BOMAG Roller BW202AD-4 Operation Manual

Operating instructions
Maintenance instructions
BW 161 AD-4 / BW 202 AD-4

BW 161 ADH-4 / BW 203 AD-4
S/N 101 920 02 ....> S/N 101 920 03 ....>
S/N 101 920 04 ....> S/N 101 920 05 ....>
Tandem Vibratory Roller
Catalogue number
008 111 81
11/2004
Foreword
BOMAG machines are products from the wide
range of BOMAG compaction equipment.
F oreword
BOMAGs vast experience in connection with

state-of-the-art production and testing methods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your machine.
You should only operate the machine after you

have been instructed and in compliance with these
instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil Engineering Liability Association Safety Rules for
the Operation of Road Rollers and Soil Compactors and all relevant accident prevention regulations.
This manual comprises:

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Safety regulations
Operating instructions
Maintenance instructions
Trouble shooting
For your own personal safety you should only

use original spare parts from BOMAG.
In the course of technical development we reserve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Using these instructions will

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help you to become familiar with the machine.
avoid malfunctions caused by unprofessional

operation.
Compliance with the maintenance instructions will

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enhance the reliability of the machine on construction sites,
prolong the lifetime of the machine,
reduce repair costs and downtimes.
BOMAG will not assume liability for the function of

the machine
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if it is handled in a way not complying with the

usual modes of use,
if it is used for purposes other than those mentioned in these instructions.
Apart from that, the spare parts catalogue is available from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with information about the correct use of our machines in
soil and asphalt construction.
The above notes do not constitute an extension of
the warranty and liability conditions specified in the
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
No warranty claims can be lodged in case of damage resulting from

l
operating errors,
insufficient maintenance and
wrong fuels and lubricants.
Please note!
This manual was written for operators and maintenance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and maintenance instructions are part of the machine.
BW 161/202/203 AD-4
BOMAG
Foreword
Please fill in
............................
Machine type (Fig. 1)
............................
Serial-number (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine number (Fig. 3)
Note
Fig. 1
Supplement the above data together with the commissioning protocol.

During commissioning our organisation will instruct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 2
Fig. 3
BOMAG
BW 161/202/203 AD-4
Table of Contents
Technical Data
Safety regulations
Indicators and Controls
Operation
Maintenance
BW 161/202/203 AD-4
7
13
21
3.1 General notes

3.2 Description of indicators and control elements
24
24
4.1 General notes

4.2 Tests before taking into operation
4.3 Starting the engine
4.4 Starting with jump wires
4.5 Driving the machine
4.6 Stopping the machine, operating the parking brake
4.7 Shutting the engine down
4.8 Switching the vibration on and off
4.9 Operating the crabwalk
4.10 Switching the pressure sprinkling system on and off
4.11 Sprinkling of edge cutter
4.12 Actuating the emergency stop switch
4.13 Adjusting the rotation stop for travel lever movement
4.14 Adjusting the drivers seat
4.15 Opening or closing the cabin window
4.16 Towing
4.17 Transport
40
40
41
45
46
48
49
50
53
54
55
55
56
56
57
57
59
5.1 General notes on maintenance

5.2 Fuels and lubricants
5.3 Fuels, lubricants and filling capacities
5.4 Running-in instructions
5.5 Maintenance chart
5.6 Check the engine oil level
5.7 Check the fuel level
5.8 Check the hydraulic oil level
5.9 Check the coolant level
5.10 Check / empty the fuel pre-cleaner (water separator) / bleed
5.11 Check the water level
5.12 Check, clean radiator, fuel cooler, hydraulic oil cooler and intercooler
5.13 Checking the oil level in vibrator shaft tube
5.14 Change the engine oil
5.15 Change the engine oil filter cartridge
5.16 Checking the anti-freeze concentration
5.17 Servicing the air conditioning (summer operation)
62
63
66
67
68
70
70
71
72
72
74
75
76
77
78
78
79
BOMAG
39
61
Table of Contents
Trouble shooting
5.18
5.19
5.20
5.21
5.22
5.23
5.24
5.25
5.26
5.27
5.28
5.29
5.30
5.31
5.32
5.33
5.34
5.35
5.36
5.37
5.38
5.39
Service the battery

Cleaning the fuel pre-cleaner, replacing, bleeding the filter if necessary
Change the fuel filter cartridge
Changing the oil in the drum drive gear
Checking, tensioning, lubricating the steering chain
Check the engine mounts
Checking the V-belt, tighten, if necessary replace the V-belt
Changing the oil in the vibrator shaft tube
Check, adjust the valve clearance
Changing hydraulic oil and breather filter
Changing the hydraulic oil filter
Grease the articulated joint
Change the coolant
Replace the injection valve
Check, clean, change the combustion air filter
Clean the water tank
Clean the water filter
Water sprinkler system, maintenance in the event of frost
Fill the provision tank for the windscreen washer system
Adjust the scrapers
Tightening torques
Engine conservation
6.1 General notes

6.2 Engine
81
83
85
86
87
88
88
92
93
95
96
97
98
99
101
103
104
105
106
107
107
108
109
110
111
BOMAG
BW 161/202/203 AD-4
1 Technical Data
BW 161/202/203 AD-4
BOMAG
Technical Data
Fig. 4
Dimensions in
mm
H2
BW 161 AD-4
3300
1840
715
1220
2320
3000
400
4520
80
1680
BW 202 AD-4
3300
2295
715
1220
2320
3000
400
4520
80
2135
BW 161 AD-4
BW 202 AD-4
kg
kg
9600
10100
11300
11800
kg
kg
kg/cm
5050
5050
30,1
5900
5900
27,6
kg/cm
30,1
27,6
Dimensions
Oscillation angle
Inner track radius
+/-
mm
6
4400
6
4170
BOMAG
Weights
Operating weight (CECE)
with ROPS-cabin
Front axle load (CECE)
Rear axle load (CECE)
Static linear load front
(CECE)
Static linear load rear
(CECE)
BW 161/202/203 AD-4
Technical Data
*
Travel characteristics
Travel speed (1)
Travel speed (2)
Max. gradability without/
with vibration (soil dependent)
Drive
Engine manufacturer
Type
Cooling
Number of cylinders
Rated power ISO 9249
Rated speed
Electrical equipment
Battery
Drive system
Driven drum
km/h
km/h
%
kW (PS)
1 rpm
V
V/AH
Brakes
Service brake
Parking brake
Steering
Type of steering
Steering operation
Steering angle
Crabwalk, lateral offsetting of drum (right/left)
+/- degree
mm
Vibration system
Drive system
Frequency 1/2
Amplitude 1/2
Vibrating drum
Hz
mm
Water sprinkler system

Type
Interval control
Filling capacities
Fuel (diesel)
Water
Hydraulic oil
Engine oil
*
l
l
l
l
BW 161 AD-4
BW 202 AD-4
0-6
0-11
40/35
0-6
0-11
40/35
Deutz
BF4M 2012
Water
4
74,9
2300
12
12/100
hydrost.
front + rear
Deutz
BF4M 2012 C
Water
4
98
2300
12
12/100
hydrost.
front + rear
hydrost.
mechanical
hydrost.
mechanical
Oscill.-articul.
hydrost.
30
170
Oscill.-articul.
hydrost.
30
170
hydrost.
40/50
0,91/0,39
front + rear
hydrost.
40/50
0,83/0,35
front + rear
Pressure
(+)
Pressure
(+)
200
1000
60
13,5
200
1000
60
13,5
The right for technical modifications remains reserved
BW 161/202/203 AD-4
BOMAG
Technical Data
Fig. 5
Dimensions in
mm
H2
BW 161 ADH-4
3300
1840
715
1220
2320
3000
400
4520
80
1680
BW 203 AD-4
3300
2300
715
1220
2320
3000
400
4520
80
2135
BW 161 ADH-4
BW 203 AD-4
kg
kg
10200
10700
12700
13200
kg
kg
kg/cm
kg/cm
5300
5400
31,5
32,1
6600
6600
30,9
30,9
Dimensions
Oscillation angle
Inner track radius
+/-
mm
6
4400
6
4170
10
BOMAG
Weights
Operating weight (CECE) with
ROPS-cabin
Front axle load (CECE)
Rear axle load (CECE)
Static linear load front (CECE)
Static linear load rear (CECE)
BW 161/202/203 AD-4
Technical Data
*
Travel characteristics
Travel speed (1)
Travel speed (2)
Max. gradability without/with vibration (soil dependent)
Drive
Engine manufacturer
Type
Cooling
Number of cylinders
Rated power ISO 9249
Rated speed
Electrical equipment
Battery
Drive system
Driven drum
km/h
km/h
%
kW (PS)
rpm
V
V/AH
Brakes
Service brake
Parking brake
Steering
Type of steering
Steering operation
Steering/oscillation angle
Crabwalk, lateral offsetting of
drum (right/left)
+/- degree
mm
Vibration system
Drive system
Frequency 1/2
Amplitude 1/2
Frequency 1/2 (US-version)
Amplitude 1/2 (US-version)
Vibrating drum
Hz
mm
Hz
mm
Water sprinkler system

Type
Interval control
Filling capacities
Fuel (diesel)
Water
Hydraulic oil
Engine oil
*
l
l
l
l
BW 161 ADH-4
BW 203 AD-4
0-6,0
0-11,0
40/35
0-6,0
0-11,0
40/35
Deutz
BF4M 2012 C
Water
4
98
2300
12
12/100
hydrost.
front + rear
Deutz
BF4M 2012 C
Water
4
98
2300
12
12/100
hydrost.
front + rear
hydrost.
mechanical
hydrost.
mechanical
Oscill.-articul.
hydrost.
30/6
170
Oscill.-articul.
hydrost.
30/6
170
hydrost.
40/50
0,91/0,39
45/60
0,91/0,39
front + rear
hydrost.
40/50
0,70/0,30
front + rear
Pressure
(+)
Pressure
(+)
200
1000
60
13,5
200
1000
60
13,5
The right for technical modifications remains reserved
BW 161/202/203 AD-4
BOMAG
11
Technical Data
The following noise and vibration values according to the EC-directive for machines, edition (98/37/
EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with
the vibration switched on. The machine was standing on an elastic base.
During operation these values may vary because of the existing operating conditions.
Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
sound pressure level at the work place of the operator (with cabin):
LpA =79,7 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is
guaranteed sound capacity level of the machine:
LWA = 103,3 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO
11204 for sound pressure level (LpA) at the place of the operator.
Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:
Vibration of the entire boy (drivers seat)
The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2.
Hand-arm vibration values
The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2.
12
BOMAG
BW 161/202/203 AD-4
2 Safety regulations
BW 161/202/203 AD-4
BOMAG
13
Safety regulations
General notes
Unintended use
This BOMAG machine is built in accordance

with the latest technical standard and the valid
technical rules and regulations. There is, however, a risk of danger for persons and property
if:
Dangers may, however, arise from the machine if

it is used by untrained personnel in an unprofessional way or if it is used for purposes other than
those mentioned in these instructions.
the machine is used for purposes other than

those it is intended for
Starting and operation of the machine in an explosive environment is prohibited.
the machine is operated by untrained personnel
the machine is modified or converted in an unprofessional way
the applicable safety regulations are not observed.
Each person involved in operation, maintenance and repair of the machine must therefore read and apply these safety regulations.
This should be confirmed by obtaining the signatures of the customer, if necessary.
Furthermore the following regulations and instructions are obviously also valid:
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applicable accident prevention instructions
generally acknowledged safety and road traffic

regulations
country specific safety regulations. It is the

duty of the operator to know and observe
these regulations. This applies also for local
regulations and the regulations for various
types of manual work. If the recommendations
in this manual differ from the regulations valid
in your country, you must strictly observe the
regulations in your country.
Intended use
This machine must only be used for:
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Compaction of bituminous material, e.g. road

surface layers.
medium to heavy compaction work in earth

construction (road sub-bases)
You should only operate the machine with fully

functional safety equipment.
Have the machine inspected by an expert

once every year.
14
Do not work with vibration on hard concrete, on a

cured concrete layer or heavily frozen ground.
Who is allowed to work with the machine?

The machine must only be operated by trained
and authorized persons which are at least 18
years of age. The responsibilities for the operation
of the machine must be clearly specified and complied with.
Persons under the influence of alcohol, medication or drugs must not operate, service or repair
the machine.
Maintenance and repair tasks require specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Conversions and alterations to the machine

Unauthorized conversions to the machine are prohibited for safety reasons.
Original parts and accessories have been specially designed for this machine. We wish to make expressly clear that we have not tested or authorized
any original parts or special equipment not supplied by us. The installation and/or use of such
products can impair the active and/or passive driving safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
Safety notes in the operating and maintenance instructions:

Danger
Sections marked like this point out possible
dangers for persons.
!
BOMAG
BW 161/202/203 AD-4
Safety regulations
Caution
Sections marked like this point out possible
dangers for the machine or for parts of the machine.
!
Towing the machine

You should generally use a tow bar.
Max. towing speed 1 km/h, max. towing distance
500 m.
Before releasing the parking brake secure the machine against rolling.
Note
Sections marked like this provide technical information concerning the optimal economical use of
the machine.
Checking the Roll Over Protection

Structure (ROPS)
The machine frame must not be distorted, bent or
cracked in the area of the ROPS fastening points.
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fuels and lubricants as well as replaced parts.
The ROPS must not show any signs of corrosion,

damage, hairline cracks or open fractures.
Observe all environment protection regulations.
Information and safety stickers/decals

on the machine
Keep stickers/decals complete (see spare parts
catalogue) and fully legible and observe their
meaning.
The ROPS must not rattle about when driving.

