Description
BOMAG BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 Service Manual
This is the full BOMAG Service Manual for the fifth-generation single drum rollers BW 219 DH-5, BW 219 PDH-5, BW 226 DH-5 and BW 226 PDH-5. It is the same document BOMAG Customer Service and trained technicians use in the workshop, and it covers these four rollers end-to-end: diesel engine, travel and vibration hydraulics, electrics and CAN bus, drum assembly, drive axle, air conditioning, auxiliary heating and ROPS/FOPS mounting.
Because DH and PDH variants share the same base machine and only differ at the drum (smooth versus padfoot), one manual covers all four models. Every procedure is written with the values, torques, pressures and tolerances a technician actually needs on the shop floor.
File Details
- Manual type: Service Manual (workshop repair and maintenance)
- Brand: BOMAG (FAYAT Group)
- Covered models: BW 219 DH-5, BW 219 PDH-5, BW 226 DH-5, BW 226 PDH-5
- Machine type: Single drum roller
- Document number: 00840250EN
- Edition / date: 2018
- Language: English
- File format: PDF
- Serial number prefixes: S/N 101 586 63 1001>, 101 586 64 1001>, 101 586 65 1001>, 101 586 66 1001>
Chapters Covered
- 1. General information — introduction, safety fundamentals, fuel and lubricant handling, loading and transport, start-up, driving and working operation, refuelling, emergency procedures, maintenance work, repair notes, tightening torques for metric, UNC, UNF and hydraulic fittings.
- 2. Technical data — full specification blocks for each of the four models, plus additional engine, pump, motor, axle and gear data, terms and basis of calculation, fuels and lubricants, and the complete filling capacity list.
- 3. Overview of machine — machine layout, TERRAMETER, ECONOMIZER, BCM 05, BCM start, BCM net, BOMAG Telematic, electrical layout, hydraulic layout and major machine assemblies.
- 4. Electric systems — measuring methods, circuit diagram reading, Telemecanique switches, Deutsch DT/DTM plugs, central electrics, wiring looms, CAN bus overview, fuse assignment, component descriptions and a full ESX machine control training section with input codes, fault codes and calibration procedures.
- 5. Hydraulic system — open and closed circuits, swash plate pump and motor principles, gear pumps, hydraulic overview, travel/vibration pumps, travel motors, vibration motor, steering valve, charge circuit, travel circuit, vibration circuit, steering circuit, bypass flow filter, flushing and bleeding procedures.
- 6. Machine assemblies — diesel engine overviews, lubrication circuit, cooling circuit, fuel system, Deutz Common Rail, wastegate, EGR, engine electrics and sensors; drum dismantling and assembly, change-over weights, rubber buffers, scrapers, padfoot shells; oscillating articulated joint; drive axle; air conditioning; AIRTRONIC auxiliary heating; cabin assembly; ROPS/FOPS assembly.
- 7. Troubleshooting — emergency procedures and towing, electrical diagnostics, ESX power supply testing, diesel engine malfunction tables, the complete Deutz EMR3 DTC fault code list, hydraulic troubleshooting tables, air conditioning diagnostics and auxiliary heating diagnostics.
- 8. Special tools — special tools for electrics, hydraulic testing and flushing, oscillating articulated joint and drum.
