BOMAG BW 219 BW 226 DH-4 PDH-4 Single Drum Roller Repair Instructions Manual – PDF Download

Description

BOMAG BW 219 / BW 226 DH-4 / PDH-4 Single Drum Roller Repair Instructions Manual

This is the complete BOMAG repair instructions manual for the BW 219 DH-4, BW 219 PDH-4, BW 226 DH-4, and BW 226 PDH-4 single drum rollers. Document number 008 910 28 covers the removal, dismantling, assembly, testing, and adjustment of every major component and assembly group on these machines. Written for the workshop, it gives you the torque values, pressure settings, flush procedures, wiring and hydraulic schematics, and troubleshooting steps needed to keep these rollers working. Whether you are servicing the travel circuit, rebuilding the drum, chasing an electrical fault, or replacing a steering component, this manual provides the procedure and the numbers.

File Details

• Manual Type: Repair Instructions
• Brand: BOMAG
• Models Covered: BW 219 DH-4, BW 219 PDH-4, BW 226 DH-4, BW 226 PDH-4
• Serial Numbers: 101 582 70, 101 582 71, 101 582 80, 101 582 81
• Document Number: 008 910 28
• Language: English
• Pages: 962
• Format: PDF

Chapters Covered

• General
• Technical Data
• Connection Overview
• Tests and Adjustments
• Flushing and Bleeding
• Fundamental Electrics
• Special Tools, Electrics
• Service Training
• Air Conditioning System
• Replacing the Cab Window Panes
• Drum
• Oscillating Articulated Joint
• Suppliers Documentation
• Circuit Diagrams

General, Safety and Tightening Torques

The opening chapter covers the introduction to the machine, the safety regulations that apply to repair work, and the general repair instructions for both hydraulic and electrical systems. It includes the tightening torque tables for metric unified and fine-thread screws, plus the torque values for screws treated with anti-seize paste OKS 240. The safety section covers hydraulic oil hazards, battery handling, air conditioning refrigerant safety, and the general precautions for working on the machine.

Technical Data

This chapter lays out the technical data and adjustment values for each model. It covers the Deutz BF6M 2012 C engine, the travel pump 90R 100 EP, the travel motor 51D110 (EP), the drum drive 51C 110 (EP), the vibration pump 90R 075 (EP), the vibration motor A2FM 63 HDD or A2FM 80 HDD, the steering and charge pump HY/ZFS11/16, and the rear axle CHC 193/55 with No-Spin differential. Filling capacities for engine coolant, engine oil, hydraulic oil, vibration bearing housing, rear axle, wheel hubs, transmission, drum reduction gear, and A/C refrigerant are all listed, along with dimensions and weights for each model.

Maintenance Chart and Fuels / Lubricants

The maintenance chart chapter lists the service intervals for engine oil level checks, water separator checks, fuel level checks, V-belt inspection, engine mount checks, oil changes in the drive axle, wheel hubs, axle reduction gear, drum drive reduction gear, vibration bearings, hydraulic oil and filter changes, coolant changes, injection valve checks, combustion air filter service, scraper adjustment, parking brake adjustment, and tire changes. The fuels and lubricants chapter specifies the approved engine oils (Deutz DQC II-05, ACEA E3-96/E5-02/E07-04, API CH-4/CG-4/CI-4), oil viscosity charts, diesel fuel quality requirements, coolant and anti-freeze proportions, hydraulic oil HV 46, and the lubricating grease specification.

Connection Overview

The connection overview chapter identifies the travel/vibration pump ports and their functions using a labeled photo and an exploded illustration. Each port is numbered and cross-referenced to the high pressure, charge pressure, leak oil, and pressure test connection descriptions. The multi-function valves, charge pressure relief valves, high pressure ports, and pressure test ports are all identified.

Tests and Adjustments

This chapter walks through the special tools required for testing, how to activate service mode on the machine, how to drive against the closed brake, how to check engine speed, and how to run pressure tests in the travel circuit, vibration circuit, and steering circuit. It includes procedures for checking and adjusting the neutral position of the travel pump and checking the leakage rate of the vibration motor. The hydraulic test case, vibration reed frequency meter, RPM meter, pressure gauges, and adapters are all documented.

Flushing and Bleeding

Flushing procedures are documented for the travel circuit with both travel pump distribution and axle motor distribution, plus the vibration circuit. Bleeding procedures for the travel and vibration circuits are also included, with step-by-step instructions for installing the flushing filter, isolating the motors, circulating the tank content, and verifying function after the flush. The special tools for flushing, including the filling and filtering unit, flushing filters, flushing hoses, and connection fittings, are all listed with part numbers.