This would indicate that it is not sufficiently fastened. All screw connections must be in accordance with the respective specifications and
correctly tightened (observe the tightening torques). Screws and nuts must not be damaged,
bent or deformed.
Neither must any additional parts be welded or
bolted on, nor must any holes be drilled without the
permission of the manufacturer, since this may impair the strength of the structure.
Replace damaged or illegible stickers/decals immediately.
Starting the machine
Loading the machine
Before starting
Use only stable loading ramps of sufficient load

bearing capacity. The ramp inclination must be
less than the gradability of the machine.
The machine must only be operated from the drivers seat.
Switch only to first speed range (do not activate

the crabwalk).
Use only machines which are serviced at regular

intervals.
Secure the machine against tipping or slipping off.
Become acquainted with the equipment, the control elements, the working principle of the machine
and the working area.
Secure the machine on the transport vehicle

against rolling, slipping and turning over.
Wear your personal protective outfit (hard hat,

safety boots, etc.).
Persons are highly endangered if

l
they step or stand under loads being lifted
they remain in the drive range of the machine

during an instruction and during loading.
Before mounting the machine check whether:

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persons or obstructions are beside or under

the machine
The machine must not swing about when being lifted.
the machine is free of oily and combustible

material
Use only safe lifting gear of sufficient load bearing

capacity
all grips, steps and platforms are free of

grease, oils, fuel, dirt, snow and ice
Fasten the lifting gear only at the specified lifting

points.
Maintenance doors must be closed and

locked.
BW 161/202/203 AD-4
BOMAG
15
Safety regulations
Use steps and grips to mount the machine.
Give warning signals, if necessary. Stop work immediately if persons remain in the danger zone,
despite the warning.
Before starting the machine check whether:

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the machine shows any obvious faults
all guards and safety elements are in place
steering, brakes, control elements, light system and warning horn work correctly
the seat is correctly adjusted
mirrors (if present) are clean and correctly adjusted.
Do not step or stand in the articulation area of the

machine when the engine is running. Danger of
squashing!
Driving
Do not start the machine with defective gauges,

control lights or control elements.
In events of emergency and in case of danger actuate the emergency stop switch immediately. Do
not use the emergency stop switch as service
brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop switch
has been eliminated.
Do not take any loose objects with you or fasten

them to the machine.
If the machine has contacted high-voltage power

lines:
On machines with roll over protection system you

must always wear your seat belt!
do not leave the operators stand
warn others from coming close to or touching

the machine
if possible drive the machine out of the danger

zone
have the power switched off
Starting
Start and operate the machine only from the drivers seat (seat contact switch).
For starting set all control levers to 'neutral position'.
Do not use any starting aids like start pilot or ether.
After starting check all gauges and control lights.
Operate the machine only from the operators

stand.
Starting with jump wires
Keep the cabin doors closed.
Connect positive with positive and negative with

negative (ground cable) always connect the
ground strap last and disconnect it first! A wrong
connection will cause severe damage in the electric system.
Do not adjust the drivers seat while driving.
Do not start the engine by shorting the electric terminals on the starter motor, because the machine
may start to drive immediately.
Do not use the machine to transport persons.
Starting in closed rooms
Do not climb onto or off the machine while the machine is driving.
Change the travel direction only at standstill.
In case of unusual noises and development of
smoke perform trouble shooting and have the fault
corrected.
Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting
in closed rooms!
Always keep a sufficient distance to excavation

walls and embankments and do not use working
methods that could impair the stability of the machine.
Driving the machine
Do not work with vibration on hard concrete, cured

bitumen layers or extremely frozen ground.
Persons in the danger area
Always keep a sufficient distance when passing

through subways, under bridges, tunnels, electric
power lines etc.
Before taking up work, also after breaks, you

should always convince yourself that the danger
zone is free of persons or obstructions, especially
when driving in reverse.
Driving on inclinations and slopes

Do not drive on gradients exceeding the maximum
gradability of the machine.
16
BOMAG
BW 161/202/203 AD-4
Safety regulations
On slopes drive extremely careful and always directly up or down the slope. Change to a lower
gear before starting to drive.
No open fire, do not smoke.
Wet and loose soils considerably reduce the

ground adhesion of the machine on inclinations
and slopes. Higher risk of accident!
Wipe off spilled fuel. Keep dirt and water away

from the fuel.
Do not spill any fuel. Catch running out fuel, do not

let it seep into the ground.
Match the speed to the working conditions.
A leaking fuel tank can cause an explosion. Ensure tight fit of the fuel tank cover, if necessary replace immediately.
Always give way to loaded transport vehicles.
Fire protection measures
Switch the lights on if the visibility is poor.
Familiarise yourself with the location and the operation of fire fighting equipment. Observe all fire reporting and fire fighting possibilities.
Behaviour in traffic
Keep away from edges and embankments.

Checking the effect of vibration
When compacting with vibration you must check
the effect on nearby buildings and underground
supply lines (gas, water, sewage, electric power),
if necessary stop compaction work with vibration.
Do not activate the vibration on hard (frozen, concrete) ground. Danger of bearing damage!
Parking the machine

Park the machine on horizontal, level, firm ground.
Before leaving the machine:
Maintenance work
Comply with the maintenance work described in
the operating and maintenance instructions, including the information concerning the replacement of parts.
Maintenance work must only be performed by
qualified and authorized persons.
For overhead maintenance and assembly work
use the access steps and working platforms provided or other secure means. Do not use machine
parts as access steps.
return the control lever to neutral position
apply the parking brake
shut the engine down, pull the ignition key off
close the cabin
Do not perform maintenance work while the machine is driving or the engine is running.
secure the machine against unauthorized use.
Park the machine on horizontal, level, firm ground.
pull the key off the main battery switch.
Keep unauthorized persons away from the machine.
Pull the key out of the ignition switch.

pull the key off the main battery switch.
Do not jump off the machine, but use hand grips

and access steps.
Work on hydraulic lines
Mark machines, which could be in the way, with a

clearly visible sign.
Parking on slopes and inclinations
Secure the machine against rolling, place metal
chocks in front of and behind the wheels.
Do not step in front of or behind the drums/wheels

when performing adjustment work in the hydraulic
system.
Filling in fuel
Do not inhale any fuel fumes.
Refuel only with the engine stopped and the auxiliary heater switched off.
Always use access steps.
Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe
injury. When being injured by hydraulic oil consult
a medical doctor immediately, as otherwise this
may cause severe infections.
Do not change the setting of pressure relief valves.

Drain the hydraulic oil at operating temperature
danger of scalding!
Do not refuel in closed rooms.
BW 161/202/203 AD-4
BOMAG
17
Safety regulations
Catch running out hydraulic oil and dispose of environmentally.
Always catch and dispose of hydraulic oils separately.
Do not leave and tools or other objects, that could

cause damage, in the engine compartment.
Do not start the engine after draining the hydraulic

oil.
Check and change coolant only when the engine

is cold.
Once all work is completed (with the system still

depressurized!) check all connections and fittings
for leaks.
Catch coolant and dispose of environmentally.

Working on electric parts of the machine
Changing hydraulic hoses

Hydraulic hoses must be visually inspected at regular intervals.
the outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
the outer layer is brittle (formation of cracks in

the hose material)
the hose shows deformations in pressurized

and depressurized condition, which do not
comply with the genuine shape of the hydraulic hose
Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire hazard!
Hydraulic hoses must be immediately replaced if:

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Store used filters and other oil contaminated materials in a separate, specially marked container
and dispose of environmentally.
Disconnect the battery before starting welding

work on the machine.
Working on the battery
When working on the battery do not smoke, do not
use open fire!
Do not let acid come in contact with hands or
clothes! When injured by acid flush off with clear
water and seek medical advice.
the hose shows deformations in bends, e.g.

squeezing, buckling, layer separation, formation of blisters
Metal objects (e.g. tools, rings, watch straps) must

not come in contact with the battery poles danger of short circuit and burning!
parts of the hose are leaking.
hoses are not correctly installed.
the hydraulic hose has separated from the fitting
When recharging serviceable batteries remove all

plugs, to avoid the accumulation of explosive gases.
the fitting shows corrosion that impairs both

function and strength.
Observe the applicable instructions when starting

with an auxiliary battery.
hoses are mixed up by mistake.
Dispose of old batteries according to regulations.
fittings are damaged or deformed, whereby

the function and strength of the hose/hose
connection is impaired.
Switch off the charging current before removing

the charging clamps.
Only genuine BOMAG replacement hydraulic hoses ensure that the correct hose type (pressure
range) is used at the right location.
Working on the engine
Shut the engine down before opening the service
doors.
Drain the engine oil at operating temperature
danger of scalding!
Wipe off spilled oil, catch running out oil and dispose of environmentally.
18
Ensure sufficient ventilation, especially if the battery is to be charged in a closed room.

Working on the fuel system
No open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground and dispose off environmentally.
Cleaning work
Do not perform cleaning work while the engine is
running.
BOMAG
BW 161/202/203 AD-4
Safety regulations
Do not use gasoline or other easily inflammable
substances for cleaning.
When cleaning with steam cleaning equipment do
not subject electrical parts and insulation material
to the direct jet of water, or cover it beforehand.
l
Do not guide the water jet into the exhaust and

into the air filter.
After maintenance work

After all maintenance work is completed reinstall
all guards and safety installations.
Repair
Attach a warning tag to the steering wheel if the
machine is defective.
Repairs must only be performed by qualified and
authorized persons. Refer to our repair instructions.
Exhaust fumes are highly dangerous! Always ensure an adequate supply of fresh air when starting
in closed rooms!
Test
Depending on the type of application and the operating conditions vibratory equipment has to be
examined by a specialist whenever required, but
at least once every year.
BW 161/202/203 AD-4
BOMAG
19
Safety regulations
20
BOMAG
BW 161/202/203 AD-4
3 Indicators and Controls
BW 161/202/203 AD-4
BOMAG
21
Fig. 6
22
BOMAG
BW 161/202/203 AD-4

1
Omegameter (E-Vib display)*
18 Rotary switch for lighting (StVZO)*
Instrument cluster, left
19 Rotary switch for working head lights*
Emergency stop push button
20 Lever, swivelling of drivers seat
Push button for hazard light system*
Instrument cluster, right
21 Momentary contact push button to raise the

edge cutter
Speedometer*
Ignition switch
Rotary switch for chip spreader*
Rotary momentary contact switch for chipping

quantity control*
22 Momentary contact push button to lower the

edge cutter
23 Travel lever, right
27 Interval switch for pressure sprinkler system
11 Rotary switch for speed range selection
28 Travel lever, left
12 Riotary switch for tire sprinkling system (only

AC-4)
29 Momentary contact push button for crabwalk,

left
13 Rotary switch for sprinkling pumps

14 Rotary switch for vibration, drum pre-selection
15 Rotary switch for vibration, manual - zero - automatic
17 Rotary switch for direction indicators left/right*
BW 161/202/203 AD-4
30 Momentary contact push button for crabwalk,

right
31 Push buttin for manual vibration
32 Lever, lateral sliding of drivers seat
16 Rotary switchfor amplitude pre-selection

Optional equipment
25 Push button for warning horn

26 Rotary momentary contact switch for edge cutter sprinkling system*
10 Rotary momentary contact switch for engine

speed
24 Push buttin for manual vibration
33 Rotation stop for travel lever movement

34 2-pole socket
BOMAG
23

3.1
General notes
3.2
Description of indicators
and control elements
Please read this section thoroughly before operating this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise descriptions of the individual operating steps.
Fig. 7
No. 1 = Omega-meter*
a compaction measuring instrument, which continually shows the load bearing values during the
compaction pass.
Omega value
increase
= higher load bearing capacity
constant
= end of compaction
1 digit
= 20 Omega values
Fig. 8
No. 2 = Instrument cluster, left
Note
With the ignition switch in position I all gauges and

instruments are switched on for 3 seconds.
24
BOMAG
Option
BW 161/202/203 AD-4

a red flashing
= Overheating of engine, higher than
110C, warning buzzer sounds.
Switch off vibration, run engine with
idle speed or shut down engine if
necessary, clean engine oil cooler
and radiator, if necessary repair engine.
= Operating hour meter, counts the operating hours while the engine is running. All maintenance work must be
performed according to the indicated
operating hours.
= Fuel tank filling level
Note
b red flashing
= Engine oil pressure too low, engine is
shut down after 10 seconds. Check
engine oil level, repair the engine if
necessary.
When falling below the lowest filling level the last

green LED will light and the red LED will additionally come on.
c yellow = Engine air filter, air filter cartridge

soiled, clean or replace if necessary.
When the fuel tank is empty only the red LED will
flash.
Nine green and one red LED.
d yellow = Charge control mlight, batteries are

not being charged, check V-belt, repair the generator if necessary
e yellow = Hydraulic oil filter, check hydraulic
system, replace hydraulic oil filter.
f yellow = Seat contact monitoring while machine is travelling, warning buzzer
sounds, engine is shut down after 4
seconds.
g red
= Parking brake, with lever shifted to

parking brake position, with drivers
seat unoccupied.
h green
flashing = Travel direction indicator, with travel
direction lever actuated.
Fig. 9
No. 3 = Emergency stop push button
i yellow = Water separator in fuel pre-filter, if

the water proportion in the transparent section of the fuel pre-filter reaches the contacts.
j red flashing
= Optional; coolant provision (filling level)
*
k yellow = Pre-heating and after-heating

= Between -30C and +10C pre-heating in ignition switch position I and
momentary contact switch for engine
speed in idle speed position. After
light goes out start within 14 seconds.
l red flashing
= Hazard light, with hazard light switch
depressed
Danger
Danger of accident!
Use only in events of emergency during operation.
Do not use as parking brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop
switch has been eliminated.
The machine is braked immediately, the engine
is shut down.
actuate
switch off/unlock
= press the button completely

down, it automatically locks in
fully pressed position.
= Turn button clockwise. Restart the engine.
Optional equipment
BW 161/202/203 AD-4
BOMAG
25

e yellow = Crabwalk, with crabwalk actuated to
left/right, goes out in middle position
f yellow = Air condition failure.
g red flashing
= Fault light/ failure of Asphalt Manager
control*
h green = Chip spreader switched on.
i empty
= not used
j green
= maximum speed switched on.
k yellow = Minimum fuel filling level, reserve

Fig. 10
l red flashing
= no function; hydraulic oil temperature
No. 4 = Hazard light button
pressed = hazard light system switched on,

warning light (l) in left hand instrument cluster flashes red
press
again
= hazard light switched off, warning

light (l) goes out
= Water tank filling level

Note
Nine green and one red LED.