- 9. Index
- Appendix A — Circuit diagrams — full wiring schematic set (drawing 523), hydraulic diagram 479 for BW 219 DH-5 and hydraulic diagram 480 for BW 226 DH-5.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “BOMAG BW 219 DH-5 BW 219 PDH-5 BW 226 DH-5 BW 226 PDH-5 Single Drum Roller Service Manual 2018” are as follows:
Table of contentsp. 3
+1 General informationp. 9
1.1 Introductionp. 10
+1.2 Concerning your safetyp. 12
+1.2.1 Basic prerequisitesp. 12
1.2.1.1 Generalp. 12
1.2.1.2 Explanation of signal words used:p. 12
1.2.1.3 Personal protective equipmentp. 13
1.2.1.4 Intended usep. 14
1.2.1.5 Improper usep. 14
+1.2.2 Definition of responsible personsp. 15
1.2.2.1 Operating companyp. 15
1.2.2.2 Expert / qualified personp. 15
1.2.2.3 Driver / operatorp. 16
+1.2.3 Fundamentals for safe operationp. 16
1.2.3.1 Remaining dangers, remaining risksp. 16
1.2.3.2 Regular safety inspectionsp. 16
1.2.3.3 Modifications and alterations to the machinep. 16
1.2.3.4 Damage, defects, misuse of safety devicesp. 17
1.2.3.5 Roll Over Protective Structure (ROPS)p. 17
+1.2.4 Handling fuels and lubricantsp. 17
1.2.4.1 Preliminary remarksp. 17
1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuelp. 19
1.2.4.3 Safety regulations and environmental protection regulations for handling oilp. 20
1.2.4.4 Safety regulations and environmental protection regulations for handling hydraulic oilp. 21
1.2.4.5 Safety regulations and environmental protection regulations for handling coolantsp. 22
1.2.4.6 Safety regulations and environmental protection regulations for handling battery acidp. 23
1.2.5 Load/transport the machinep. 23
+1.2.6 Start-up procedurep. 24
1.2.6.1 Prior to starting upp. 24
1.2.6.2 Starting the enginep. 25
1.2.6.3 Starting the engine with jump leadsp. 25
+1.2.7 Driving the machine; working operationp. 25
1.2.7.1 Persons in the danger areap. 25
1.2.7.2 Driving the machinep. 26
1.2.7.3 Driving up and down slopesp. 26
1.2.7.4 Cross-slopep. 27
1.2.7.5 Working with vibrationp. 27
1.2.7.6 Parking the machinep. 27
1.2.8 Refuellingp. 27
+1.2.9 Emergency proceduresp. 28
1.2.9.1 Actuating the emergency stop switchp. 28
1.2.9.2 Disconnecting the batteryp. 28
1.2.9.3 Towing the machinep. 28
+1.2.10 Maintenance workp. 29
1.2.10.1 Preliminary remarksp. 29
1.2.10.2 Work on hydraulic linesp. 29
1.2.10.3 Working on the enginep. 29
1.2.10.4 Maintenance work on electric components and batteryp. 30
1.2.10.5 Working on the air conditioningp. 30
1.2.10.6 Working on wheels and tyresp. 30
1.2.10.7 Cleaning workp. 31
1.2.10.8 After maintenance workp. 31
1.2.11 Repairp. 31
1.2.12 Signagep. 31
+1.3 Maintenance and repairp. 40
+1.3.1 Notes on repairp. 40
+1.3.1.1 General repair instructionsp. 40
1.3.1.1.1 Repair notes for electricsp. 40
1.3.1.1.2 Repair notes for hydraulicsp. 42
1.3.1.1.3 Repair notes for Common Rail enginesp. 43
1.3.1.1.4 Repair notes for gaskets and mating surfacesp. 45
1.3.1.1.5 Repair notes for ball and roller bearingsp. 47
1.3.1.1.6 Feather keys and keywaysp. 47
1.3.1.1.7 Repair notes for cotter pinsp. 48
1.3.1.1.8 Repair notes for screws and nutsp. 48
1.3.1.1.9 Strength classes, metric screws and nutsp. 48
1.3.1.1.10 Identification of UNF-threadsp. 50
1.3.1.2 Tightening torquesp. 50
