Catalogue number: 008 910 96
• Date: 11/2006

Hydraulic Testing, Adjustment and Circuit Service

A major portion of the BOMAG BW 161 AD-4 ADH-4 AC-4 BW 190 AD-4 BW 202 AD-4 BW 203 AD-4 Tandem Vibratory Roller Service Manual is devoted to systematic hydraulic diagnosis. The manual identifies test ports and connection points, lists the required test equipment and provides procedures for checking travel and vibration circuits at operating temperature. Procedures include checking engine and vibrator-shaft speeds, measuring travel-circuit pressure, setting mechanical and hydraulic neutral positions of the travel pump, checking high-pressure relief valves, testing vibration-circuit pressures, adjusting vibrator-shaft speed, measuring vibration-motor leakage and checking the steering circuit.

The flushing and bleeding material is particularly detailed. Separate schematics and procedures are provided for front drum drive, rear drum drive, rear wheel drive on AC machines and vibration circuits on AD and AC machines. Instructions cover filter installation, hydraulic-tank cleaning, isolating motors during flushing, circulation and flushing procedures, reconnecting components, bleeding closed circuits and post-repair function and leakage checks. This makes the manual useful not only for fault finding but also for correct recommissioning after hydraulic component replacement.

Electrical and Electronic Diagnostic Content

The electrical portion develops from basic circuit interpretation into machine-specific diagnostics. It explains wiring-diagram structure, current paths, terminal designations, voltage, current, resistance, series and parallel circuits, Ohm’s law, electrical power, measuring methods, diodes, relays, fuses, batteries, generators and starters. It also covers inductive proximity switches, the angle sensor with current output, Deutsch DT and DTM connectors and spring-clamp terminal technology. Special electrical tools and measuring adapters are illustrated and identified.

Electronic-control material includes module descriptions for A03, A68, A71 and A04, along with the speedometer module and service-training sections. The manual provides hardware and pin information, input and output descriptions, operating logic and diagnostic material associated with the control systems. This content supports a more structured approach to electrical troubleshooting instead of replacing components before wiring, connectors, sensors and signals have been checked.

Engine, Cooling, Fuel and Air-Conditioning Service

The engine chapter covers general diesel-engine information, service and starter sides, lubrication and coolant circuits, oil-pressure monitoring, engine-oil and filter service, cooling-system work, radiator and cooler cleaning, generator service, fuel supply and injection systems, injection-pump and injection-valve work, fuel filtration, compression checking, valve-clearance adjustment, engine shut-down controls, air filtration, heating-flange control, electric throttle control and engine monitoring. A special-tools section is included for the Deutz BFM 2012 engine material.

The air-conditioning chapter covers R134a refrigerant, compressor oil, system operating principles, monitoring devices, component descriptions, compressor-oil level and magnetic-clutch checks, V-belt service, seasonal servicing, evacuation, repair emptying, leak testing, filling and refrigerant-circuit troubleshooting. It includes both troubleshooting principles and circuit-based diagnostic procedures.

Mechanical Repair and Component Overhaul

Mechanical repair chapters address work that is easy to overlook in a manual focused only on routine service. Cab-window replacement procedures include special tools and auxiliary materials. Front-frame crack repair includes a welding repair overview. The drum section provides special tools, repair overviews and procedures for drum removal, AD-drum dismantling, exciter-unit dismantling and assembly, and drum reassembly. The oscillating articulated joint has its own repair overview, removal and disassembly procedure and assembly instructions. Vibration valve Y54/Y55 repair information is also included.

Supplier documentation extends the reference into individual hydraulic assemblies, including the A4VG 40 … 56 travel pump, A10VG28…63 vibration pump, A4FM22….28 vibration motor, travel drive series 51, drum reduction gear and MS/MSE 02 ….. 18. This is followed by a large circuit-diagram section containing multiple wiring diagrams and hydraulic diagrams, plus supplementary information on control elements, monitoring module A15 and machine representation in the electrical circuit diagram.