When falling below the lowest filling level the last
green LED will light and the red LED will additionally come on.
When the fuel tank is empty only the red LED will
flash.
Fig. 11
No. 5 = Instrument cluster, right
Note
With the ignition switch in position I all gauges and

instruments are switched on for 3 seconds.
a red flashing
= No function; immobilizer
b empty = not used
Fig. 12
No. 6 = Speedometer*
Shows the travel speed of the machine.
black display
scale
km/h
red display
scale
M.P.H.
c yellow = Remaining water quantity, warning

buzzer sounds
d yellow = Fast travel range, vibration goes out
or cannot be switched on
26
BOMAG
BW 161/202/203 AD-4

i
Note
Perform the starting process for maximum 15 20

seconds without interruption and pause for about
a minute between starting attempts. Should the
engine not start in this time, perform trouble shooting and rectify the cause.
!
Caution
Run the engine warm for a short while before
starting work. Do not allow the engine to run
longer than 10 minutes with idle speed.
Do not shut the engine down all of the sudden

from full speed, but let it idle for a while for
temperature equalization.
Fig. 13
No. 7 = Ignition switch

Position "P"/"0" =
Ignition off, key can be pulled

out
Position "I"
Ignition on, all instruments in

the instrument cluster light up
for 3 seconds. The lighting
system can be switched on.
Note
The engine can only be started if both travel levers

are in neutral.
The ignition switch is designed with a lock to prevent repetitive starting. For a new starting attempt
the ignition key must first be turned back to position "0".
With a cold-start system installed* and at temperatures between -30C and 10C run a pre-heating
process.
*
= Turn the rotary momentary

contact switch for engine
speed once to idle speed position. Control light (k) in the instrument cluster will only light
up if fuse F 15 is installed.
Once the control light (k) in the
left hand instrument cluster
has gone out start the engine
within 14 seconds.
Position "II"
(Start)
Fig. 14
No. 8 = Rotary switch for chip spreader**

Position
left
= Chip spreader switched off
Position
right
= Chip spreader switched on
Note
Control light (h) in right hand instrument cluster

lights up.
turn further against spring

pressure, start engine, return
ignition key to position "I".
Optional equipment
BW 161/202/203 AD-4
**
BOMAG
Optional equipment
27

i
Note
Control light (j) in right hand instrument cluster

lights up.
To start under cold ambient temperatures:
with ignition switch in position "I" turn rotary momentary contact switch clockwise. The engine can
be started with max. speed.
!
Caution
Always drive and vibrate with max. engine

speed! Control the travel speed with the travel
lever.
Fig. 15
No. 9 = Rotary momentary contact switch for

chip quantity*
Position left
= Reduce chip quantity
Position right
= Increase chip quantity
Fig. 17
No. 11 = Rotary switch for speed range selection

Position left
= Ist travel range 0 ... 6 km/h
Fig. 16
Note

engine speed
Vibration is only possible in speed range 1.
Electric engine speed adjustment
Position right
turn clockwise = Idle speed position, pre-heating**
= IInd travel range 0 ... 11 km/h,

control light (d) in right hand instrument cluster lights up.
Note
Normal position for engine start.

turn clockwise = Full load position, operating
position for driving and vibration
*
**
28
Optional equipment
Optional equipment
BOMAG
BW 161/202/203 AD-4
Fig. 18
Fig. 20

tire sprinkling system (only AC-machines)
No. 14 = Rotary switch for vibration, drum preselection
Position "left"
= 5 sec. on / 20 sec. off (interval)

emulsion sprinkling
Position "0"
= Sprinkler system switched off
Momentary contact switch

"right"
= 5 sec. emulsion sprinkling on
Note
Vibration change-over is only activated if the vibration is switched off beforehand.

Position "left"
= Vibration of front drum
Position "middle"
= Vibration of front and rear
drums
Position "right" = Vibration of rear drum
Fig. 19
No. 13 = Rotary switch for sprinkling pumps

Position left
= Sprinkling pump I switched on
Position middle = Sprinkling pumps switched off

Position right
= Sprinkling pump II switched on
Fig. 21
No. 15 = Rotary switch for vibration, manual or

automatic
Position "left"
Note
Sprinkling pumps I and II switched on alternately
= Pre-selection for vibration activation during travel via the vibration push button in the
travel lever
Position "right" = Pre-selection for automatic activation and deactivation of vibration when exceeding or
BW 161/202/203 AD-4
BOMAG
29

falling below a certain slow
travel speed.
Position "middle"
= Vibration off
Fig. 24
No. 18 = Rotary switch for light system (StVZO)**

Position "left"
Position "middle"
= Sidelights on, with ignition
switch in position "I" or with
only ignition on.
Fig. 22
No. 16 = Rotary switch for vibration, amplitude

selection
Position "left"
= Light off
= low amplitude, high frequency
Position "right" = high amplitude, low frequency
Position "right" = Travel light on, with ignition

switch in position "I"
Fig. 23
Fig. 25
No. 17 = Rotary switch for direction indicators

left / right*
No. 19 = Rotary switch for working lights***

Position "left"
Position "middle"
= Direction indicators disabled
= Light off
Position "right" = Working lights on, with ignition

switch in position "I"
Position "left or
right"
= The front and rear direction indicators for the corresponding
side of the machine light up,
the control light (h) in the instrument cluster flashes
30
Optional equipment
** Optional equipment
*** Optional equipment
BOMAG
BW 161/202/203 AD-4
Fig. 26
Fig. 28
No. 20 = Lever, swivelling of drivers seat
No. 22 = Momentary contact push button to

lower the edge cutter**
Danger
Danger of accident!
press
= Edged cutter is lowered.
release
= Edge cutter remains in position

reached last.
Always lock the drivers seat in one of the locking positions while driving.
Do not swivel the drivers seat while driving.
swivel
= Stop he machine, apply the

parking brake. Pull the lever
and swivel the drivers seat to
the desired position. Let lever
click securely into place.
Fig. 29
No. 23 = Travel lever, right
Fig. 27
Position 0
= start forward and backward

travel from position 0. From
forward or backward travel to
position 0 = service brake
Position "I"
= Forward travel
Position "II"
= Backwards travel
No. 21 = Momentary contact push button to

raise the edge cutter*
press
= Edged cutter is raised.
release
= Edge cutter remains in position

reached last.
Optional equipment
BW 161/202/203 AD-4
Note
The right hand travel lever is mechanically linked

with the left hand travel lever.
When leaving the seat (seat contact switch) with
the engine is running and/or the machine driving,
the engine will be shut down after the 4 seconds,
**
BOMAG
Optional equipment
31

the warning buzzer will sound and warning light (f)
in the instrument cluster will light up.
If the engine speed drops under load when driving
on steep gradients, take the travel lever slightly
back towards neutral. This relieves the hydraulic
system and reduces the load on the diesel engine.
Position "III"
= notched position to the right =

parking brake, starting of engine
Note
The parking brake control light (g) in the left hand

instrument cluster lights up.
Fig. 32
No. 26 = Push button, edge cutter sprinkling

system*
press
= Edge cutter sprinkling system

switched on.
Note
The edge cutter sprinkler system works when the

rotary switch has been switched to sprinkling
pump I or II.
press again
= Edge cutter sprinkling system

switched off
Fig. 30
No. 24 = Momentary contact push button for

manual vibration, right
press
= to switch manual vibration on

and off.
Fig. 33
No. 27 = Interval switch for pressure sprinkler

system
Position 12 left = permanent sprinkling when
pressure sprinkling is enabled
Fig. 31
No. 25 = Push button for warning horn
32
BOMAG
Optional equipment
BW 161/202/203 AD-4

i
Note
In travel lever position 0 the sprinkling system is

switched off, except in position 12 (permanent
sprinkling).
Note
The parking brake control light (g) in the left hand

instrument cluster lights up.
further positions
to the right, between 11 and 1 = various sprinkling intervals
Fig. 35

crabwalk, left
press
Fig. 34
= the crabwalk is infinitely adjusted to left.
No. 28 = Travel lever, left

Position 0
= start forward and backward

travel from position 0. From
forward or backward travel to
position 0 = service brake
Note
Control light (e) in right hand instrument cluster

lights up.
Position "I"
= Forward travel
Control light goes out when middle position is

reached.
Position "II"
= Backwards travel
release
= Crabwalk remains in position

reached last.
Note
The left hand travel lever is mechanically linked

with the right hand travel lever.
When leaving the seat (seat contact switch) with
the engine is running and/or the machine driving,
the engine will be shut down after the 4 seconds,
the warning buzzer will sound and warning light (f)
in the instrument cluster will light up.
If the engine speed drops under load when driving
on steep gradients, take the travel lever slightly
back towards neutral. This relieves the hydraulic
system and reduces the load on the diesel engine.
Position "III"
= notched position to the left =

parking brake, starting of engine
Fig. 36

crabwalk, right
press
BW 161/202/203 AD-4
BOMAG
= the crabwalk is infinitely adjusted to right.
33

i
sliding
Note
Control light (e) in right hand instrument cluster

lights up.
reached.
release
= Stop machine, apply parking

brake, pull lever and slide drivers seat sideways to desired
position. Let lever click securely into place.
= Crabwalk remains in position

reached last.
Fig. 39
No. 33 = Rotation stop for travel lever movement

Fig. 37
Turn anti-clockwise
= long travel lever movement

manual vibration, left
press
= to switch manual vibration on

and off.
Note
machine can be driven with max. speed.

turn clockwise = short travel lever movement
Note
machine can be driven with reduced speed in accordance with the length the stop is screwed in.
Fig. 38
No. 32 = Lever, lateral sliding of drivers seat
Danger
Danger of accident!
Always lock the drivers seat in one of the locking positions while driving.
Fig. 40
Do not slide the drivers seat while driving.
Permanent current when main battery switch is

switched on.
34
No. 34 = 2-pole socket
BOMAG
BW 161/202/203 AD-4

(9), 10A =
(F14) engine solenoid
(10), 15A = (F129) MD+

(11), 5A =
(F04) gauges
(12), 10A = (F23) warning horn

(13), 10A = (F03) vibration
(14), 15A = (F08) direction indicators and working head lights
(15), 10A = (F101) Variomatic, potential 15
(16), 10A = (F06) water sprinkling system
(17), 10A = (F09) parking and tail light, left hand
side
Fig. 41
No. 35 = Main battery switch
(18), 10A = (F10) parking and tail light, right

hand side
The main battery switch is installed in the engine

compartment.
(19), 10A = (F11) head lights, left hand side
inserted and
turned in
removed
(20), 10A = (F12) head lights, right hand side

= machine can be started.
= engine cannot be started, (anti-theft protection)
Danger
Fire hazard!
!
Do not use fuses with higher ampere ratings

and do not bridge fuses.
Fig. 42
No. 36 = Fuses in electric junction box

Fig. 43
Fuses
(1), 30A =
(F01) main fuse
(2), 15A =
(F05) socket
(3), 10A =
(F93) control potential 30
(4), 20A =
(F105) engine speed
(5), 25A =
(F68) potential 30
(6), 15A =
(F07) hazard light
(7), 7,5A =
(F119) engine
(8), 5A
(F25) solenoid valve for driving and

braking
BW 161/202/203 AD-4
No. 37 = Main fuse for battery

Main fuse for battery and fuse for white fume control are located in the battery compacrtment.
(1), 125A
= (F00) main fuse for battery
(2), 125A
= (F15) Fuse for white fume control
Note
When installing fuse F 15 the engine is after-heated. The battery is recharged by a longer running
time of the engine.
BOMAG
35

Caution
Gefahr der Tiefentladung der Batterie.Risk of
total discharge of battery.
!
down
= Switches on wiping of rear

windscreen.
Push button
= Rear windscreen is sprayed

during wiping.
h = toggle switch for working headlights
Fig. 44
No. 38 = Control elements, cabin*

Fig. 46
d = Fuse box in cabin

!
Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
(1), 15A = (F41) flashing beacon
(2), 15A = (F27) wiper/washer, front
(3), 15A = (F28) wiper/washer, rear
(4), 25A = (F31) cabin fan
Fig. 45
(5), 25A = (F110) working head lights, front/rear
a = toggle switch for flashing beacon
(6), 5A
b = toggle switch for front windscreen wiper/

washer
(7), 10A = (F68) potential 30
up
= windscreen wiper moves to

end position and stops.
down
= Switches on wiping of front

windscreen.
Push button
= Front windscreen is sprayed

during wiping.
= (F90) cabin heater
(8), 20A = (F40) cabin heater
c = toggle switch for rear windscreen wiper/

washer
up
36
= windscreen wiper moves to

end position and stops.
Optional equipment
BOMAG
BW 161/202/203 AD-4

Position red
range
= Temperature selection for cabin heater.
Fig. 47
e = Rotary switch for cabin ventilator

Position Off
= cabin ventilator switched off.

Fig. 48
Position 1, 2 and
3
= ventilator stages of different
strengths
i = reading and dshboard light

j = toggle switch for reading and dashboard
light
Note
k = toggle switch for cabin light
The 3rd stage cannot be switched on when the

cabin mounted working headlights are switched
on.
l = cabin light
f = Push button for air conditioning*

press
= air conditioning switched on.
Note
The light above the push button and control light (f)
in the instrument cluster light up.
With rotary switch (g) the air conditioning unit can
be regulated within the blue range.
press again
= air conditioning switched off.
Note
The light go out.

g = Rotary switch for cabin heater (temperature selector switch)
Position Off
Position blue
range
Fig. 49
No. 39 = Vents for air conditioning, ventilation

and heating, left hand side**
= cabin heater switched off.