1.3.2 Preliminary remarks and safety notesp. 56
+1.3.3 Preparations / concluding workp. 57
1.3.3.1 Open and secure the engine hoodp. 57
+1.3.3.2 Engaging / releasing the articulation lockp. 58
1.3.3.2.1 Engaging the articulation lockp. 58
1.3.3.2.2 Disengaging the articulation lockp. 59
1.3.4 Parking the machine in secured conditionp. 59
+2 Technical datap. 61
+2.1 Technical data, BW 219 DH-5p. 62
+2.1.1 Technical datap. 62
+2.1.1.1 Noise and vibration datap. 64
2.1.1.1.1 Noise datap. 65
2.1.1.1.2 Vibration datap. 65
+2.2 Technical data, BW 219 PDH-5p. 66
+2.2.1 Technical datap. 66
+2.2.1.1 Noise and vibration datap. 68
2.2.1.1.1 Noise datap. 68
2.2.1.1.2 Vibration datap. 69
+2.3 Technical data, BW 226 DH-5p. 70
+2.3.1 Technical datap. 70
+2.3.1.1 Noise and vibration datap. 72
2.3.1.1.1 Noise datap. 72
2.3.1.1.2 Vibration datap. 72
+2.4 Technical data, BW 226 PDH-5p. 73
+2.4.1 Technical datap. 73
+2.4.1.1 Noise and vibration datap. 75
2.4.1.1.1 Noise datap. 75
2.4.1.1.2 Vibration datap. 76
2.5 Additional technical datap. 77
2.6 Terms and basis of calculationp. 80
+2.7 Fuels and lubricantsp. 81
+2.7.1 Engine oilp. 81
2.7.1.1 Oil qualityp. 81
2.7.1.2 Oil viscosityp. 82
2.7.1.3 Oil change intervalsp. 82
+2.7.2 Fuelp. 82
2.7.2.1 Fuel qualityp. 82
2.7.2.2 Winter fuelp. 83
2.7.2.3 Storagep. 83
+2.7.3 Coolantp. 83
2.7.3.1 Generalp. 83
2.7.3.2 Water qualityp. 84
2.7.3.3 Cooling system protection agentp. 84
+2.7.4 Hydraulic oilp. 86
2.7.4.1 Mineral oil based hydraulic oilp. 86
2.7.4.2 Bio-degradable hydraulic oilp. 86
2.7.5 Gear oil SAE 75W-90p. 86
2.7.6 Gear oil SAE 80W-140p. 86
2.8 List of fuels and lubricantsp. 88
+3 Overview of machinep. 91
+3.1 General informationp. 92
3.1.1 Terrameterp. 95
3.1.2 Economizerp. 96
+3.1.3 BCM 05p. 97
3.1.3.1 Network structurep. 98
3.1.3.2 Position detectionp. 98
3.1.4 BCM startp. 99
3.1.5 BCM netp. 100
3.1.6 BOMAG Telematicp. 101
3.2 Electric systemsp. 103
3.3 Hydraulic systemp. 105
+3.4 Machine assembliesp. 106
3.4.1 Diesel enginep. 106
3.4.2 Drump. 107
3.4.3 Air conditioningp. 108
3.4.4 Auxiliary heating, AIRTRONICp. 109
+4 Electric systemsp. 111
+4.1 Basic principlesp. 113
4.1.1 Measuring methodp. 113
+4.1.2 Understanding circuit diagramsp. 118
4.1.2.1 Circuit diagramsp. 118
4.1.2.2 Circuit symbols in E-Planp. 125
4.1.2.3 Identification of switch blocksp. 128
4.1.3 Telemecanique switchp. 129
4.1.4 Deutsch plug, series DT and DTMp. 131
+4.2 Overview of electric systemp. 135
4.2.1 Central electricsp. 137
4.2.2 Operator’s standp. 138
4.2.3 Wiringp. 139
4.2.4 CAN BUS overviewp. 156
4.2.5 Table of fuels and lubricantsp. 158
4.3 Starting the engine with jump leadsp. 166
+4.4 Fuse assignmentp. 167
4.4.1 Notes on safetyp. 167
4.4.2 Central electricsp. 167
4.4.3 Main fusesp. 168
4.4.4 Control console cabinp. 169
4.4.5 Auxiliary heatingp. 170
4.5 Central electricsp. 171
+4.6 Description of electrical componentsp. 178
4.6.1 Control console cabin p. 178
4.6.2 Acceleration transducer, B62 & B171p. 181
4.6.3 Differential pressure switch for hydraulic oil filter, B21p. 182
4.6.4 Air filter vacuum switch, B03p. 182
4.6.5 Sensor, water in fuel, B124p. 183
4.6.6 Float switch coolant tank, B55p. 183
4.6.7 Level sensor in diesel tank (R03)p. 184
4.6.8 Charge control lightp. 184
