BOMAG BW 219 DH/PDH-4 & BW 226 DH/PDH-4 Service Manual
This is the complete BOMAG Service Manual for the BW 219 DH-4, BW 219 PDH-4, BW 226 DH-4 and BW 226 PDH-4 single drum rollers, catalogue number 008 911 07, published September 2007. It is the same workshop documentation used by BOMAG technicians to maintain, test, adjust, troubleshoot and repair these machines down to component level. The manual is written in English and covers serial numbers from 101 582 77, 101 582 78, 101 582 88 and 101 582 89 onward.
File Details
Manual type: BOMAG Service Manual / Workshop Repair Manual
+5.5 Checking / adjusting the neutral positions of the travel pumpp. 64
Fig. 1p. 64
Fig. 2p. 64
Fig. 3p. 64
Fig. 4p. 65
Fig. 5p. 65
Fig. 6p. 65
+5.6 Pressure measurements in the vibration circuitp. 66
Fig. 1p. 66
Fig. 2p. 66
+5.7 Check the leakage rate of the vibration motorp. 67
Fig. 1p. 67
Fig. 2p. 67
Fig. 3p. 67
+5.8 Pressure test in steering circuitp. 68
Fig. 1p. 68
Fig. 2p. 68
+Fig. 3p. 69
6 Flushing and bleedingp. 71
+6.1 Special tools for flushingp. 72
+Fig. 1p. 72
1. Filling and filtering unit with oil bagp. 72
2. Filter elementp. 72
+Fig. 2p. 72
3. Flushing filter (S connection)p. 72
4. Filter element 1mp. 72
5. Flushing hose 20S – 25S (2 pieces)p. 72
6. Screw socket R1“ – 25S (2 pieces)p. 72
+Fig. 3p. 72
7. Flushing filter (L connection)p. 72
8. Filter elementp. 72
9. Flushing hose 15L (2 pieces)p. 72
10. Screw socket R3/4“ — 15L (2 pieces)p. 72
+Fig. 4p. 72
11. SAE-flange 1“ – 20Sp. 72
12. O-ringp. 72
+Fig. 5p. 73
13. Flanged plate 1“ – 25Sp. 73
14. O-ringp. 73
+Fig. 6p. 73
15. Reducing fitting 18L – 15Lp. 73
+Fig. 7p. 73
16. Reducing fitting 25S – 20Sp. 73
+Fig. 8p. 73
17. Reducing fitting 20S – 16Sp. 73
+Fig. 9p. 74
18. Connecting socket 15Lp. 74
+Fig. 10p. 74
19. Connecting socket 18Lp. 74
+Fig. 11p. 74
20. Connecting socket 16Sp. 74
+Fig. 12p. 74
21. Connecting fitting 20Sp. 74
+Fig. 13p. 75
22. Connecting fitting 25Sp. 75
+Fig. 14p. 75
23. Angular fitting 18Lp. 75
+Fig. 15p. 75
24. Elbow fitting 16Lp. 75
+Fig. 16p. 75
25. Elbow 20Sp. 75
+Fig. 17p. 76
26. Elbow 25Sp. 76
+Fig. 18p. 76
27. Pipe connection 16S – 16Sp. 76
+Fig. 19p. 76
28. Connecting hose 15Lp. 76
+6.2 Flushing – generalp. 77
Changing a componentp. 77
+Chips (abrasion) in the oilp. 77
l Open and clean all components in the oil circuit, replace if necessary.p. 77
l Clean all high pressure hoses in the oil circuit, replace if necessary.p. 77
l If abrasion is found in the travel circuit you should also flush the vibration circuit.p. 77
l If abrasion is found in the vibration circuit you should also flush the travel circuit.p. 77
+Before flushingp. 77
+Fig. 1p. 77
l Change the hydraulic oil filter element (1).p. 77
+Fig. 2p. 77
l Filter the tank content with the filling and filtering unit and pump it into the oil bag.p. 77
l Mark all hoses and disconnect them from the hydraulic oil tank.p. 77
l Clean the oil tank thoroughly from inside, if necessary remove the complete tank cover.p. 77
l Reconnect all hoses.p. 77
l Fill the hydraulic oil tank again with the filling and filtering unit.p. 77
+Bleedingp. 77
+Fig. 3p. 77
l Always bleed closed hydraulic circuits if lines had been removed or connected.p. 77
+Servicing the flushing filter kitp. 78
+Fig. 4p. 78
l Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the filtering process.p. 78
l Clean hoses and connections and store the flushing kit in a clean and protected environment.p. 78
8 Flushing filter with filter element 1m (tool)p. 80
9 Elbow union (tool)p. 80
10 Reducing fitting (tool)p. 80
11 Travel pumpp. 80
12 High pressure hose (B, drum drive motor reverse)p. 80
13 High pressure hose (A, drum drive motor forward)p. 80
14 High pressure hose (B, axle motor reverse)p. 80
15 High pressure hose (A, axle motor forward)p. 80
16 High pressure hose (B, axle motor reverse)p. 80
17 High pressure port (B, drum drive motor reverse)p. 80
18 Flushing hose 25S – 20S (tool)p. 80
19 Flushing hose 25S – 20S (tool)p. 80
+6.4 Flushing the travel circuit (travel pump distribution)p. 81
+Flushing the drum drivep. 81