= temperature selection for air
conditioning.
Optional equipment
BW 161/202/203 AD-4
**
BOMAG
Optional equipment
37
Fig. 50
No. 40 = Vents for air conditioning, ventilation

and heating, right hand side*
38
Optional equipment
BOMAG
BW 161/202/203 AD-4
4 Operation
BW 161/202/203 AD-4
BOMAG
39
Operation
4.1
General notes
Please read section 3 Indicators and Control Elements thoroughly before operating the machine if
you are not yet fully familiar with the indicators and
control elements of the machine.
4.2
Tests before taking into operation
The following inspections must be carried out before each working day or before a longer working
period.
All indicators and control elements are described

in detail in this chapter.
!
Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
Park the machine on ground as level as possible.
Check:
l
fuel tank and fuel lines for leaks
screw joints for tight fit
function of steering
machine for cleanliness, damage
Presence of the appropriate operating and

maintenance instructions
proper maintenance of the machine
right and left hand service doors closed and

locked
Note
For a description of the following tasks refer to the

chapter "maintenance every 10 operating hours".
Engine oil level
Note
In hydraulic systems filled with Panolin HLP Synth.

46 always use the same oil to top up. With other
ester based oils consult the lubrication oil service
of the respective oil manufacturer.
l
Check the hydraulic oil level, top up if necessary.
Check the coolant level, top up if necessary.
Danger
Fire hazard!
l
40
BOMAG
Check the fuel level, top up if necessary.

BW 161/202/203 AD-4
Operation
l
Check water separator in fuel system, drain if

necessary.
Fill water tanks
Clean the scrapers, check their condition, replace if necessary.
4.3
Starting the engine
Open the right hand service door.
Fig. 51
l
Insert and lock the main battery switch (Fig.

51).
Close the right hand service door.
Fig. 52
Always start the engine from the drivers seat

with seat contact switch (Fig. 52).
Danger
Danger of accident!
!
Always wear your seat belt.
BW 161/202/203 AD-4
BOMAG
41
Operation
Fig. 53
l
Fig. 56
Fasten your seat belt (Fig. 53).
Check, whether the emergency stop switch

(Fig. 56) is unlocked.
Fig. 54
l
Fig. 57
Adjust the drivers seat and let it click into

place (Fig. 54).
Fig. 55
l
42
Turn the ignition key (Fig. 57) to position "I".
Fig. 58
Check, whether the travel lever (Fig. 55) is engaged in brake position (III).
All control and warning lights (Fig. 58) and (Fig.

59) in the fault monitoring board light up for approx. 3 seconds.
BOMAG
BW 161/202/203 AD-4
Operation
Fig. 59
Fig. 61
Charge control light (d), engine oil pressure warning light (b) and brake warning light (g) stay on.
Note
Control light (j) (Fig. 61) in right hand instrument

cluster lights up.
Starting with fuse F15 (pre-heating facility) installed
Fig. 60
l
To start under cold temperatures turn the rotary momentary contact switch (Fig. 60) for engine speed clockwise to "MAX".
Fig. 62
Turn the rotary momentary contact switch for

engine speed (Fig. 62) once to the left to engine speed MIN.
Note
The pre-heating facility is switched on.
BW 161/202/203 AD-4
BOMAG
43
Operation
Caution
Run the engine warm for a short while, but do
not run with idle speed for more than 10 minutes.
!
Fig. 63
Note
Control light k (Fig. 63) in the left hand instrument

cluster lights as long as the pre-heating facility is
in operation (between 32 ... 54 seconds).
Fig. 65
After control light goes out start within 14 seconds.

engine speed (Fig. 65) counter-clockwise to
position MIN to run the engine warm.
Fig. 64
Turn the ignition key to position "II" (Fig. 64),

the starter will crank the engine.
Caution
Perform the starting process for maximum 20
seconds without interruption and pause for a
minute between starting attempts.
!
If the engine has not started after two attempts

perform trouble shooting.
l
As soon as the engine ignites return the ignition key to position "I".
Charge control light and engine oil pressure warning light go out. The brake warning light stays on.
44
BOMAG
BW 161/202/203 AD-4
Operation
4.4
Caution
If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which
could damage electrical components.
Starting with jump wires
After starting disconnect the negative poles

(ground cable) first and the positive poles after.
Switch off the consumer.
Fasten the battery cover again.
Fig. 66
l
Remove the battery cover (Fig. 66).
Fig. 67
!
Caution
A wrong connection will cause severe damage
in the electric system.
Only use a 12 Volt battery to bridge the machine.
When jump starting with an external battery

connect both plus poles first.
Then connect the ground cable first to the minus pole of the current supplying battery and
then to engine or chassis ground, as far away
from the battery as possible (Fig. 67).
Start as described under 'Starting the engine'.
Once the engine is running switch on a powerful consumer (working light, etc.).
BW 161/202/203 AD-4
BOMAG
45
Operation
4.5
!
Driving the machine
Danger
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive up and down inclinations exceeding the maximum gradability of the machine
(see technical data).
Fig. 69

engine speed clockwise to "MAX"(Fig. 69).
Always give way to loaded transport vehicles!

Before starting to drive make sure that the
drive range is absolutely safe.
Note
The engine revs up to maximum speed.

Caution
Always drive and vibrate with max. engine
speed! Control the travel speed with the travel
lever.
!
Fig. 68
Caution
Pre-select the travel speed range at standstill.
!
Pre-select the desired speed range (Fig. 68).

Fig. 70
Note
Control light j (Fig. 70) in right hand instrument

cluster lights up.
46
BOMAG
BW 161/202/203 AD-4
Operation
Do not operate jerkily! Control the travel speed
with the travel lever.
When driving up and down inclinations move
the travel lever slowly back towards neutral to
brake the machine.
If the engine speed drops when driving up extreme inclinations move the ravel lever slightly
back, if necessary change to the lower speed
range.
Seat contact switch

Fig. 71
Disengage the travel lever (Fig. 71) from

notched position III towards the inside.
Note
The brake warning lamp (g) in the instrument cluster goes out.
Move the travel lever form "0"-position slowly
to forward or reverse.
Note
Fig. 72
The machine drives forward or backward with a

speed that corresponds with the actuation of the
travel lever.
In travel lever positions "I" and "II" the seat contact

switch is active (Fig. 72).
Move the travel lever back to "0"-position.
Note
Danger
Danger of accident!
!
The machine is braked and stops in "0"-position.

!
Note
If the seat is not occupied when the engine is

running the warning horn will sound and the
engine will be shut down after 4 seconds.
Danger
Danger of accident!
When stopping on inclinations and slopes engage the travel lever towards the outside in
parking brake position.
Important notes on travel operation

Caution
When changing the travel direction hold the
travel lever for a moment in "0"-position, until
the machine has stopped, before actuating to
the new travel direction.
!
BW 161/202/203 AD-4
BOMAG
47
Operation
4.6
Stopping the machine, operating the parking brake
Fig. 73
Note
The warning lights for seat occupation and parking

brake f and g (Fig. 73) in the left hand instrument
cluster light up.
Fig. 74
Return the travel lever (Fig. 74) slowly to "0"position and engage it towards the outside in
notched position "III", parking brake position.
l
l
To continue travelling you must occupy the

seat and put on the seat belt within 4 seconds.
The warning lights go out and the warning
horn stops sounding.
If the engine stops restarting is required.
Note
The machine is automatically braked by the hydrostatic drive and the parking brake is applied.
Fig. 75
The parking brake warning light g (Fig. 75) in the

left hand instrument cluster lights up.
Note
The parking brake also closes automatically when

shutting the engine down.
48
BOMAG
BW 161/202/203 AD-4
Operation
4.7
Do not shut the engine down all of the sudden from

full speed, but let it idle for a while for temperature
equalization.
Shutting the engine down
Fig. 76
Fig. 78
Return the travel lever (Fig. 76) slowly to "0"position and engage it towards the outside in
notched position "III", parking brake position.
Turn the ignition switch (Fig. 78) to position "0"

or "P" and pull the ignition key out.
Note
Note
The parking brake closes automatically when

shutting the engine down.
The machine is automatically braked hydrostatically.

The parking brake warning light in the left hand instrument cluster lights up.
Fig. 79
Fig. 77

engine speed counter-clockwise to "MIN" (idle
speed) (Fig. 77).
Remove the main battery switch (Fig. 79) and

store it in a safe place.
Close the right hand service door.
Danger
Danger of accident!
!
Note
The control light for maximum engine speed j in

the right hand instrument cluster goes out.
BW 161/202/203 AD-4
Secure the machine against unauthorized use,

pull the ignition key out, lock the cabin door.
BOMAG
49
Operation
4.8
Switching the vibration on

and off
Note
Vibration is only possible in speed range 1.
Pre-selecting the vibration
Note
Switch the vibration on only at maximum engine

speed.
Vibration at standstill causes transverse ruts,
therefore:
l
switch the vibration on only after shifting the

travel lever to the desired travel direction.
Switch the vibration off before stopping the

machine.
Caution
Danger of bearing damage!
!
Do not activate the vibration on hard (frozen,

concrete) ground.
Fig. 81
Pre-select amplitude/frequency with the rotary

switch (Fig. 81).
Danger
Risk of damage!
When compacting with vibration you must
check the effect of nearby buildings and underground supply lines (gas, water, sewage,
electric power), if necessary stop compaction
with vibration.
Fig. 82
Preselect the desired drum or drums with the

rotary switch (Fig. 82).
Note
The drum pre-selection "front/ both/ rear" can only

be changed after switching the vibration off.
Fig. 80
l
50
Turn the rotary speed range selector switch

(Fig. 80) anti-clockwise to the first speed
range.
BOMAG
BW 161/202/203 AD-4
Operation
Vibration in manual mode
Fig. 85
Actuate the vibration push button (Fig. 85) in

the left or right hand travel lever only after shifting the travel lever to the desired travel direction.
Fig. 83
Turn the rotary switch for vibration in manual

or automatic mode (Fig. 83) anti-clockwise to
the symbol "Manual".
Switching the vibration off

Switch the vibration on
Press the vibration push button again.
Caution
Switch the vibration on only at max. engine
speed.
!
Note
Always switch the vibration off before stopping the

machine.
Vibration in automatic mode
Note
In automatic mode the vibration is switched on at

a speed of more than 1.3 km/h, when riving in travel speed ranges I + II.
Vibration is switched off at a speed below
1.3 km/h.
Fig. 84

engine speed clockwise to "MAX" (Fig. 84).
Note
Control light j in right hand instrument cluster lights

up.
BW 161/202/203 AD-4
BOMAG
51
Operation
Switching the vibration off
Fig. 86
Turn the rotary switch (Fig. 86) clockwise to

"Automatic".
Fig. 88
Shift the travel lever (Fig. 88) towards "0"-position to brake the machine.
Switch the vibration on
Note
The vibration switches off when falling below the

slow travel speed.
Vibration in automatic mode avoids the formation
of transverse marks caused by vibration with the
machine at standstill.
Fig. 87
Shift the travel lever (Fig. 87) in direction forward or backward.
Note
The vibration comes on at a low travel speed.
52
BOMAG
BW 161/202/203 AD-4
Operation
4.9
Operating the crabwalk
Fig. 91
Fig. 89
Note
The crabwalk control light e (Fig. 91) in the right

hand instrument cluster lights up.
Note

reached.
The maximum offset (Fig. 89) to right and left is

170 mm.
Danger
Operate the crabwalk only at low travel speed,
in order to stay in track.
!
Fig. 92
Press and hold the right hand push button

(Fig. 92) on the left hand travel lever.
Fig. 90
Press and hold the left hand push button (Fig.

90) on the left hand travel lever.
Note
the crabwalk is infinitely adjusted to right.

The crabwalk operates immediately, also in standstill.
Note
The crabwalk is infinitely adjusted to left.

The crabwalk operates immediately, also in standstill.
BW 161/202/203 AD-4
BOMAG
53
Operation
4.10 Switching the pressure
sprinkling system on and
off
Fig. 93
Turn the rotary switch for the pressure sprinkling system (Fig. 93) to position "left" (sprinkling pump I) or position right (sprinkling
pump II).
Note
The pressure sprinkler system is switched on.

For sprinkling switch alternately between sprinkling pumps I and II to achieve even straining of
the sprinkling pumps.
Note
Permanent sprinkling, stage 12, is always active in

travel lever position 0, stages 11 to 1 are
switched off after 30 seconds when the travel lever
is in 0-position.
Fig. 95
Note
When the water tank is empty the warning light for

residual water quantity in water sprinkling system
c (Fig. 95) in the right hand instrument cluster will
light up and the warning buzzer will sound.
In the water tank filling level gauge (m) the last
green and the red LED will light or the red LED will
flash.
l
Perform trouble shooting and rectify the

cause.
Fig. 94
l
54
Set the interval switch for pressure sprinkling

system to the desired sprinkling interval (Fig.
94).
BOMAG
BW 161/202/203 AD-4
Operation
4.12 Actuating the emergency
stop switch
4.11 Sprinkling of edge cutter*
Danger
Danger of accident!
In events of emergency and in case of danger
actuate the emergency stop switch immediately.
Start travel operation of the machine only after
the danger that caused the actuation of the
emergency stop switch has been eliminated.
Caution
Do not use as service brake. The deceleration
is extremely high. In case of frequent use the
wear on the multi-dics brakes will be very high.
!
Fig. 96
Turn the rotary sprinkling system switch (Fig.