4.6.9 Electric module, A108p. 186
+4.7 Training of electric systemp. 187
4.7.1 Electrics training machine controlp. 187
+4.8 Inspection and maintenance workp. 296
4.8.1 Maintenance Tablep. 296
+4.8.2 Every 500 operating hoursp. 296
+4.8.2.1 Servicing the battery, checking the main battery isolationp. 296
4.8.2.1.1 Battery servicep. 296
4.8.2.1.2 Checking the main battery shutoffp. 297
+4.8.3 As requiredp. 297
4.8.3.1 Battery service during prolonged machine downtimesp. 297
+5 Hydraulic systemp. 299
+5.1 Basic principlesp. 301
5.1.1 Open and closed hydraulic circuitp. 301
5.1.2 Swash plate principle, pumpp. 303
5.1.3 Swash plate principle, motorp. 304
5.1.4 External gear pumpsp. 305
5.2 Overview of hydraulicsp. 308
+5.3 Description of hydraulic componentsp. 311
+5.3.1 Travel / vibration pump, H1p. 311
5.3.1.1 Variable displacement pumps, H1 P045/P053/P060/P078/P089/P100 RAp. 311
+5.3.2 Travel motor, H1p. 315
5.3.2.1 Swash plate motor (H1) with variable displacementp. 315
+5.3.3 Vibration motor A2FMp. 317
5.3.3.1 Axial piston motor A2FE/FMp. 317
5.3.4 Steering valvep. 319
+5.4 Description of hydraulic circuitsp. 321
5.4.1 Charge circuitp. 322
5.4.2 Travel circuitp. 323
5.4.3 Vibration circuitp. 332
5.4.4 Steering circuitp. 339
5.4.5 Bypass flow filterp. 343
+5.5 Flushing and bleedingp. 345
5.5.1 Flushing – generalp. 345
+5.5.2 Drum drivep. 348
5.5.2.1 Flushing the drum drivep. 349
+5.5.3 Axle drivep. 354
5.5.3.1 Flushing the axle drivep. 355
+5.5.4 Vibration circuitp. 360
5.5.4.1 Flushing the vibration circuitp. 361
5.5.5 Bleeding the travel circuitp. 365
5.5.6 Bleeding the vibration circuitp. 367
+5.6 Inspection and maintenance workp. 369
5.6.1 Maintenance Tablep. 369
+5.6.2 Checks prior to start upp. 369
5.6.2.1 Checking the hydraulic oil levelp. 369
+5.6.3 Every 500 operating hoursp. 370
5.6.3.1 Replacing the bypass filterp. 370
5.6.3.2 Checking the hydraulic linesp. 371
+5.6.4 Every 1000 operating hoursp. 372
5.6.4.1 Replacing the hydraulic oil filterp. 372
+5.6.5 Every 2000 operating hoursp. 373
5.6.5.1 Changing the hydraulic oilp. 373
+6 Machine assembliesp. 375
+6.1 Diesel enginep. 377
6.1.1 Overviewsp. 378
6.1.2 Lubrication oil circuitp. 383
6.1.3 Cooling circuitp. 385
6.1.4 Fuel systemp. 387
6.1.5 Deutz Common Railp. 390
6.1.6 Wastegate charge pressure controllerp. 395
6.1.7 Exhaust gas recirculation p. 396
+6.1.8 Engine electricsp. 398
6.1.8.1 CAN BUS overviewp. 400
6.1.8.2 EMR3 system overviewp. 402
6.1.8.3 Pin assignment of engine controlp. 411
6.1.8.4 Rotary speed sensor for camshaft, B114p. 416
6.1.8.5 Crankshaft speed sensor, B130p. 417
6.1.8.6 Rail pressure sensor, B93p. 419
6.1.8.7 Fuel pressure sensor, B145p. 421
6.1.8.8 Fuel Control Unit Y137p. 423
6.1.8.9 Injectors, Y147, Y149, Y169 and Y170p. 423
6.1.8.10 Oil pressure sensor, B88p. 424
6.1.8.11 Charge air temperature/charge pressure sensor, B133p. 425
6.1.8.12 EMR coolant – temperature sensor, B113p. 427
+6.1.8.13 Glow plugs, R81 to R84p. 430
6.1.8.13.1 Main fusesp. 431
6.1.8.14 Fuel pre-heatingp. 431
6.1.8.15 Removing and installing the electric starterp. 432
+6.1.9 Inspection and maintenance workp. 433
6.1.9.1 Maintenance Tablep. 433
+6.1.9.2 Checks prior to start upp. 434
6.1.9.2.1 Checking the engine oil levelp. 434
