3 hours ago
A roller built for modern paving projects
The Bomag BW160 is a mid-sized tandem vibratory roller designed for asphalt compaction in road construction and municipal projects. Manufactured by Bomag, a German company founded in 1957 and now part of the Fayat Group, the BW160 was introduced as part of a product line that emphasized operator comfort, electronic monitoring, and fuel efficiency. By 2016, Bomag had sold tens of thousands of rollers worldwide, making it one of the most recognized names in compaction equipment. The BW160, with an operating weight of around 3,500 kilograms and a drum width of 1.6 meters, is widely used in Europe and Asia for both highway and urban paving.
Terminology clarification
Operators have reported that the BW160 may start normally and move a short distance, but after being shut down and restarted, the machine refuses to release the parking brake or travel in either direction. The joystick becomes unresponsive, and multiple fault codes appear on the display. In some cases, the machine will operate again after the battery isolator is switched off and reset, only for the problem to return minutes later.
Likely causes
One contractor in Ireland reported that his BW160 would only travel after disconnecting and reconnecting the battery isolator. After repeated failures, the issue was traced to a corroded ground cable on the engine block. Cleaning and reattaching the cable permanently solved the problem. Another operator in Oklahoma noted that a faulty seat switch caused identical symptoms, with the machine refusing to move until the switch was replaced.
Conclusion
The 2016 Bomag BW160 is a reliable roller, but its electronically controlled systems make it sensitive to electrical faults. Travel failures accompanied by fault codes are most often linked to seat switch malfunctions, poor grounding, or ECU irregularities. By focusing on electrical integrity and systematic diagnostics, operators can restore functionality and avoid unnecessary downtime. This case highlights how modern compaction equipment, while efficient, requires careful attention to electronic systems that safeguard both performance and operator safety.
The Bomag BW160 is a mid-sized tandem vibratory roller designed for asphalt compaction in road construction and municipal projects. Manufactured by Bomag, a German company founded in 1957 and now part of the Fayat Group, the BW160 was introduced as part of a product line that emphasized operator comfort, electronic monitoring, and fuel efficiency. By 2016, Bomag had sold tens of thousands of rollers worldwide, making it one of the most recognized names in compaction equipment. The BW160, with an operating weight of around 3,500 kilograms and a drum width of 1.6 meters, is widely used in Europe and Asia for both highway and urban paving.
Terminology clarification
- ECU (Electronic Control Unit): The onboard computer that manages engine and hydraulic functions.
- Seat Safety Switch: A sensor that prevents machine movement unless the operator is seated.
- Joystick Control: The lever that commands travel direction and vibration functions.
- Ground Cable: The main negative electrical connection between the battery, chassis, and engine.
Operators have reported that the BW160 may start normally and move a short distance, but after being shut down and restarted, the machine refuses to release the parking brake or travel in either direction. The joystick becomes unresponsive, and multiple fault codes appear on the display. In some cases, the machine will operate again after the battery isolator is switched off and reset, only for the problem to return minutes later.
Likely causes
- Seat switch malfunction: If the seat sensor fails or wiring is damaged, the ECU disables travel functions for safety.
- Electrical grounding issues: Corroded or loose ground cables can cause intermittent ECU faults, leading to dead controls.
- ECU instability: Fault codes that clear after a battery reset suggest possible electronic memory or voltage irregularities.
- Wiring harness faults: Damaged connectors or moisture intrusion can interrupt signals to the joystick and brake solenoids.
- Inspect and test the seat safety switch, ensuring continuity when pressed.
- Clean and tighten all ground cable connections, including the engine ground strap.
- Record displayed fault codes before resetting, as they provide valuable diagnostic clues.
- Check fuses and relays for corrosion or poor contact.
- If problems persist, test ECU voltage supply and consider software updates or replacement.
- Keep electrical connectors sealed and protected from moisture.
- Perform regular inspections of wiring harnesses routed near moving parts.
- Train operators to report intermittent faults immediately, as early detection prevents costly downtime.
- Maintain a log of fault codes and conditions under which they occur to assist technicians.
One contractor in Ireland reported that his BW160 would only travel after disconnecting and reconnecting the battery isolator. After repeated failures, the issue was traced to a corroded ground cable on the engine block. Cleaning and reattaching the cable permanently solved the problem. Another operator in Oklahoma noted that a faulty seat switch caused identical symptoms, with the machine refusing to move until the switch was replaced.
Conclusion
The 2016 Bomag BW160 is a reliable roller, but its electronically controlled systems make it sensitive to electrical faults. Travel failures accompanied by fault codes are most often linked to seat switch malfunctions, poor grounding, or ECU irregularities. By focusing on electrical integrity and systematic diagnostics, operators can restore functionality and avoid unnecessary downtime. This case highlights how modern compaction equipment, while efficient, requires careful attention to electronic systems that safeguard both performance and operator safety.