+Fig. 1p. 81
1. Disconnect the high pressure hose 12 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 17) and connect it with the flushing hose (7) (flushing filter inlet "IN").p. 81
2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port 17) on the travel pump.p. 81
+Fig. 2p. 81
3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and 13) on the drum drive motor together.p. 81
Fig. 3p. 82
+Fig. 4p. 82
4. Block drums and wheels with suitable chocks.p. 82
Fig. 5p. 82
+Fig. 6p. 82
5. Start the engine and shift the travel lever to travel direction forward.p. 82
6. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 82
7. Shut down the engine.p. 82
8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor.p. 82
+Fig. 7p. 83
9. Jack up the front of the machine, so that the drum can rotate freely.p. 83
10. Secure the rear wheels with chocks.p. 83
11. Pre-select the slow speed range.p. 83
Fig. 8p. 83
+Fig. 9p. 83
12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 83
13. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 83
14. Shut down the engine.p. 83
15. Remove the flushing filter and reconnect the high pressure lines.p. 83
+Flushing the axle drivep. 84
+Fig. 10p. 84
16. Disconnect the high pressure hose 14 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 16) and connect it with the flushing hose (18) (flushing filter inlet "IN").p. 84
17. Connect the flushing hose (19) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.p. 84
+Fig. 11p. 84
18. Take the axle drive motor out of the hydraulic circuit by joining the high pressure hoses (14 and 15) on the axle drive motor together.p. 84
Fig. 12p. 84
+Fig. 13p. 85
19. Block drums and wheels with suitable chocks.p. 85
Fig. 14p. 85
+Fig. 15p. 85
20. Start the engine and shift the travel lever to travel direction forward.p. 85
21. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 85
22. Shut down the engine.p. 85
23. Reconnect the hydraulic hoses (14 and 15) to the axle drive motor.p. 85
+Fig. 16p. 85
24. Jack up the rear of the machine, so that the wheels can rotate freely.p. 85
25. Secure the drum with wheel chocks.p. 85
26. Pre-select the slow speed range.p. 85
Fig. 17p. 86
+Fig. 18p. 86
27. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 86
28. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 86
29. Shut down the engine.p. 86
30. Remove the flushing filter and reconnect the high pressure lines.p. 86
31. Bleed the travel circuit (see corresponding chapter).p. 86
32. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 86
+Fig. 19p. 86
33. Check the hydraulic oil level in the tank, fill up if necessary.p. 86
34. Check all connections for leaks with the engine running (visual inspection).p. 86
35. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.p. 86
36. Check all ports and connections for leak tightness (visual inspection).p. 86
8 Flushing filter with filter element 1m (tool)p. 91
9 not usedp. 91
10 Reducing fitting (tool)p. 91
11 Travel pumpp. 91
12 High pressure hose (drum drive motor reverse)p. 91
13 High pressure hose (drum drive motor forward)p. 91
14 High pressure hose (B, axle motor reverse)p. 91
15 High pressure hose (A, axle motor forward)p. 91
16 High pressure hose (B, axle motor reverse)p. 91
17 not usedp. 91
18 Flushing hose 25S – 20S (tool)p. 91
19 Flushing hose 25S – 20S (tool)p. 91
+6.6 Flushing the travel circuit (axle motor distribution)p. 92
+Flushing the drum drivep. 92
+Fig. 1p. 92
1. Disconnect the high pressure hose 14 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 16) and connect it with the flushing hose (19) (flushing filter inlet "IN").p. 92
2. Connect the flushing hose (18) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.p. 92
+Fig. 2p. 92
3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and 13) on the drum drive motor together.p. 92
Fig. 3p. 93
Fig. 4p. 93
+Fig. 5p. 93
4. Block drums and wheels with suitable chocks.p. 93
+Fig. 6p. 93
5. Start the engine and shift the travel lever to travel direction forward.p. 93
6. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 93
