BOMAG BW 161 AD-4 & BW 202 AD-4 Tandem Roller Service Training Manual 00809981 – 2003

Description

BOMAG BW 161 AD-4 & BW 202 AD-4 Service Training Manual

This is the BOMAG Service Training manual issued for the BW 161 AD-4 and BW 202 AD-4 tandem rollers, document number 00809981 and dated 2003. It was prepared for BOMAG service personnel, Profit Centre technicians and dealer workshop staff, and it walks through the machine system by system: the Deutz diesel engine, the hydrostatic travel circuit, the vibration circuit, the steering and crab-walk hydraulics, the drum assemblies and the electronic monitoring modules fitted to these rollers. Every chapter is written with the workshop in mind, so the text is procedural rather than promotional and is paired with cut-away illustrations, hydraulic schematics, wiring diagrams, adjustment values and fault tables.

File Details

• Manual type: Service Training Manual
• Brand: BOMAG
• Models covered: BW 161 AD-4, BW 202 AD-4 tandem rollers
• Document number: 00809981
• Edition / status: 2003 (technical data status 2003-05-21)
• Language: English
• File format: PDF
• Page count: 178 pages

Chapters Covered

• Foreword, Documentation and General machine description
• Technical Data and Adjustment Values (BW 161 AD-4 and BW 202 AD-4)
• Maintenance schedule and maintenance work by interval
• DEUTZ diesel engine: service side layout
• DEUTZ diesel engine: starter side layout
• Lubrication oil circuit
• Coolant circuit
• Fuel system and SEPAR fuel pre-filter / water separator
• Main fuel filter (pressure-resistant element)
• Checking and adjusting valve clearance
• Plug-type injection pump: removal, shim calculation and installation
• Electrical components and measuring points on the engine
• Travel pump (Bosch-Rexroth A4VG 56 HW/32)
• Travel pump servo control
• Charge pressure relief valve
• High pressure relief valve
• Pressure override
• Travel motor (Sauer-Danfoss 51C 060)
• Drum reduction gear (Bonfiglioli 706 C 2H)
• Travel system test and adjustment points
• Travel system troubleshooting chart
• Vibration pump (Bosch-Rexroth A10VG 45 EZ)
• Vibration motors (Bosch-Rexroth A4FM 28)
• Vibration shut-off valve
• Flushing valve
• Drum assembly: BW 161 AD-4
• Drum assembly: BW 202 AD-4
• Vibration system test and adjustment points
• Vibration system troubleshooting chart
• Steering / charge pump (Bosch HY/ZFFS11/16+8 tandem gear pump)
• Steering valve (Sauer-Danfoss OSCP 400 LS)
• Priority valve
• Crab-walk valve and crab-walk cylinder
• Articulated joint
• Steering system test and adjustment points
• Steering system troubleshooting chart
• UPF04 travel lever monitoring module (description and pin-out)
• UPM03 seat occupation monitoring module
• UPM03 vibration interlock module
• Wiring diagram sheets and component lists

Read as a whole, this document is a complete technician’s walkthrough of the BW 161 AD-4 / BW 202 AD-4 platform. It starts with a description of how the hydrostatic closed circuits for travel and vibration actually function, moves through the axial piston pumps and motors that make those circuits work, and then gives the reader the means to test, adjust and diagnose each one using the pressure test ports, measuring points and fault tables printed in the manual. The engine section is equally practical: the plug-in injection pump procedure shows the pump shim thickness calculation (using the EP code stamped on the engine type plate, the L0 base measurement of 117.5 mm and the A/100 measurement marked on the pump), which is the kind of detail that is normally only found in factory service literature.

What is covered in the hydraulic and electrical chapters

The travel system chapter explains the closed-loop hydrostatic drive in detail. It documents the travel pump’s swash-plate servo control, the charge pressure relief valve (set at 25 bar), the high pressure relief valves (455 bar) with integrated boost check valves, and the pressure override (420 bar) that prevents overheating and protects the diesel engine from overload. The travel motor chapter covers the two-displacement Sauer-Danfoss motor, the speed range selector valve, and the flushing valve with its flushing pressure limitation. Test and adjustment values are listed for each port.

The vibration chapter follows the same pattern. It covers the A10VG 45 EZ pump, the two A4FM 28 motors, the vibration shut-off valve, the flushing valve and the exciter shaft arrangement inside the drum, including the change-over weights that switch the machine between high amplitude / low frequency and low amplitude / high frequency depending on the direction of rotation. Starting pressure of 360 ± 20 bar, operating pressure around 100 bar (soil dependent) and the 380 bar pressure override setting are all documented.

The steering chapter explains the tandem gear pump (16 + 8 cm³/rev), the priority valve that guarantees steering is always prioritised over the charge circuit and crab-walk, the OSCP 400 LS steering unit with its 170 bar pressure relief valve and 235 bar shock valves, the crab-walk valve, and the articulated joint. The electrical section of the manual documents the wiring diagrams, the three control modules (UPF04, UPM03 seat contact, UPM03 vibration interlock) and their pin assignments, including emergency-operation jumpers and software version histories.

Why this manual is useful in the workshop

The BW 161 AD-4 and BW 202 AD-4 are compact tandem rollers working in asphalt and earthwork, and most of their major systems are hydrostatic. That means the classic symptoms a technician sees — no travel in one direction, vibration only with one amplitude, steering hard to turn, machine overheating, crab-walk not working — all point into the closed circuits described in this book. The troubleshooting charts at the end of the travel, vibration and steering chapters list the likely causes of each symptom in numerical order of probability, so the reader can follow a rational diagnostic path instead of guessing. Combined with the pressure test port tables (M1 to M7, MA, MB, MH, MM), the technician has an actual measurement plan.

Specification coverage includes the engine power output (74.9 kW for the BW 161 AD-4, 98 kW for the BW 202 AD-4, both to ISO 9249), valve clearance (0.3 mm intake / 0.5 mm exhaust), injection valve opening pressure (220 bar), high idle speed (2400 ± 50 rpm / 2430 ± 50 rpm), hydraulic oil, engine oil and coolant capacities, drum drive gear ratios, and the amplitude and frequency values for both machines.

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Instant delivery

The manual is delivered as an instant PDF download. There is no shipping and no waiting for a physical book — the file is available as soon as checkout is complete. The PDF can be opened on a laptop, tablet or phone in the workshop, printed out page by page for the machine file, or kept as a searchable reference on a shop computer. Because it is a complete document with the engine, hydraulic, electrical and maintenance sections all in one place, it gives a technician the reference material needed to carry out service work, diagnose faults, set pressures correctly, replace injection pumps, adjust valve clearance and understand the electronics on these two BOMAG tandem rollers.