96) to left or right.
Fig. 97
Fig. 98
Press push button for edge cutter sprinkling

system (Fig. 97).
Note
The edge cutter is sprinkled in the same interval as

the drums.
Press the button of the emergency stop switch

(Fig. 98) completely down, it automatically
locks in fully pressed position.
Note
Shuts the engine down and closes the brake.

l
Turn the button clockwise to unlock the emergency stop switch.
Start the engine again, see chapter "Starting

the engine".
Optional equipment
BW 161/202/203 AD-4
BOMAG
55
Operation
4.13 Adjusting the rotation stop
for travel lever movement
4.14 Adjusting the drivers seat

!
Danger
Danger of accident!
Note
Use the rotation stop only to adjust a predetermined travel speed, then release the full travel lever movement again.
Do not adjust the drivers seat while driving.
Fig. 100
Fig. 99
= Pull the lever and lock the driver's

seat (Fig. 100) in one of 9 possible rotary positions.
Loosen the fastening nut.
Turn the rotary stop (Fig. 99) in or out, until the

desired travel lever movement is reached.
= Disengage the lever and adjust the

seat in longitudinal direction.
Retighten the fastening nut.
= Operate the lever and adjust the back

rest.
= Pull the lever and lock the driver's

seat in one of 9 possible lateral positions.
= read the adjusted drivers weight in

the window.
= Adjust the weight of the driver with

the lever.
56
BOMAG
BW 161/202/203 AD-4
Operation
4.15 Opening or closing the cabin window
4.16 Towing
!
Danger
Danger of accident!
Caution
Always keep the cabin doors closed while driving.
Before releasing the brake secure the machine

against unintended rolling.
Always lock the cabin windows in open position or close them.
Caution
Tow the machine only after releasing the parking brake.

Towing speed 1 km/h, max. towing distance
500 m.
Fasten the towing hitch
Fig. 101
l
Open the locking (Fig. 101) of the cabin window.
Swing out and lock the cabin window.
Fig. 103
l
Fasten the towing hitch at front (Fig. 103) or

rear with a tightening torque of 578 Nm (426
ft.lb).
Fig. 102
l
To close the cabin window press the locking

button (Fig. 102), swing the cabin window
back and lock it.
BW 161/202/203 AD-4
BOMAG
57
Operation
Releasing the parking brake in case of
a battery failure
Note
The pump lever extension is stored in the tool box

in the cabin.
Fig. 104
Fig. 106
Open the left hand maintenance door (Fig.

104).
Release the brake by operating the hand

pump (Fig. 106).
After towing
Caution
Before detaching the tow bar block the machine with chocks to prevent unintended rolling.
!
Unlock the emergency control button and lock

it with the clamp.
Fig. 105
l
Loosen clamp 1 (Fig. 105).
Press the emergency control button (2) in and

turn it clockwise against the end stop.
Danger
Danger of accident!
!
If the emergency control button remains

pressed in, the automatic parking brake is out
of function.
Once the function of the machine has been reestablished unlock the emergency control button and assemble the clamp.
58
BOMAG
BW 161/202/203 AD-4
Operation
4.17 Transport
!
Danger
Danger of accident!
Use only stable loading ramps of sufficient
load bearing capacity. Make sure that persons
are not endangered by the machine tipping or
sliding off.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
Do not stand or step under loads being lifted.
Always use shackles on the lifting points for
loading, tying or lifting the machine.
Fig. 108
l
After driving the machine onto the low loader

take the transport locks out of the brackets on
both sides of the articulated joint (Fig. 108).
Fig. 107
Turn the rotary speed range selector

switch(Fig. 107) to low speed range.
Fig. 109
l
Place the articulation joint lock (Fig. 109) on

both sides over the piston rods and lock with
bolts and split pins.
Danger
Danger of accident!
!
Do not drive with crabwalk onto the transport

vehicle.
BW 161/202/203 AD-4
BOMAG
59
Operation
Fig. 110
l
Lash the machine to the transport vehicle, fasten the lashing gear (Fig. 110) to the front and
rear support legs.
Fig. 111
l
Use the four lifting eyes (Fig. 111) to lift the

machine.
Loading weight: see technical data.
60
BOMAG
BW 161/202/203 AD-4
5 Maintenance
BW 161/202/203 AD-4
BOMAG
61
Maintenance
5.1
General notes on maintenance
Do not let the suction hose disturb the sludge

on the bottom of the drum.
Fuel left in the fuel drum is not suitable for the

engine and should only be used for cleaning
purposes.
When servicing the machine pay careful attention

to all applicable safety instructions.
Thorough maintenance of the machine ensures
maximum reliability and prolongs the lifetime of important components. The necessary effort can by
no means be compared with the faults which may
occur when not observing these instructions.
Notes on the engine performance
The terms left/right are always related to travel direction forward.
Combustion air and fuel injection rates of the diesel engine have been carefully adjusted and determine the engine's performance and temperature
level as well as the quality of the exhaust gas.
Clean machine and engine thoroughly before

starting maintenance work.
If your machine has to work permanently in "thin

air" (at high altitudes) and with full load you should
consult or service department or the service department of the engine manufacturer.
For maintenance work park the machine on

level ground.
Notes on the hydraulic system
Maintenance work must generally be carried

out with the engine shut down.
Depressurize hydraulic lines before working

on them.
Disconnect the battery and cover it with insulation material before starting to work on electrical components.
Always attach the articulation lock (transport

lock) before starting to work in the articulation
area of the machine.
Environment
During maintenance work catch all oils and fuels and do not let them seep into the ground or
into the sewage system. Dispose of oils and
fuel environmentally.
When servicing the hydraulic system cleanliness if

of utmost importance. make sure that no dirt or
other contaminating systems can enter the system. Small particles can flute valves, cause pumps
to seize and block restrictors and pilot bores,
thereby causing costly repairs.
l
If during the daily oil level check the oil level is

found to have dropped, check all lines, hoses
and components for leakages.
Seal leakages immediately. If necessary inform the responsible service department.
Always use the filling and filtering unit

(BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is equipped with a
fine filter which cleans the hydraulic oil and
prolongs the lifetime of the filter.
Clean fittings, filler caps and their immediate

surrounding area before removing them, so
that no dirt can fall in.
Do not leave the tank opening unnecessarily

open, cover it so that no dirt can fall in.
Store used filters in a special waste container

and dispose of environmentally.
Always catch biodegradable oil separately.
Notes on the fuel system

The lifetime of the diesel engine is decisively depending on the cleanliness of the fuel.
l
Keep the engine free of dirt and water as this

could damage the injection elements of the engine.
When choosing the storage location for fuel

make sure that spilled fuel will not harm the environment.
62
BOMAG
BW 161/202/203 AD-4
Maintenance
5.2
fect the cold starting ability of the engine, but will

not cause any engine damage.
Fuels and lubricants
Temperature related lubrication oil changes can

be avoided by using multi-purpose oils. The following oil change intervals apply also when using multi-purpose oils.
Engine oil
l
Use winter grade engine oil for winter operation!
Regular lubrication oil changes

The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed
at least once per year, irrespective of the operating
hours reached.
Oil quality
Preferably use oils of ACEA-classification E3-96/
E5-02. This enables utilization of the longest oil
change intervals. Oil of ACEA-classification E2-96
may also when reducing the period between oil
changes by 50 percent.
Oils of API-quality class CG-4/CH-4 enable utilization of the longest oil change intervals. Oils of APIquality classes CF/CF-4 may also be used when
reducing the period between oil changes by 50
percent.
Lubrication oil change intervals

Fig. 112
Oil change intervals with oil quality
In order to assure perfect cold starting it is import

to chose the viscosity (SAE-class) of the engine oil
according to the ambient temperature.
For winter operation below -10 C the oil change
intervals must be shortened.
ACEA
E2-96
= 250 operating hours
API
Lubrication oil with a too high viscosity index causes starting difficulties. The temperature when
starting the engine is therefore of highest importance when choosing the viscosity of engine oil for
winter operation.
API CF/CF-4
ACEA
E3-96/E5-02
API
CG-4/CH-4
Oil viscosity
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAEclass) (Fig. 112).
Occasional falling short of the temperature limit
(e.g. use of SAE 15W/40 down to -15 C) may ef-
BW 161/202/203 AD-4
Caution
These intervals apply only when using a diesel

fuel with maximum 0.5 % sulphur by weight
and for ambient temperatures higher than -10
C.
When using fuels with a sulphur content of
more than 0.5% to 1% or under ambient tem-
BOMAG
63
Maintenance
peratures below -10 C the oil change intervals
specified in the table must be halved. When using fuels with a sulphur content higher than 1%
to 1.5% the engine oil must have a TBN of approx. 12 x the S-content in % by weight when
halving the oil change intervals.
46 mm2/s at 40 C. For topping up or for oil changes use only high-quality hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils of
type HV according to ISO 6743/3. The viscosity index (VI) must be at least 150 (observe information
provided by manufacturer).
Lubrication oil quality classes
Bio-degradable hydraulic oil
The oil manufacturer is solely responsible for assigning a product to a certain quality class.
On request the hydraulic system can also be filled

with ester based biodegradable hydraulic oil, Panolin HLP Synth. 46. This biologically quickly degradable hydraulic oil Panolin HLP Synth.46 meets all
demands of a mineral oil based hydraulic oil according to DIN 51524. In hydraulic systems filled
with Panolin HLP Synth. 46 always use the same
oil to top up.
Note
When changing to a higher alloyed oil quality after

a longer period of operation, it is recommended to
perform the first oil change of the higher quality oil
already after 20 operating hours. The lubrication
oil filter cartridge must be changed at the same
time.
When changing from mineral oil based hydraulic

oil to an ester based biologically degradable oil,
you should consult the lubrication oil service of the
oil manufacturer for details.
Fuels
Check the filter more frequently after this change.
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and
ensure strict cleanliness when filling in. A higher
sulphur content has a negative effect on the oil
change intervals. Use only winter-grade diesel fuel
under low ambient temperatures. The fuel level
should always be topped up in due time so that the
fuel tank is never run dry, as otherwise filter and injection lines need to be bled.
The following fuel specifications are permitted:
DIN 51601; Nato Codes: F-54, F-75; BS 2869: A1
and A2; ASTM D 975-78: 1-D and 2-D; VV-F-800
a: DF-A, DF-1 and DF-2.
Winter fuel
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At
very low temperatures disturbing paraffin separation can also be expected when using winter diesel
fuel.
In most cases a sufficient cold resistance can also
be achieved by adding flow enhancing fuel additives. Consult the engine manufacturer.
Mineral oil based hydraulic oil

The hydraulic system is operated with hydraulic oil
HV 46 (ISO) with a kinematic viscosity of
64
Drum drive gear oil

For the gearbox use only multi-purpose transmission oil of API-class GL5 with viscosity class SAE
80W-90.
Lubrication grease
For lubrication purposes use an EP-high pressure
grease, calcium and/or lithium saponified (penetration 2), acc. to DIN 51502 KP 2G.
Coolant
High performance diesel engines require a well
balanced coolant mixture of water, anti-freeze and
supplementary coolant additives.
For coolant mixtures use only soft tap water with a
water hardness between 3 and 20 dGH. The water should not contain more than 100 mg/dm3 of
chlorine and sulphate.
Prepare and check coolant with highest care,
since otherwise the engine may be damaged by
corrosion, cavitation and freezing.
As a protection against frost and boiling point antifreeze agents must be used under any climatic
conditions.
Mixing of coolant water and cooling system protection agent must be performed at a concentration
BOMAG
BW 161/202/203 AD-4
Maintenance
level of the cooling system protection agent of minimum 35% and maximum 45%.
!
Caution
Do not mix different coolants and additives of

any other kind.
Environment
Cooling system protection agents must be disposed of environmentally.
BW 161/202/203 AD-4
BOMAG
65
Maintenance
5.3
Fuels, lubricants and filling

capacities
Assembly
Fuel or lubricant
Summer
Winter
Quantity approx.
Attention
Observe the level marks
Engine
Engine oil
ACEA: E3-96/E5-02
8.5 litres without oil filter,

10 litres with oil filter
API: CG-4/CH-4
SAE 10W/40 (-20 C to +30 C)
SAE 10W/40 (-10 C to +40 C)
SAE 30
SAE 10W
(+5 C to +30 C)
(-5 C to -30 C)
SAE 40
SAE 20W/20
(+25 C to +40 C)
(-10 C to +10 C)
Fuel
Diesel
Winter diesel fuel

(down to -12 C)
200 litres
Coolant
Mixture of water and anti-freeze agent
Hydraulic system
Sprinkler system
Drum
Hydraulic oil (ISO), HV46, kinem. viscosity

46 mm 2/s at 40 C or
ester based biodegradable hydraulic oil
Water
Anti-freeze mixture
water *
SAE 15W/40
- Exciter shaft tube

Travel gear, drum
approx. 15 litres
60 litres
1000 litres
7.5 litres (BW 161 AD-4)
9.5 litres (BW 202 AD-4)
SAE 80W-90, API GL5
approx. 1.5 litres
Steering chains
High pressure grease (lithium saponified)
as required
Oscillating articulated joint
High pressure grease (lithium saponified)
as required
66
Mix water and anti-freeze agent by following the instructions of the manufacturer
BOMAG
BW 161/202/203 AD-4
Maintenance
5.4
Running-in instructions
The following maintenance work must be performed when running in new machines or
overhauled engines:
!
Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected

to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.
Maintenance after 50 operating hours
l
Check the engine for leaks.
Retighten bolted connections on intake and

exhaust tubes, oil sump and engine mounts.
Retighten the bolted connections on the machine.

l
Engine oil change
1st oil change in drum drive gear.
1. Oil change in the exciter shaft tube

l
2. Oil change in drum drive gear.
2. Oil change in the exciter shaft tube
Special intervals
l
BW 161/202/203 AD-4
BOMAG
Switch the heating system* on every month for

about 10 minutes.
Switch the air conditioning* on every month for
about 10 minutes.
Optional equipment
67
Maintenance
5.5
Maintenance chart
With all maintenance intervals perform also

the work for shorter preceding service intervals.
No.
Designation
Note
Every 10 operating hours

5.6
5.7
5.8
5.9
5.10
5.11
Check the engine oil level

Check the fuel level
Check the hydraulic oil level
Check the coolant level
Check/empty the fuel pre-cleaner (water separator)
Check the water level
Observe the dipstick marks