6.1.9.2.2 Checking the coolant levelp. 435
+6.1.9.3 Every 250 operating hoursp. 436
6.1.9.3.1 Cleaning the radiator modulep. 436
+6.1.9.3.2 Checking, tensioning the V-belt for the generator systemp. 437
Checking the condition of the V-beltp. 437
Checking the V-belt tensionp. 437
Tightening the V-beltp. 438
+6.1.9.4 Every 500 operating hoursp. 438
6.1.9.4.1 Change engine oil and oil filter cartridgep. 438
+6.1.9.4.2 Replacing the fuel filter; bleeding the fuel systemp. 440
Preliminary remarksp. 440
Replacing the fuel filterp. 440
Replacing the fuel pre-filterp. 441
Bleeding the fuel systemp. 442
6.1.9.4.3 Checking the anti-freeze concentration and the condition of the coolantp. 442
+6.1.9.5 Every 1000 operating hoursp. 442
6.1.9.5.1 Checking the ribbed V-beltp. 442
6.1.9.5.2 Replacing the air conditioning compressor V-beltsp. 444
6.1.9.5.3 Checking the engine mountsp. 444
+6.1.9.6 Every 2000 operating hoursp. 445
6.1.9.6.1 Checking, adjusting the valve clearancep. 445
6.1.9.6.2 Changing the coolantp. 446
+6.1.9.7 Every 4000 operating hoursp. 449
6.1.9.7.1 Replace ribbed V-belt and idler pulleyp. 449
+6.1.9.8 As requiredp. 450
+6.1.9.8.1 Air filter maintenancep. 450
Replacing the safety elementp. 452
6.1.9.8.2 Checking and cleaning the water separatorp. 453
+6.1.9.8.3 Measures prior to extended shutdown periodp. 453
Measures before shutting downp. 453
Battery service during prolonged machine downtimesp. 454
Measures before restartingp. 454
+6.2 Drump. 456
6.2.1 Repair overview for drump. 456
6.2.2 Dismantling the drump. 459
6.2.3 Dismantling and assembling the change-over weightp. 474
6.2.4 Assembling the drump. 477
6.2.5 Changing the rubber buffers, adjusting the pretensionp. 500
+6.2.6 Smooth drum scraper; installation and removalp. 505
6.2.6.1 Removing the scrapersp. 506
6.2.6.2 Attaching the scrapersp. 508
+6.2.7 Pad foot scraper; installation and removalp. 509
6.2.7.1 Removing the scrapersp. 509
6.2.7.2 Attaching the scrapersp. 511
+6.2.8 Padfoot shell; installation and removalp. 513
+6.2.8.1 Attaching the padfoot shellsp. 513
6.2.8.1.1 Preliminary remarks and safety notesp. 513
6.2.8.1.2 Preparationsp. 514
6.2.8.1.3 Removing the scrapersp. 515
6.2.8.1.4 Attaching segmentsp. 517
6.2.8.1.5 Attaching the scrapersp. 521
+6.2.8.2 Removing the padfoot shellsp. 523
6.2.8.2.1 Preliminary remarks and safety notesp. 523
6.2.8.2.2 Preparationsp. 524
6.2.8.2.3 Removing the scrapersp. 524
6.2.8.2.4 Removing segmentsp. 526
6.2.8.2.5 Attaching the scrapersp. 528
+6.2.9 Inspection and maintenance workp. 529
6.2.9.1 Maintenance Tablep. 529
+6.2.9.2 Every 250 operating hoursp. 530
6.2.9.2.1 Checking the oil level in the exciter housingp. 530
6.2.9.2.2 Checking the oil level in the drum drive reduction gearp. 531
+6.2.9.3 Every 1000 operating hoursp. 532
6.2.9.3.1 Change the oil in the exciter housingp. 532
6.2.9.3.2 Change the oil in the drum drive reduction gearp. 533
+6.2.9.4 As requiredp. 534
6.2.9.4.1 Retightening the padfoot shellp. 534
6.2.9.4.2 Adjust the scrapersp. 534
+6.3 Oscillating articulated jointp. 535
6.3.1 Overviewp. 535
6.3.2 Dismantling the oscillating articulated jointp. 536
6.3.3 Assembly of oscillating articulated jointp. 537
+6.4 Drive axlep. 541
6.4.1 Drive axlep. 541