7. Shut down the engine.p. 93
8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor.p. 93
+Fig. 7p. 94
9. Jack up the front of the machine, so that the drum can rotate freely.p. 94
10. Secure the rear wheels with chocks.p. 94
11. Pre-select the slow speed range.p. 94
Fig. 8p. 94
+Fig. 9p. 94
12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 94
13. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 94
14. Shut down the engine.p. 94
+Flushing the axle motorp. 95
+Fig. 10p. 95
15. Jack up the rear of the machine, so that the wheels can rotate freely.p. 95
16. Secure the drum with wheel chocks.p. 95
17. Pre-select the slow speed range.p. 95
Fig. 11p. 95
+Fig. 12p. 95
18. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 95
19. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.p. 95
20. Shut down the engine.p. 95
21. Remove the flushing filter and reconnect the high pressure lines.p. 95
22. Bleed the travel circuit (see corresponding chapter).p. 95
23. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 95
+Fig. 13p. 96
24. Check the hydraulic oil level in the tank, fill up if necessary.p. 96
25. Check all connections for leaks with the engine running (visual inspection).p. 96
26. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.p. 96
27. Check all ports and connections for leak tightness (visual inspection).p. 96
+Flushing schematic for vibration drive
1 Elbow union (tool)p. 97
2 Connecting union (tool)p. 97
3 Vibration motorp. 97
4 Vibration pumpp. 97
5 Screw socket R1 – 25S (tool)p. 97
6 Flushing hose 25S – 20S (tool)p. 97
7 Flushing hose 25S – 20S (tool)p. 97
8 Flushing filter with filter element 1m (tool)p. 97
9 SAE flange (tool)p. 97
10 High pressure hose (B, high frequency)p. 97
11 High pressure hose (A, low frequency)p. 97
+6.8 Flushing the vibration circuitp. 98
+Fig. 1p. 98
1. Disconnect the high pressure hose 10 (see chapter "Flushing schematic – vibration circuit") from the vibration pump (4) and connect it with the flushing hose (7) (flushing filter inlet "IN").p. 98
2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port A) on the vibration pump.p. 98
+Fig. 2p. 98
3. Take the vibration motor out of the hydraulic circuit by joining the high pressure hoses (10 and 11) on the vibration motor together.p. 98
Fig. 3p. 99
+Fig. 4p. 99
4. Block drums and wheels with suitable chocks.p. 99
Fig. 5p. 99
+Fig. 6p. 99
5. Switch on vibration with high frequency.p. 99
6. Start the engine and run it with maximum speed.p. 99
7. Flush the circuit for approx. 10 minutes, thereby switch the vibration on and off at intervals of approx. 30 seconds.p. 99
8. Shut down the engine.p. 99
9. Reconnect the hydraulic hoses (10 and 11) to the vibration motor.p. 99
+Fig. 7p. 100
10. Unscrew the fastening screws for the vibration motor and pull the motor out of the coupling.p. 100
Fig. 8p. 100
+Fig. 9p. 100
11. Start the engine and run it with maximum speed.p. 100
12. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of approx. 30 seconds.p. 100
13. Shut down the engine.p. 100
14. Remove the flushing filter and reinstall the vibration motor.p. 100
15. Bleed the vibration circuit (see corresponding chapter).p. 100
16. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 100
+Fig. 10p. 101
17. Check the hydraulic oil level in the tank, fill up if necessary.p. 101
18. Test drive.p. 101
19. Check all ports and connections for leak tightness (visual inspection).p. 101
+6.9 Bleeding the travel circuitp. 102
1. Install a pressure test hose to the charge pressure test port.p. 102
2. Install a pressure test hose each to the high pressure test ports.p. 102
+Fig. 1p. 102
3. Actuate the emergency stop switch.p. 102
+Fig. 2p. 102
4. Hold the open ends of the pressure test hoses (Fig. 2) into a container.p. 102
5. Operate the starter motor for approx. 30 seconds. Wait one minute and repeat this procedure, until oil starts to run out from the pressure test hoses.p. 102
6. Remove the pressure test hoses.p. 102
+Fig. 3p. 102
7. Unlock the emergency stop switchp. 102
+Fig. 4p. 103