Inspection glass
Inspection glass
Inspection glass
Summer: Water, winter: Anti-freeze agent

5.12
5.13
Check, clean radiator, fuel cooler, hydraulic oil cooler

and intercooler
Check the oil level in vibrator shaft tube

5.14
5.15
5.16
5.17
5.18
Change the engine oil (at least 1x per year)*

Change the engine oil filter cartridge
Check the coolant concentration
Service the air conditioning
Check the battery condition, grease the poles
Dipstick mark

5.19
5.20
5.21
5.22
5.23
5.24
5.25
Clean the fuel pre-cleaner, replace, bleed the filter if

necessary
Change the fuel precleaner, bleed the fuel system
Change the oil in the drum drive gear
Check, tension, lubricate the steering chain
Check the engine mounts
Check the V-belt, tighten, if necessary replace the Vbelt
Change the oil in the vibrator shaft tube

5.26
Check, adjust the valve clearance
on cold engine

5.27
5.28
5.29
5.30
68
Change the hydraulic oil**

Replace the hydraulic oil filter element
Grease the articulated joint
Change the coolant
at least every 2 years

High pressure grease
BOMAG
BW 161/202/203 AD-4
Maintenance
No.
Designation
Note

5.31
Replace the injection valve
As required
5.32
5.33
5.34
5.35
5.36
5.37
5.38
5.39
*
**
Clean, change the dry air filter cartridge

Clean the water tank
Clean the water filter
Sprinkler system
Fill the windscreen washer tank
Check the scrapers
Engine conservation
Tightening torques for screws with metric unified
thread
at least 1x per year
Maintenance in case of frost
Retighten bolted connections
When using diesel fuel with a sulphur content of more than 0,5 % by weight the engine oil change intervals must be halved. The same
applies when using engine oil of API-class CF/CF-4 and engine oil of ACEA-class E2-96
Also in case of repairs in the hydraulic system
BW 161/202/203 AD-4
BOMAG
69

Every 10 oper ating hours
5.6
Check the engine oil level
5.7
!
Check the fuel level
Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke.
Catch running out fuel.
Fig. 113
Note
Park the machine horizontally, shut down the engine and wait for 5 minutes.
l
Pull the dipstick (Fig. 113) out, wipe it off with

a lint-free, clean cloth and reinsert it until it bottoms.
Pull the dipstick back out again.
Check the oil level, top up to MAX-mark if necessary.
If the oil level is too low top up oil immediately.
Fig. 114
Check the fuel level on the fuel gauge (Fig.

114).
For quality of oil refer to the table of fuels, lubricants and filling capacities.
Check the oil level again after running the engine for approx. 1 minute.
Note
Do not drive the fuel tank empty, since this may

damage the engine.
Always bleed the fuel system after running the
tank empty.
Caution
Before longer work periods you should always
top the oil up to the "MAX"-mark.
!
70
BOMAG
BW 161/202/203 AD-4

5.8
Check the hydraulic oil level
!
Caution
In hydraulic systems filled with Panolin HLP
Synth. 46 always use the same oil to top up.
With other ester based oils consult the lubrication oil service of the respective oil manufacturer.
Fig. 115
Use access steps (Fig. 115).
Fig. 117
Check the oil level in the oil level inspection

glass (Fig. 117).
Fig. 116
l
Clean the area around the filler opening.
Open the fuel tank cover (Fig. 116).
If necessary top up with fuel (diesel or winter

diesel).
At a room temperature of approx. 20C the oil level

should reach approx. 2/3 way up the inspection
glass.
Caution
Contaminated fuel can cause malfunction or

even damage of the engine.
If necessary, fill in fuel through a funnel with
screen filter.
BW 161/202/203 AD-4
If the oil level is too low top up hydraulic oil immediately.
For specified fuel refer to the table of fuels, lubricants and filling capacities.
!
Note
Caution
If, during the daily inspection of the oil level
the hydraulic oil level is found to have
dropped, check all lines, hoses and components for leaks.
!
BOMAG
71

5.9
!
Check the coolant level
5.10 Check / empty the fuel precleaner (water separator) /

bleed
Danger
Danger of scalding!
Fill up coolant only when the engine is cold.
Danger
Fire hazard!
!
When working on the fuel system do not use

open fire, do not smoke.
Environment
Catch running out fuel and dispose of environmentally.
The service intervals for the water separator depend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should check the filter bowl initially every day, later as required, for
signs of water.
Fig. 118
Check the coolant level (Fig. 118) only when

the engine is cold.
Note
Caution
If, during the daily inspection the coolant level
is found to have dropped, check all lines, hoses and engine for leaks.
!
To top up unscrew the filler cap and fill in coolant up to the MAX-mark.
For quality of coolant refer to the chapter 5.2,

fuels and lubricants.
Fig. 119
If the water separator control light (Fig. 119) in

the left hand instrument cluster lights up during
starting or operation, drain the water from the
prefilter.
Note
Open the service flap on the right hand side.
72
BOMAG
BW 161/202/203 AD-4
Fig. 120
l
Fig. 122
Unscrew the bleeding screw (Fig. 120) on the

filter cover.
Drain the fuel off until there is no water or dirt

left (Fig. 122). Close the drain tap.
Environment
Dispose of catched fuel environmentally.
Note
After draining the water separator the control light

must go out and the fuel pre-cleaner must be bled.
Bleeding
Fig. 121
l
Place a collecting vessel (Fig. 121) under the

drain opening.
Press the drain cock to the valve body and

open it.
Fig. 123
l
Operate the manual pump (Fig. 123) until fuel

runs out of the bleeding screw without air bubbles.
Environment
l
BW 161/202/203 AD-4
BOMAG
Open the bleeding screw .
73

5.11 Check the water level
!
Caution
Risk of damage!
Do not step on the water tank and do not place

any heavy objects on it.
Fig. 126
Open the caps on both water tanks and top up

with water (Fig. 126) and screw the caps back
on.
Fig. 124
Note
Note
If there is a risk of frost observe the special service

instructions under "water sprinkler system, maintenance in case of frost".
Make sure that the ventilation bore in the filler cap
is free.
In case of a pressure drop and when the water

tank is empty the warning light for residual water
quantity in water sprinkling system c (Fig. 124) in
the right hand instrument cluster will light up and
the warning buzzer will sound.
In the water tank filling level gauge (m) the last
green and the red LED will light or the red LED will
flash.
Fig. 125
l
74
Use access steps (Fig. 125).
BOMAG
BW 161/202/203 AD-4

5.12 Check, clean radiator, fuel

cooler, hydraulic oil cooler
and intercooler
Note
Dirty operating conditions, particularly lubrication

oil and fuel deposits on the cooling fins reduce the
cooling effect. You should therefore immediately
seal any oil or fuel leaks near cooling fan, cylinder
or oil cooler and subsequently clean the cooling
fins.
Danger
Danger of injury!
Fig. 128
l
Remove dried on dirt from the cooling fins with

a suitable brush.
Blow coolers (Fig. 128) out with compressed

air. Remove all dirt that has been blown into
the engine compartment.
In case of oily dirt spray the cooler with a cold

cleansing agent and let it soak in for about 10
minutes.
Perform cleaning work only with engine

stopped and cooled down!
Environment
Catch running off fluid and dispose of environmentally.
l
Clean off with water or steam jet.
Repeat the process if necessary.
Fig. 127
l
Unscrew the fastening screws from the radiator covering plate (Fig. 127) and fold the covering plate back.
BW 161/202/203 AD-4
BOMAG
75

5.13 Checking the oil level in vibrator shaft tube
!
Caution
Check the oil level in both drums, rear right

and front left.
Fig. 129
l
Move the machine so that the level inspection

plug is exactly behind bore (Fig. 129).
Clean and unscrew oil level inspection plug

(1).
The oil level must reach the bottom edge of the

bore, top up oil if necessary.
76
BOMAG
BW 161/202/203 AD-4

5.14 Change the engine oil

!
Danger
Danger of scalding!
Danger of scalding when draining off hot engine oil!
Note
Drain the oil only when the engine is warm.

For quality and quantity of oil refer to the section on fuels and lubricants as well as the section on fuels, lubricants and filling capacities.
Fig. 131
l
Fill in new engine oil (Fig. 131) through the oil

filler neck.
Screw the cover back on.
Environment
Do not let old oil seep into the ground, but dispose off environmentally.
l
Unscrew the oil filler cap .
Fig. 132
l
After a short test run check the oil level on the

dipstick (Fig. 132). The oil level should reach
the MAX-mark, top up oil if necessary.
Fig. 130
l
Unscrew the drain plug (Fig. 130), catch running out oil.
Screw the plugs back in.
BW 161/202/203 AD-4
BOMAG
77

5.15 Change the engine oil filter
cartridge
!
5.16 Checking the anti-freeze

concentration
Danger
Danger of scalding!
In order to avoid damage to the engine e.g. by

corrosion, cavitation and freezing, particular
attention must be paid to the inspection of the
coolant.
Danger of scalding by hot oil when unscrewing

the filter cartridge.
Caution
Catch running out oil, e.g. with a cloth.
!
Danger
Danger of scalding!
!
Environment
Do not let old oil seep into the ground, but dispose off environmentally.
l
Caution
Check the anti-freeze concentration only when

the engine is cold.
l
Perform the inspection with conventional test

equipment.
The anti-freeze concentration (additive) must

be at least 35 Vol% and maximum 45 Vol%.
Danger
Health hazard!
The mixing of nitrite based anti-freeze agents
with amine based agents results in the formation of health affecting nitrosamines.
Environment
Catch all anti-freeze agent and dispose of environmentally.
Fig. 133
l
Loosen and unscrew the fuel filter cartridge

(Fig. 133) using an appropriate filter wrench.
Wipe the sealing face clean.
Cover the rubber seal of the new filter cartridge slightly with clean oil.
Spin the new fuel filter cartridge on and tighten

it hand tight.
Perform a short test run and inspect the engine for leaks and check the oil level, top up oil
if necessary.
78
BOMAG
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5.17 Servicing the air conditioning* (summer operation)
Caution
Under very dusty conditions clean every day in
order to maintain the cooling power of the air
conditioning system.
!
Danger
Danger of accident!
!
Fig. 135
Do not clean with a hot water jet. Heat will

cause extreme overpressure, which could
cause damage or explosion of the system.
Clean the condenser fins on front and back

with compressed air or cold water (Fig. 135).
Caution
During cleaning work do not damage the cooling fins and realign bent fins.
!
Cleaning the condenser
Checking the refrigerant level

l
Start the engine.
Fig. 134
l
Unscrew the fastening screws from the radiator covering plate (Fig. 134) and fold the covering plate back.
Fig. 136
l
Switch the air (Fig. 136) conditioning on.
Optional equipment
BW 161/202/203 AD-4
BOMAG
79
Fig. 137
l
Choose a cooling temperature with the rotary

switch for cabin heater (Fig. 137) in the blue
section.
Open the air outlet nozzles.
Check, whether the outflowing air is noticeably

cooler.
Fig. 139
Note
The refrigerant level is not correct.

l
If the white float (Fig. 139) inside the inspection glass of the drier/collector unit floats at the
bottom, inform the service department.
Note
The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.
Refrigerant must be filled up, if necessary

check the air conditioning system for leaks.
Checking the moisture level of the drying agent
Fig. 140
Fig. 138
Check whether the white float (Fig. 138) inside

the inspection glass of the drier/collector unit
floats right at the top.
Check the moisture indication pearl (Fig. 140)

inside the inspection glass of the drier/collector unit.
blue
= drying agent o.k.
purple
= moisture level of drying agent too

high.
Note
The refrigerant level is correct.
80
BOMAG
Inform the service department. Replace drier/

collector unit, check air conditioning system.
BW 161/202/203 AD-4

Caution
Have the drier/collector unit replaced by the
service department every year before the operating season.
5.18 Service the battery
Checking the condition of the drier/collector unit
Danger of cauterisation ! Danger of explosion!
Caution
According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense
repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with this inspection the
drier/collector unit must be visually examined
twice every year. During these inspections
special attention must be paid to corrosion
and mechanical damage. If the reservoir is not
in proper condition it must be replaced for
safety reasons, as a precaution to protect operators and third parties against any danger
arising from the handling and operation of
pressure reservoirs.
!
Danger
When working on the battery do not use open

fire, do not smoke!
The battery contains acid. Do not let acid come
in contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
Environment
Dispose of the old battery environmentally.
Note
Maintenance free batteries also need care. Maintenance free only means that the fluid level does
not need to be checked. Each battery suffers under self-discharge, which may, in not checked occasionally, even cause damage to the battery as a
result of exhaustive discharge.
The following therefore applies for the service
life:
Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced, to avoid bursting and further damage.
Switch off all consumers (e.g. ignition, light, inside light, radio).
Check open-circuit voltage of the battery at

regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =

50% discharged.
l
Recharge the battery immediately after an

open-circuit voltage of 12.25 V or less is
reached. Do not perform boost charging.
The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or
one hour after the last discharge.
l
After each charging process allow the battery

to rest for one hour before taking it into service.
For resting periods of more than one month

you should always disconnect the battery. Do
not forget to perform regular open-circuit voltage measurements.
Fig. 141
l
Check the drier/collector unit (Fig. 141) for mechanical damage or rust.
BW 161/202/203 AD-4
BOMAG
81

Charging voltage recommendation
Fig. 144
l
Clean the outside of the battery (Fig. 144).
Clean battery poles and pole clamps and

grease them with pole grease (Vaseline).
Check the fastening of the battery.
On serviceable batteries check the acid level,

if necessary top up to the filling mark with distilled water.
Fig. 142
Caution
Exhausted batteries (batteries with formation

of sulphate on thge plates are not covered under warranty!
Fig. 143
l
Disassemble the battery compartment cover

(Fig. 143).
Clean the battery compartment.
82
BOMAG
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5.19 Cleaning the fuel pre-cleaner, replacing, bleeding the

filter if necessary
Danger
Fire hazard!
!