+6.4.2 Checks prior to start upp. 541
6.4.2.1 Checking wheels and tyresp. 541
+6.4.3 Every 250 operating hoursp. 542
6.4.3.1 Checking the oil level in the drive axlep. 542
6.4.3.2 Checking the oil level in the drive axle reduction gearp. 543
6.4.3.3 Checking the oil level in the wheel hubsp. 544
+6.4.4 Every 1000 operating hoursp. 544
6.4.4.1 Change the oil in the drive axlep. 544
6.4.4.2 Change the oil in the drum drive reduction gearp. 545
6.4.4.3 Changing the oil in the wheel hubsp. 546
6.4.4.4 Retightening the fastening of the axle on the framep. 547
6.4.4.5 Retightening the wheel nutsp. 548
+6.4.5 As requiredp. 548
6.4.5.1 Adjust the parking brakep. 548
+6.5 Air conditioningp. 550
6.5.1 Overview of air conditioning systemp. 550
6.5.2 Physical principlesp. 553
6.5.3 Refrigerant R134ap. 555
6.5.4 Compressor oil / refrigeration oilp. 557
6.5.5 Working principle of the air conditioning systemp. 559
6.5.6 Monitoring devicesp. 560
6.5.7 Description of componentsp. 561
6.5.8 Compressorp. 567
6.5.9 Emptying in case of repairp. 568
6.5.10 Drying and evacuationp. 569
6.5.11 Filling instructionsp. 570
6.5.12 Steam table for R134ap. 573
+6.5.13 Inspection and maintenance workp. 577
6.5.13.1 Maintenance Tablep. 577
+6.5.13.2 Every 250 operating hoursp. 577
+6.5.13.2.1 Checking, tensioning the V-belt for the generator systemp. 577
Checking the condition of the V-beltp. 578
Checking the V-belt tensionp. 578
Tightening the V-beltp. 579
6.5.13.2.2 Changing the fresh air filter in the cabinp. 579
+6.5.13.3 Every 500 operating hoursp. 580
+6.5.13.3.1 Servicing the air conditioning systemp. 580
Cleaning the condenserp. 580
Air conditioning function testp. 581
Checking the condition of the drier/collector unitp. 581
+6.5.13.4 Every 1000 operating hoursp. 582
6.5.13.4.1 Replacing the air conditioning compressor V-beltsp. 582
6.5.13.4.2 Cleaning the circulation air filter of the heatingp. 583
+6.5.13.5 As requiredp. 584
6.5.13.5.1 Checking the compressor oil level / refrigeration oil levelp. 584
+6.6 Auxiliary heating, AIRTRONICp. 585
6.6.1 Description of functionp. 586
6.6.2 Fuse assignmentp. 589
6.6.3 Control panelp. 589
+6.6.4 Inspection and maintenance workp. 591
6.6.4.1 Maintenance Tablep. 591
+6.6.4.2 Monthlyp. 591
6.6.4.2.1 Notes on maintenancep. 591
+6.6.4.3 Heating seasonp. 592
6.6.4.3.1 Notes on maintenancep. 592
+6.6.4.4 Every 1000 operating hoursp. 592
+6.6.4.4.1 Servicing the auxiliary heatingp. 592
Replacing the fuel filter for the auxiliary heatingp. 592
Replacing the air filter for the auxiliary heatingp. 593
+6.7 Cabin assemblyp. 594
6.7.1 Safetyp. 594
6.7.2 Preparationsp. 595
6.7.3 Cabin assemblyp. 596
6.7.4 Final function tests and checksp. 601
+6.8 ROPS/FOPS assemblyp. 603
6.8.1 Safetyp. 603
6.8.2 Preparationsp. 604
6.8.3 ROPS/FOPS assemblyp. 605
6.8.4 Final workp. 609
+7 Troubleshootingp. 611
7.1 Preliminary remarksp. 612
+7.2 Emergency proceduresp. 613
7.2.1 Actuating the emergency stop switchp. 613
7.2.2 Disconnecting the batteryp. 613
7.2.3 Emergency exitp. 613
7.2.4 Towing the machinep. 614
7.2.5 After towingp. 616
+7.3 Troubleshooting, electrical systemsp. 619
7.3.1 Preliminary remarksp. 619
7.3.2 Starting the engine with jump leadsp. 622
+7.3.3 Servicing the battery, checking the main battery isolationp. 623