Fundamental Electrics

This section is a training-level introduction to electrical principles for the machine. It explains how to read circuit diagrams, terminal designations, current and voltage, resistance, series and parallel connections, Ohm’s law, electrical energy, formula diagrams, metrology, diodes, relays, fuses, batteries, three-phase generators, electric starters, Telemeanique switches, inductive proximity switches, Deutsch DT and DTM plugs, and spring-clamp terminals. This is the foundation for the fault-finding work covered in the service training chapters.

Service Training – Electrics and Machine Systems

The service training chapters cover the BOMAG Evib-meter (BEM) system, the ESX control, the MESX software, and the BOMAG Operation Panel (BOP). It documents fault codes, input codes, signal descriptions on the ESX control, the data collector, the travel lever, the LC display, and the DIOS module. It also covers the Deutz diesel engine with EMR, the travel system, vibration, and steering systems, including diagnostic procedures and adjustment values. The service training sections on the travel system, vibration system, and steering system describe the pump and motor functions, the multi-function valves, the charge pressure relief valves, the flushing valves, and the brake control.

Air Conditioning System

This chapter covers safety notes, repair notes, physical basics, refrigerant R134a, compressor oil, the working principle of the A/C system, monitoring devices, component descriptions, checking the compressor oil level, checking the magnetic clutch, inspection and maintenance work, checking and replacing the V-belt, servicing the A/C, drying and evacuation, emptying for repair, leak testing, filling instructions, and troubleshooting in the refrigerant circuit. A steam table for R134a and heating/air conditioning control information are also included.

Cab Window Panes

Assembly of window panes, special tools, auxiliary materials, and the procedure for removing and installing the cab window panes are all documented, including the bonding agent, activator, silicone sealant, and the locking handle and suction lifter tools.

Drum

The drum chapter covers special tools, a repair overview, removing and installing the drum, repairing the drum, dismantling and assembling the change-over weights, and changing the rubber buffers and adjusting the pretension. It includes the travel motor removal, exciter unit disassembly and assembly on both the travel motor side and the vibration motor side, and the side plate procedures. The vibration bearings, basic weight, vibrator shaft, coupling, and travel bearings are all covered.

Oscillating Articulated Joint

This chapter documents the special tools, a repair overview, removing and installing the oscillating articulated joint, dismantling the joint, and assembling the joint. It covers the four-point bearing, centring disc, rocker bearings, spacer ring, and bolt procedures, with notes on the correct pretension of the centre pin.

Suppliers Documentation

The suppliers documentation chapter reproduces the technical documentation for the major bought-in components: the travel pump and vibration pump series 90R, the vibration motor A2FM, the travel drive series 51, the transmission CR, and the axle DANA 193. This gives you the OEM-level repair information for the hydraulic and driveline components used on the machine.

Circuit Diagrams

Two wiring diagram versions and two hydraulic diagram versions are included, covering the machine’s electrical and hydraulic systems in full. The wiring diagrams cover supply and starting, the Deutz EMR II engine, the driving system with slope sensor and seat contact, the data collector and LC display, steering and vibration, the joystick and vibration plates, Variocontrol and measurement equipment, BOMAG Compaction Management, illumination, cabin equipment, and cabin heating and air conditioning. The hydraulic diagrams cover the travel and vibration circuits.

What This BOMAG Repair Manual Does for You

With this manual on hand, you can tear down and rebuild the drum, service the travel and vibration pumps, diagnose fault codes on the ESX control, flush and bleed the hydraulic circuits, replace the steering valve or axle sensors, service the air conditioning system, and replace the cab window panes. The procedures are written for a trained mechanic, so you get the specific values and sequences rather than a generic overview. That matters when a torque value is the difference between a reliable repair and a comeback, or when a pressure reading tells you whether a pump or a valve is at fault.

IMAGES PREVIEW

This BOMAG BW 219 / BW 226 DH-4 / PDH-4 repair instructions manual is delivered as an instant PDF download. There is no shipping and no waiting. Open it on any device, print the pages you need for the shop, and keep the file as a permanent reference for the machines in your fleet. Document number 008 910 28, 962 pages, covering BW 219 DH-4, BW 219 PDH-4, BW 226 DH-4, and BW 226 PDH-4.