Fig. 146
Environment
Catch running out fuel, do not let it seep into
the ground.
l
Place a collecting vessel (Fig. 146) under the

drain opening.
Press the drain cock to the valve body and

open it.
Open the service flap on the right hand side.
Cleaning the fuel pre-cleaner
Fig. 147
Drain the fuel off until there is no water or dirt

left (Fig. 147). Close the drain tap.
Fig. 145
l
Unscrew the bleeding screw (Fig. 145) on the

filter cover.
Environment
Note
After draining the fuel pre-cleaner must be bled.
BW 161/202/203 AD-4
BOMAG
83

Changing the fuel precleaner
Fig. 149
l
Fig. 148
l
Unscrew the hexagon screws (Fig. 148) from

the filter cover and take the cover off.
Take the filter element out of the filter housing.
Insert the new filter element into the filter housing.
Check the seal of the filter cover, replace if

necessary.
Install the filter cover with seal and tighten the

hexagon screws crosswise.
Slacken the bleeding screw (Fig. 149) on the

fuel prefilter for 2 to 3 turns.
Bleeding the fuel prefilter
Note
Fig. 150
Air in the fuel system causes irregular running of

the engine, a drop in engine power, stalls the engine and makes starting impossible.
Operate the hand pump (Fig. 150) manually,

until fuel flows out of the bleeding screw without air bubbles.
Therefore bleed the fuel system after changing the

fuel prefilter.
Then tighten the bleeding screw while pumping.
84
BOMAG
BW 161/202/203 AD-4

5.20 Change the fuel filter cartridge
!
Danger
Fire hazard!
Environment
Catch running out fuel, do not let it seep into
the ground.
l
Fig. 152
Open the right hand engine compartment

doors.
Slightly oil the rubber seal on the new filter cartridge (Fig. 152).
Fill the filter cartridge with clean diesel fuel.
Turn the new filter cartridge on by hand, until

the seal contacts.
Then tighten hand-tight.
Check for leaks after a short test run.
Fig. 151
l
Loosen fuel filter (Fig. 151) using a suitable filter wrench and screw it off.
Clean the sealing face on the filter carriers

from any dirt.
BW 161/202/203 AD-4
BOMAG
85

5.21 Changing the oil in the drum
drive gear
Note
Drain oil only at operating temperature. Change

the oil in front right and rear left hand travel gears.
Danger
Danger of scalding!
!
Danger of scalding when draining off hot gear

oil!
Environment
Environmental damage!
Catch old oil and dispose of environmentally.
Fig. 154
l
Fill in oil through the oil filler opening (Fig.

154), until it reaches the bottom edge of the oil
level inspection bore.
For quality and quantity of oil refer to the table

of fuels, lubricants and filling capacities.
l
Clean filler and level plug and screw it back in

tightly fitted with a new sealing ring.
Fig. 153
l
Clean and unscrew filler and drain plugs (Fig.

153).
Drain and catch all oil.
Once all oil has run out clean the drain plug
and screw it back in fitted with a new sealing
ring.
86
BOMAG
BW 161/202/203 AD-4

5.22 Checking, tensioning, lubricating the steering chain
l
Unscrew the dashboard from the drive console

and lay down to the front.
Check
Fig. 157
l
Check the condition of the left hand sliding

block (Fig. 157), replace if necessary.
Fig. 155
l
Unscrew the cover plate (Fig. 155) from the

steering chain and take it off.
Fig. 158
l
Check the condition of the right hand sliding

block (Fig. 158), replace if necessary.
Tension
l
Loosen four fastening screws on the steering

column.
Press the steering columns towards the outside and retighten the fastening screws.
Fig. 156
l
Check the entire circumference of chain and

sprockets (Fig. 156).
Lubricating
l
Cover the entire circumference of the chain

with grease.
For quality of grease refer to the table of fuels,

lubricants and filling capacities.
BW 161/202/203 AD-4
BOMAG
87

5.23 Check the engine mounts
5.24 Checking the V-belt, tighten, if necessary replace the

V-belt
Danger
Danger of injury!
!
Work on the V-belt must only be performed

with the engine shut down.
Checking the V-belt for the air conditioning compressor

Fig. 159
l
Tighten fastenings of intake and exhaust manifolds (Fig. 159) on the cylinder heads.
Check sockets and clamps between air filter,

exhaust turbocharger and charge air line as
well as the lubrication air lines for tight fit and
leaks.
Retighten the fastening screws for oil sump

and engine mounts.
Fig. 160
88
Inspect the entire circumference of the V-belt

(Fig. 160) visually for damage and cracks. Replace damaged or cracked V-belts.
Check with thumb pressure whether the V-belt

can be depressed more than 10 to 15 mm (0.4
0.6 inches) between the V-belt pulleys,
retighten if necessary.
BOMAG
BW 161/202/203 AD-4

Tighten the V-belt.
Checking the generator V-belt
Fig. 161
Fig. 162
Slightly slacken the fastening screws 1, 2 and

3 (Fig. 161).
Press the compressor in direction of arrow, until the correct V-belt tension is reached.
Retighten all fastening screws.
Inspect the entire circumference of the V-belt

(Fig. 162) visually for damage and cracks. Replace damaged or cracked V-belts.
Changing the V-belt

l
Slightly slacken the fastening screws 1, 2 and

3.
Press the compressor against the direction of

arrow completely against the engine.
Take the old V-belt off.
Fit the new V-belt to the V-belt pulleys.
Tension the V-belt as previously described.
Fig. 163
Caution
Check the V-belt tension after a running time of
30 minutes.
Press the indicator arm of the tester a (Fig.

163) into the gap of the measuring scale.
Lay the measuring unit loosely onto the back

of the fan V-belt.
Note
To measure the V-belt tension a free length of at

least 200 mm is required.
BW 161/202/203 AD-4
BOMAG
89

Tightening the generator V-belt
Fig. 164
l
Operate measuring unit b (Fig. 164) with a finger (I or II or III), until the pressure spring disengages audibly or noticeably.
Fig. 166
l
Slacken the fastening screws 1,2 and 3 (Fig.

166) slightly.
Note
Press the generator towards the outside until

the correct tension is achieved. Check with the
tester.
The indicator arm remains in the measured position.

l
take the measuring unit carefully off, without

moving the indicating arm.
Replacing the generator V-belt

l
Slightly slacken fastening screws 1,2 and 3.
Press the generator towards the engine.
Take the old V-belt off the V-belt pulley.
Fig. 165
l
Read the V-belt tension where the upper edge

of the indicating arm intersects with the measuring scale (Fig. 165).
First installation = approx. 45050 N

Retighten after
15 minutes
= approx. 30050 N
90
BOMAG
BW 161/202/203 AD-4

Checking the V-belt for coolant pump
and fuel pump
Replacing the V-belt for coolant pump

and fuel pump
l
Disassemble the generator and compressor

V-belts
Slightly slacken fastening screw 1 and 2.
Press the fuel towards the engine.
Take the old V-belt off the V-belt pulley.
Reassemble and tighten generator and compressor V-belts.
Fig. 167
l
Inspect the entire circumference of the pump

V-belt (Fig. 167) visually for damage and
cracks. Replace damaged or cracked V-belts.
Tightening the V-belt for coolant pump

and fuel pump
Fig. 168
l
Slightly slacken fastening screws 1 and 2 (Fig.

168) on the fuel pump.
Press the fuel pump towards the outside until

the correct tension is achieved. Check with the
tester.
First installation = 45050 N

After 15 minutes
of operation
= 300 50N
l
BW 161/202/203 AD-4
BOMAG
91

5.25 Changing the oil in the vibrator shaft tube
!
Caution
Change the oil in both drums.

Environment
Catch running out oil and dispose of environmentally.
Fig. 170
l
Clean and unscrew the oil level inspection

plug (Fig. 170).
Fill in oil through the filler bore, until it starts to

run out through the level inspection bore.

of fuels and lubricants.
l
Turn oil filling and level inspection plugs tightly

back in.
Fig. 169
l
Move the drum until drain and filler plugs (Fig.

169) are exactly vertically in line.
Clean and unscrew drain and filler plugs.
Drain off and catch old oil.
Clean and turn the oil drain plug back in tightly

after all oil has run out.
92
BOMAG
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Overlapping means: Exhaust valve not yet closed,
intake valve starts to open.
5.26 Check, adjust the valve

clearance
!
Caution
Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 1", black mark.
For control purposes mark the respective rocker arm with while chalk once the corresponding valve is adjusted.
Before checking the valve clearance let the engine cool down for at least 30 minutes. The engine oil temperature must be less than 80 C.
After a short test run check the engine for
leaks.
Valve adjustment schematic
Fig. 173
Crankshaft position 2 (Fig. 173)
Fig. 171
Turn the crankshaft one revolution (360 ) further.
Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 2", black mark.
Valve 1 (Fig. 171) white = not adjustable

Valve (2) black = adjustable
Check the valve clearance

l
Loosen the crankcase ventilation valve and

swing it to the side.
Remove the valve cover (2).
Crankshaft position as per "valve adjustment

schematic".
Fig. 172
Crankshaft position 1 (Fig. 172)

l
Crank the engine with the starter or a spanner

by the V-belt pulley until both valves on cylinder 1 are overlapping.
BW 161/202/203 AD-4
BOMAG
93

l
Swivel the ventilation valve back to correct position and fasten it.
Fasten the air filter again and ensure correct fit

of combustion air hoses and clamps.
Fig. 174
l
Check valve clearance 2 (Fig. 174) between

rocker arm (1) and valve (3) with a feeler
gauge.
Intake valve
= 0,3 mm
Exhaust valve = 0,5 mm

The feeler gauge must fit with little resistance.
l
If the gap is too narrow or too wide for the feeler gauge, the valve must be adjusted.
Adjusting the valve clearance
Fig. 175
l
Slightly slacken the counter nut. Adjust setscrew 7 (Fig. 175) with a screwdriver, until the
feeler gauge (6) can be inserted and pulled out
with little resistance after retightening the
counter nut.
Perform tests and adjustments on all other adjustable valves.
Check the gasket of the valve cover, replace it

if necessary.
Reassemble the cylinder head cover.
94
BOMAG
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5.27 Changing hydraulic oil and

breather filter
Note
See also chapter 5.1 "Notes on the hydraulic system".

Caution
Apart from the normal oil change intervals, the
hydraulic oil must also be changed after major
repairs in the hydraulic system.
!
Fig. 176
l
Perform the oil change when the hydraulic oil

is warm.
Remove the filler cap (Fig. 176).
Clean the area round hydraulic oil tank, filler

opening and breather filter.
Do not use any detergents to clean the system.
Do not start the engine after draining the hydraulic oil.
Replace the hydraulic oil filter element with
every hydraulic oil change.
Danger
Danger of scalding!
Danger of scalding by hot oil.
Fig. 177
l
Unscrew the plug (Fig. 177) and drain off all

hydraulic oil.
Check the seal ring, replace if necessary and

turn the plug tightly back in.
Environment
Catch running out oil and dispose of environmentally.
Note
Generally replace the hydraulic oil filter element

after the test run.
Fig. 178
l
BW 161/202/203 AD-4
BOMAG
Fill in new hydraulic oil through the screen

(Fig. 178).
95

i
Note
We recommend to use the filling and filtering unit

(BOMAG part-no. 079 930 35) with fine filter to fill
the hydraulic system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system.
Danger
Danger of scalding!
Check the oil level in the inspection glass.
5.28 Changing the hydraulic oil

filter
Danger of scalding by hot oil when unscrewing

the oil filter.
Nominal value:
At a room temperature of approx. 20C the oil level
should reach approx. 2/3 way up the inspection
glass.
Caution
If the filter has to be changed together with the
hydraulic oil, the filter must only be changed
after the oil change and after the test run.
!

of fuels and lubricants.
Do not use the oil in the filter bowl again.

Environment
Catch running out oil, dispose of oil and filter
element environmentally.
Note
Apart from the normal oil change intervals, the filter element must also be changed after major repairs in the hydraulic system.
l
Open the left hand maintenance door.
Fig. 179
Note
The breather filter (Fig. 179) for the hydraulic oil

tank is integrated in the filler cap, you must therefore replace the complete filler cap.
l
Close the tank with a new filler cap.
Fig. 180
96
Unscrew filter bowls (Fig. 180) and take off

with filter elements.
Examine the surface of the filter element thoroughly for any visible dirt.
BOMAG
BW 161/202/203 AD-4

Caution
Visible dirt may be an early sign for the failure
of system components and indicate the possible failure of components. In this case determine the cause and replace or repair the
defective components, if necessary. Negligence may cause destruction to the entire hydraulic system.
!
5.29 Grease the articulated joint
Do not clean or reuse the filter element.

l
Clean filter bowls with threads.
Assemble the filter bowls with new filter elements, check the condition of the seal rings, if
necessary use new ones.
After the test run check the filters for leaks.