7.3.3.1 Battery servicep. 623
7.3.3.2 Checking the main battery shutoffp. 623
+7.3.4 Fuse assignmentp. 624
7.3.4.1 Notes on safetyp. 624
7.3.4.2 Central electricsp. 624
7.3.4.3 Main fusesp. 625
7.3.4.4 Control console cabinp. 626
7.3.4.5 Auxiliary heatingp. 627
7.3.5 ESX, checking the electric power supplyp. 627
7.3.6 Diagnostics conceptp. 635
+7.4 Trouble shooting, diesel enginep. 638
7.4.1 Starting the engine with jump leadsp. 638
7.4.2 Engine malfunctionsp. 639
7.4.3 Deutz DTC fault code list, EMR3p. 642
+7.5 Trouble shooting, hydraulicsp. 709
7.5.1 Insufficient hydraulic powerp. 709
7.5.2 Troubleshooting axial piston pumpsp. 712
7.5.3 Troubleshooting axial piston motorsp. 714
7.5.4 Troubleshooting table for hydraulic componentsp. 716
+7.6 Troubleshooting, air conditioning systemp. 724
7.6.1 Trouble shooting in refrigerant circuit, basic principlesp. 724
7.6.2 Trouble shooting procedurep. 730
7.6.3 Leak testp. 739
7.6.4 Checking the magnetic clutch p. 740
+7.7 Troubleshooting, auxiliary heatingp. 742
7.7.1 Fuse assignmentp. 742
7.7.2 Componentsp. 743
7.7.3 Control and safety elementsp. 744
7.7.4 Trouble shootingp. 744
7.7.5 Diagnosticsp. 746
7.7.6 Check the fuel supplyp. 749
7.7.7 Circuit diagram, AIRTRONIC D2/D4p. 751
+8 Special toolsp. 755
8.1 Special tools, electricsp. 756
+8.2 Special tools, hydraulic systemp. 757
8.2.1 Special tools, tests and adjustmentsp. 757
8.2.2 Special tools for flushingp. 759
8.3 Special tools for oscillating articulated jointp. 760
8.4 Special tools, drump. 762
8.5 List of special toolsp. 764
9 Indexp. 765
+Appendixp. 781
+A Circuit diagramsp. 783
A.1 Circuit diagram 523p. 783
A.2 Hydraulic diagram 479p. 878
A.3 Hydraulic diagram 480p. 890
What the BOMAG BW 219 DH-5 / BW 226 DH-5 Service Manual Gives You
The value of this manual is in the details. Where a general workshop guide tells you to remove the drum, this BOMAG service manual tells you which bearing goes in which direction, how hot to heat the inner race, which Loctite to use on the dowel pins, and what the correct end float on the exciter shaft should measure. It covers not just one machine, but four specific fifth-generation single drum rollers and their two drum configurations.
On the Deutz TCD 2012 L06 engine side, the manual documents the Common Rail fuel system, the wastegate charge pressure control, the externally cooled exhaust gas recirculation system and the EMR3 engine electrics with the full pin assignment of the control unit. Sensor replacement procedures are laid out individually: camshaft speed sensor B114, crankshaft speed sensor B130, rail pressure sensor B93, fuel pressure sensor B145, oil pressure sensor B88, charge air temperature and pressure sensor B133 and coolant temperature sensor B113.
For the hydraulic system the manual breaks down the pump and motor units by manufacturer and model: Sauer H1 P089 travel pumps, Sauer H1 B110 travel motors, Sauer H1 P078 vibration pump, Bosch-Rexroth A2FM 63 and A2FM 80 vibration motors, Danfoss OSPC 500 ON steering valve and Dana CHC 193/99 drive axle with no-spin differential. Each unit gets its own service description with charge pressure, high pressure limitation, pressure override and flushing pressure values.