Chapters Covered

• 1 General: Introduction; safety regulations; general repair instructions; tightening torques.
• 2 Technical data: Technical data; maintenance chart; fuels, lubricants and filling capacities; fuels and lubricants.
• 3 Connection overview: Hydraulic connection overview and identified test and control points.
• 4 Tests and adjustments: Special tools; travel-control angle sensor; rotation speeds; travel-circuit pressure; travel-pump neutral position; travel and vibration relief-valve settings; vibration-circuit pressure; vibrator-shaft speed; vibration-motor leakage; steering pressure.
• 5 Flushing and bleeding: Flushing tools and general procedure; front and rear drum-drive flushing; AC wheel-drive flushing; AD and AC vibration schematics; vibration-circuit flushing; travel and vibration bleeding.
• 6 Fundamental electrics: Circuit diagrams; terminal designations; current and voltage; resistance; series and parallel connections; Ohm’s law; electrical energy; metrology; diodes, relays and fuses; batteries; generator; starter; switches, sensors and connectors.
• 7 Special tools, electrics: Measuring equipment, testers, crimping equipment, contact tools and electrical adapters.
• 8 Electronic control: A03 module descriptions; A68; A71; A04.
• 9 Speedometer Module: Speedometer module information.
• 10 Service Training: BOMAG Evib-meter electrics and service-training material.
• 11 Engine: Diesel-engine systems; lubrication and cooling; generator; fuel and injection; compression; valve clearance; air intake; heating; throttle and monitoring; Deutz engine special tools.
• 12 Air conditioning system: R134a; compressor oil; operating principle; components; inspection; evacuation; leak testing; filling and troubleshooting.
• 13 Replacing the cab window panes: Window assembly, tools, auxiliary materials, removal and installation.
• 14 Frame cracks in front frame: Repair overview and frame welding.
• 15 Drum: Drum special tools; AD-drum repair overview; drum removal; drum and exciter-unit dismantling and assembly.
• 16 Oscillating articulated joint: Repair overview; removal and disassembly; assembly.
• 17 Vibration valve Y54/Y55: Vibration control valve repair overview.
• 18 Suppliers documentation: Travel pump A4VG 40 … 56; vibration pump A10VG28…63; vibration motor A4FM22….28; travel drive series 51; drum reduction gear; MS/MSE 02 ….. 18.
• 19 Circuit diagrams: Multiple wiring diagrams and hydraulic diagrams.
• 20 Supplement to circuit diagram: Control elements; monitoring module A15; machine in electric circuit diagram.

Taken together, these chapters make the BOMAG BW 161 / BW 190 / BW 202 / BW 203 service manual a workshop-level reference for diagnosing faults, confirming adjustment values, tracing hydraulic and electrical circuits, servicing the engine and auxiliary systems, and performing substantial mechanical repairs. The combination of procedures, illustrated component work, technical data and circuit documentation allows a technician to move from diagnosis through repair and final testing using information contained in the same manual.

Repair and Maintain Your BOMAG Roller with the Correct Procedures

The BOMAG BW 161 AD-4 ADH-4 AC-4 BW 190 AD-4 BW 202 AD-4 BW 203 AD-4 Tandem Vibratory Roller Service Manual supports a wide range of workshop jobs, from routine service and adjustment through hydraulic diagnosis, electrical fault tracing, engine work, drum repairs, articulated-joint service and circuit-based troubleshooting. Having the specified procedures, test methods, technical data, adjustment information and diagrams available is especially important when work involves hydraulic pressures, vibration components, electronic controls or major assemblies where incorrect settings can lead to repeat failures or unnecessary parts replacement.

Delivered as an instant PDF download after purchase. There is no physical book and no shipping delay. Open the manual on a computer, tablet or phone, keep it available in the workshop, and print the pages you need for the job.