Fig. 181
l
Clean the grease nipple (Fig. 181) and lubricate with approx. 5 shots of high pressure
grease from the grease gun.
For quality of grease refer to the section on

"fuels, lubricants and filling capacities.
BW 161/202/203 AD-4
BOMAG
97

5.30 Change the coolant
!
Danger
Danger of scalding!
Change the coolant only when the engine is
cold.
Environment
Catch running out coolant and dispose of environmentally.
Fig. 184
l
Fill in coolant (Fig. 184) up to the MAX-mark

and screw the filler cap back on.
For quality of coolant refer to the chapter 5.2,

fuels and lubricants.
l
Start the diesel engine and run it warm to operating temperature.
Fig. 182
l
Unscrew the cap (Fig. 182) from the coolant

compensation reservoir.
Fig. 185
l
Let the engine cool down and check the coolant level (Fig. 185) again, top up if necessary.
Fig. 183
l
Unscrew the plug, let the coolant run out and

catch it (Fig. 183).
Screw the plug back in once all coolant has run

out.
98
BOMAG
BW 161/202/203 AD-4

5.31 Replace the injection valve
Note
This work must only be performed by authorized

service personnel.
BW 161/202/203 AD-4
BOMAG
99
100
BOMAG
BW 161/202/203 AD-4
As required
As r equired
5.32 Check, clean, change the

combustion air filter
Once the air filter service indicator lights up, work

may be continued until the end of the day.
l
Note
Open the left hand maintenance door.
Caution
Perform cleaning, maintenance and repair

work only with the engine shut down. Do not
start the engine after removing the filter element.
Do not use gasoline or hot fluids to clean the
filter element.
After cleaning the filter element must be inspected for damage using a torch.
Air filter elements with damaged paper bellows
or seal lips must be replaced in any case.
The main filter element must be replaced after
3 times cleaning, but at the latest after one
year, irrespective of the operating hours.
Each cleaning interval must be marked with a
cross on the cover of the filter element.
Fig. 187
l
Fold three clips up and take the filter hood (Fig.

187) off.
Clean filter hood and dust discharge valve.
Cleaning does not make sense if the air filter

element is covered with a sooty deposit. Use a
new filter element.
Incorrectly handled filter elements may become ineffective because of damage (e.g.:
cracks) and cause engine damage.
Fig. 188
l
Fig. 186
Maintenance of the dry air filter is due when control light c (Fig. 186) in the left hand instrument
cluster lights permanently when the engine is running, but at the latest after one year.
BW 161/202/203 AD-4
Carefully loosen the main filter element.
The main filter element is located directly on the air

intake tube, thereby providing a seal on the inside
of the filter cover. Carefully remove the main filter
element, in order to reduce the released amount of
dust. To release the seal pull the main filter element carefully up, down and sideways or turn it
(Fig. 188).
BOMAG
101
As required
Caution
The safety element must not be cleaned. It
must be replaced after three times cleaning of
the main filter element, but at least once every
year.
!
Do not run the engine without an intact safety

and main filter element.
Clean or replace the main filter element.
We generally recommend to change the filter. A

new filter element is far less expensive than a possible engine damage.
Fig. 189
Caution
Avoid contact between main filter element and

housing.
l
Note
Examine the main filter element thoroughly for

damage.
Before installing the new main filter element check

it for possible damage from transport, cleaning or
incorrect handling. Especially on the inside of the
open end (sealing area). Do not install damaged
filter elements.
Pull the main filter element (Fig. 189) carefully

out of the housing.
If necessary use safety elements.
Fig. 190
l
Clean the sealing face on the outlet tube (Fig.

190).
Fig. 191
Dust on the outer diameter of the outlet tube can

impair effective sealing.
l
The radial sealing area is located at the inside of

the open filter edge. This critical sealing area must
be under slight tension after the filter has been installed. In order to achieve a tight seal apply pressure to the outer edge of the filter and not to the
moveable centre.
Check the old main filter element.
The old main filter element can be of help to discover foreign particles on the sealing face, which
could lead to leaks. A line of dust on the clean air
side of the filter may be a sign for such a leak.
Eliminate this problem before installing a new
main filter element.
l
102
Insert the main filter element (Fig. 191).
Reinstall the filter hood with the dust discharge

valve.
If the main filter element is damaged, the safety element must be replaced as well.
BOMAG
BW 161/202/203 AD-4
As required
Caution
The dust discharge valve must point vertically
downwards.
!
5.33 Clean the water tank
Dry cleaning of the main filter element

!
Danger
Eye injury!
Wear protective clothing (goggles, gloves).
Fig. 193
l
Unscrew both caps (Fig. 193) from the water

tank.
Fig. 192
Note
For cleaning purposes fit a tube to the compressed

air gun (Fig. 192), the end of which should be bent
for approx. 90.
The length should reach down to the bottom of the
element.
Blow the main filter element out with compressed air (max. 5 bar) from inside to outside
by moving the tube up and down inside the element, until it if free of dust.
Fig. 194
l
Open the maintenance cover (Fig. 194) to gain

access to the water pumps.
Examine the main filter element with a torch

for cracks and holes in the paper bellows.
Caution
Do not continue to use a damaged main filter

element. If in doubt use a new main filter element.
BW 161/202/203 AD-4
BOMAG
103
As required
5.34 Clean the water filter
Fig. 195
l
Disconnect the quick lock coupling (Fig. 195)

on the water filter.
Unscrew the water filter.
Fig. 196
Let all water with dirt run out.
Fill the water tank with clean water.
Unscrew both water tank caps (Fig. 196), take

out and clean the filling screens.
Note
Replace damaged filling screens.
Fig. 197
l
104
BOMAG
Open the maintenance cover (Fig. 197) to gain

access to the water pumps.
BW 161/202/203 AD-4
As required
5.35 Water sprinkler system,
maintenance in the event of
frost
Caution
If there is a risk of frost, the water sprinkler
system must be drained.
!
Fig. 198
Disconnect the quick lock coupling (Fig. 198)

on the water filter.
In this case frost protection measures are of

greatest importance in order to avoid freezing
of sensitive components like pump, solenoid
valve and water filter.
l
Drain the water tank
Unscrew and clean the water filter.
Note
Change a damaged water filter.
Fig. 199
l
Disconnect the quick lock couplings (Fig. 199)

of the water lines from the water pumps and let
all water run out.
Fig. 200
l
BW 161/202/203 AD-4
BOMAG
Disconnect the water pipe connection (Fig.

200) at the articulated joint and let all water run
out.
105
As required
5.36 Fill the provision tank for
the windscreen washer system
l
Fig. 201
l
Open all water drain taps (Fig. 201) on the

sprinkler tubes and let all water run out.
Unscrew all nozzles.
Fig. 202
106
Check the fluid level in the tank (Fig. 202), top

up if necessary.
For winter operation fill in the appropriate

amount of ant-freeze agent; refer to the specifications of the manufacturer of the ant-freeze
agent.
BOMAG
BW 161/202/203 AD-4
As required
5.37 Adjust the scrapers
5.38 Tightening torques
Fig. 204
Fig. 203
Check the scrapers (Fig. 203), two each per

drum.
* Strength classes for screws with untreated and

non-lubricated surface. The quality designation of
the screws is stamped on the screw heads.
8.8 = 8G
Note
Replace worn scrapers.
10.9 = 10K
12.9 = 12K
The values result in a 90% utilization of the screws
yielding point at a coefficient of friction of tot. =
0,14. The tightening torques are not valid when using MOS2 lubricants.
Note
Self locking nuts must always be replaced after

they have been unscrewed.
BW 161/202/203 AD-4
BOMAG
107
As required
5.39 Engine conservation
If the engine is to be shut down for a longer period
of time (e.g. during winter) we recommend the following conservation measures for the engine to
avoid corrosion:
l
Clean the engine, including the cooling system. With cold cleansing agent, or, even better, with a steam cleaner.
Run the engine warm and shut it down.
Drain the still warm engine oil and fill in anticorrosion engine oil.
Drain the coolant and fill it back in with fresh

anti-freeze agent.
Drain the fuel from the fuel tank, mix it well with
10% anti-corrosion oil and fill it in again.
Run the engine for 10 minutes until all lines, filter, pump and nozzles are filled with the conserving mixture and the new engine oil is
distributed to all parts.
Crank the engine several times by hand (without ignition) in order to spray all combustion
chamber.
Take the V-belt off and spray the grooves of

the V-belt pulleys with anti-corrosion oil. The
anti-corrosion oil must be removed before taking the machine back into service.
Close the air intake opening on the air filter

and the exhaust opening.
Note
Depending on the weather condition these conserving measures will provide protection for approx. 6 - 12 months.
The conserving oil must be replaced by engine oil
according to the API- (MIL) classification before
taking the machine into operation. Refer to the
section "Fuels and lubricants".
Anti-corrosion oils are those that comply with
the specification MIL-L-21260 B or TL 9150037/2 resp. Nato Code C 640/642.
Mark a machine with conserved engine by attaching a clearly visible warning tag.
108
BOMAG
BW 161/202/203 AD-4
6 Trouble shooting
BW 161/202/203 AD-4
BOMAG
109
Trouble shooting
6.1
General notes
The following work must only be carried out by

qualified and trained personnel or by the sales
service.
Please observe strictly the safety regulations
in chapter 2 of these operating and maintenance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serviced. Therefore, whenever a fault occurs, read
through these instructions on correct operation
and maintenance. If you cannot locate the cause
of the fault or eliminate it yourself by following the
trouble shooting charts, you should contact our
customer service departments at our branch office
or dealers.
Danger
Danger of injury!
!
Keep away from rotating parts of the engine.
110
BOMAG
BW 161/202/203 AD-4
Trouble shooting
6.2
Engine
Faults
Possible cause
Remedy
The engine
does not start
Starter defective or pinion not engaging
Have examined by a specialist
Fuel tank empty
Fill and bleed the tank
Temperature below starting limit
Use winter fuel and engine oil acc. to the

ambient temperature.
Fuel filter clogged, in winter due to paraffin separation.
Change the filter. use winter fuel
Fuel lines leaking
Check all line connections for leakages

and tighten the fittings.
Battery discharged or not connected
Tighten the pole clamps, check the cable

connections
Injection valves or injection pump defective
Battery power too low, battery clamps

loose or oxidized, causing the starter to
turn too slowly
Have the battery checked, clean the terminal clamps, tighten them and cover
them with acid free grease
Especially during winter: the use of too

viscous engine oil
Use engine oil suitable for the ambient

temperature
Fuel supply restricted, in winter fuel system clogged due to paraffin separation
Change the fuel filter. Check the line connections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Incorrect valve clearance
Adjust the valve clearance
Injection valve defective
Injection lines leaking
Check the lines for leakages
Turbo charger defective
Dry air filter dirty
clean, replace if necessary
Excessive play in the throttle cable
Adjust the throttle cable, change it if necessary
The engine
starts poorly and
works irregularly
with poor power
BW 161/202/203 AD-4
BOMAG
111
Trouble shooting
Faults
Possible cause
Remedy
Excessive exhaust smoke
Engine oil level too high
Drain the oil to the upper dipstick mark
clean, replace if necessary
Exhaust gas turbo-charger defective
Poor compression due to burned or broken compression rings or incorrect valve

clearance
Have compression rings and pistons examined by a specialist, adjust the valve
clearance
Cooling fins on radiator extremely soiled

(the warning light "engine oil temperature"
lights)
Clean the cooling fins
Engine oil level too low
Top up engine oil to the upper dipstick

mark
Filling capacity of the injection pump not

correctly adjusted
Have adjusted by a specialist
Cooling air flow restricted
Clean the cooling air duct
V-belt loos or broken
Tension or replace the V-belt
Engine oil level too high
Drain the engine oil down to the upper dipstick mark
clean, change if necessary
Exhaust gas turbo-charger defective
Charge air hose leaking
Check fastening and connections
Engine oil level too low (control light "engine oil pressure" lights, the warning
buzzer sounds)
Top up oil
Leakages in the lubrication system
Shut the engine down immediately, check

fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
Generator speed too low
Check the V-belt tension, replace the Vbelt if necessary
The generator does not charge the battery, because generator or regulator is defective
Have examined by a specialis
Engine overheats, shut

down immediately!
Poor engine
power
Engine oil pressure too low
The charge control light lights

during operation, the warning
buzzer sounds
112
BOMAG
BW 161/202/203 AD-4
Trouble shooting
BW 161/202/203 AD-4
BOMAG
113
Trouble shooting
114
BOMAG
BW 161/202/203 AD-4

BOMAG Roller BW202AD-4 Operation Manual

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BOMAG Roller BW202AD-4 Operation Manual

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Operating instructions

BW 161 AD-4 / BW 202 AD-4

Tandem Vibratory Roller

BOMAGs vast experience in connection with

You should only operate the machine after you

This manual comprises:

For your own personal safety you should only

Using these instructions will

help you to become familiar with the machine.

avoid malfunctions caused by unprofessional

Compliance with the maintenance instructions will

enhance the reliability of the machine on construction sites,

prolong the lifetime of the machine,

reduce repair costs and downtimes.

BOMAG will not assume liability for the function of

if it is handled in a way not complying with the

if it is used for purposes other than those mentioned in these instructions.

No warranty claims can be lodged in case of damage resulting from

insufficient maintenance and

wrong fuels and lubricants.

Supplement the above data together with the commissioning protocol.

3.1 General notes

4.1 General notes

5.1 General notes on maintenance

Service the battery

6.1 General notes

Water sprinkler system

The right for technical modifications remains reserved

Water sprinkler system

The right for technical modifications remains reserved

This BOMAG machine is built in accordance

Dangers may, however, arise from the machine if

the machine is used for purposes other than

Starting and operation of the machine in an explosive environment is prohibited.

the machine is operated by untrained personnel

the machine is modified or converted in an unprofessional way

the applicable safety regulations are not observed.

applicable accident prevention instructions

generally acknowledged safety and road traffic

country specific safety regulations. It is the

Compaction of bituminous material, e.g. road

medium to heavy compaction work in earth

You should only operate the machine with fully

Have the machine inspected by an expert

Do not work with vibration on hard concrete, on a

Who is allowed to work with the machine?

Conversions and alterations to the machine

Safety notes in the operating and maintenance instructions:

Towing the machine

Checking the Roll Over Protection

The ROPS must not show any signs of corrosion,

Observe all environment protection regulations.

Information and safety stickers/decals

The ROPS must not rattle about when driving.

Replace damaged or illegible stickers/decals immediately.

Starting the machine

Loading the machine

Use only stable loading ramps of sufficient load

The machine must only be operated from the drivers seat.

Switch only to first speed range (do not activate

Use only machines which are serviced at regular

Secure the machine against tipping or slipping off.

Secure the machine on the transport vehicle

Wear your personal protective outfit (hard hat,