The drum section is fully documented down to component level — exciter unit disassembly from both the travel motor side and the vibration motor side, change-over weight removal and refilling, rubber buffer replacement with pretension adjustment, mechanical seal installation with assembly devices, and full smooth drum and padfoot shell removal and reinstallation procedures with torque values.
Electrical and Diagnostic Coverage
The electric systems chapter is effectively a training course on the machine control. It walks through the measuring method, how to read the circuit diagrams, how to handle the Telemecanique switch blocks and the Deutsch DT and DTM connectors, and then covers the central electrics, wiring harnesses and the full CAN bus architecture (CAN 1, CAN 2, CAN 3 and CAN 4).
Fuse assignments are given for the central electrics, main fuses, cabin control console and auxiliary heating. Component descriptions cover the acceleration transducers B62 and B171, the hydraulic oil filter differential pressure switch B21, air filter vacuum switch B03, water-in-fuel sensor B124, coolant float switch B55, diesel tank level sensor R03, charge control light and the electric module A108.
The ESX machine control training section is the deepest part of the electrical documentation. It gives step-by-step service mode access via the travel lever, the complete input code list, the firmware version decoding, fault log display and deletion, machine type adjustment, automatic surge current detection for the travel system, travel pump coil current and pressure displays, speed detection calibration, vibration frequency setting, cabin activation, serial number entry, cross-slope sensor adjustment and the double pump flushing and individual pump test modes.
Troubleshooting and Fault Codes
The troubleshooting chapter is written for the technician who already has a fault on the machine. It explains the diagnostics concept, the fault description and questioning process, how to determine whether a fault sits in the component or in the wiring, and how to run the electrical power supply check on the ESX control using the pinbox or measuring cables. The complete Deutz EMR3 DTC fault code list follows — from air filter differential pressure code 11 and barometric pressure code 16 all the way through injector bank errors, rail pressure monitoring codes, main relay diagnostics and the DEF and SCR aftertreatment fault codes on Tier 4f machines.
Hydraulic troubleshooting is handled separately with tables for axial piston pumps and axial piston motors, plus a full component-level troubleshooting table covering drive elements, cylinders, motors, flow valves, pressure valves, accumulators, filters, radiators, suction conditions, hydraulic oil tanks and drive motors. Air conditioning and auxiliary heating diagnostics are included with their own pressure charts, resistance tables, magnetic clutch checks and fuel delivery measurement procedures.
Why This Manual Matters for BW 219 DH-5 and BW 226 DH-5 Owners
These rollers are hydrostatically driven and hydrostatically vibrated machines — the travel circuit, vibration circuit, steering circuit and charge circuit all interact. A wrong charge pressure, a contaminated filter or an incorrectly set pressure override valve can take the whole machine out of service. The BOMAG service manual gives you the correct starting point for every adjustment, the correct torque for every critical fastener, and the correct sequence for every assembly procedure.
Because it covers the fourth-generation upgrades as well — the switch to the Common Rail TCD 2012 engine, the integrated air conditioning and AIRTRONIC auxiliary heating, the BCM compaction management options and the BOMAG Telematic system — this is not an outdated document. The serial number prefixes listed confirm it applies to machines from S/N 101 586 63 1001 onwards.
Chapters at a Glance
Whether you need to change the oil in the exciter housing, replace a rubber buffer, reseal the oscillating articulated joint, adjust the parking brake on the Dana axle, service the air conditioning compressor, check the coolant temperature sensor resistance or look up a specific EMR3 fault code, this BOMAG single drum roller service manual is the reference you reach for first. The appendix circuit diagrams (drawing 523) and hydraulic diagrams (479 and 480) provide the schematics needed for actual fault tracing rather than guesswork.
Instant PDF Delivery — No Shipping, No Waiting
The manual is delivered as a PDF the moment your order is completed. There is no physical book to wait for, no shipping cost and no chance of a lost parcel. Open it on a laptop in the workshop, a tablet beside the machine, or a phone in the field, and print any page you need — a single torque table, a wiring sheet or the whole drum assembly section.
For anyone maintaining or repairing a BW 219 DH-5, BW 219 PDH-5, BW 226 DH-5 or BW 226 PDH-5, having the genuine BOMAG service manual on hand turns a difficult job into a documented one. The correct procedure, the right specification and the correct torque value are all in this file.
Reviews
There are no reviews yet.