8. Connect a 60 bar pressure gauge to the charge pressure test port (Fig. 4) and run the engine max. 15 seconds at idle speed.p. 103
9. Pause for approx. 30 seconds and keep repeating this procedure, until the gauge shows a constant charge pressure reading.p. 103
+Fig. 5p. 103
10. Start the engine.p. 103
11. Shift the travel lever (Fig. 5) approx. 1/3 to forward direction.p. 103
12. After approx. 1 to 2 minutes shut down the engine for a minute.p. 103
13. After a waiting time of approx. 1 minute keep repeating this procedure, until the indicated charge pressure drops directly to zero when shutting down the engine.p. 103
+6.10 Bleeding the vibration circuitp. 104
1. Install a pressure test hose to the charge pressure test port.p. 104
2. Install a pressure test hose each to the high pressure test ports.p. 104
+Fig. 1p. 104
3. Actuate the emergency stop switch.p. 104
+Fig. 2p. 104
4. Hold the open ends of the pressure test hoses (Fig. 2) into a container.p. 104
5. Crank the engine approx. 10 seconds with the starter motor. Wait one minute and keep repeating this procedure, until oil starts to run out from the pressure test hoses.p. 104
6. Remove the pressure test hoses.p. 104
+Fig. 3p. 104
7. Unlock the emergency stop switchp. 104
+Fig. 4p. 105
8. Connect a 60 bar pressure gauge to the charge pressure test port (Fig. 4) and run the engine max. 15 seconds at idle speed.p. 105
9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.p. 105
+Fig. 5p. 105
10. For bleeding switch on vibration with high frequency (Fig. 5).p. 105
11. Start the engine.p. 105
12. After running the engine 1 to 2 minutes pause for approx. one minute.p. 105
13. After a waiting time of approx. 1 minute keep repeating this procedure, until the indicated charge pressure drops directly to zero when shutting down the engine.p. 105
1. Place the drum into the frame and align it parallel to the frame (Fig. 15).p. 585
+Fig. 16p. 585
2. Attach the side plate, insert the bolts 2 (Fig. 16) into rear and front cross-members and tighten with 463 Nm.p. 585
3. Close the screw holes with plugs (1).p. 585
+Fig. 17p. 585
4. Fasten the spacer blocks for the vibration motor with screws 1 (Fig. 17) and nuts to the side plate.p. 585
5. Fasten the spacer block for the travel motor with screws and nuts to the side plate.p. 585
+Fig. 18p. 585
6. Connect hydraulic hoses (Fig. 18) to the connections on travel motor and vibration motor according to the marking.p. 585
+Fig. 19p. 586
7. Connect the wiring loom with the speed sensor plug (vibration sensor).p. 586
8. Fasten bracket 1 (Fig. 19) for the hydraulic hoses.p. 586
+Fig. 20p. 586
9. Plug the plugs from solenoid valve (Fig. 20) and speed sensor on travel motor side.p. 586
+Fig. 21p. 586
10. Connect hydraulic hoses (Fig. 21) to the connections on travel motor according to the marking.p. 586
11. Reassemble the guard plates (1) and (2).p. 586
+Fig. 22p. 586
12. Assemble the front scraper 2 (Fig. 22), fasten with bolts (1), washers and nuts.p. 586
13. Assemble the rear scraper (4), fasten with bolts (3), washers and nuts.p. 586
+Fig. 23p. 587
14. On the vibration drive side measure the distance "X" between spacer block and side plate (Fig. 23).p. 587
15. Calculate the thickness of the compensation plates.p. 587
+Fig. 24p. 587
16. Turn in screws into each welded nut (Fig. 24) and provide sufficient space to insert the compensation plates.p. 587
+Fig. 25p. 587
17. Insert the compensation plates (Fig. 25).p. 587
18. Turn in the fastening screws.p. 587
19. Unscrew the screws from the welded nuts.p. 587
20. Tighten the fastening screws.p. 587
+14.4 Repairing the drump. 588
+Removing the travel motorp. 588
+Fig. 1p. 588
1. Attach the lifting tackle to travel drive 3 (Fig. 3).p. 588
2. Unscrew all nuts (1) from the rubber buffers.p. 588
3. Take drive disc (2) with travel drive off the rubber buffers and lay it down.p. 588
+Fig. 2p. 588
4. Unscrew fastening screws 3 (Fig. 5) and take off support legs (4).p. 588
5. Unscrew fastening screws 1 and take off drive disc (2).p. 588
+Disassembling the exciter unit (travel motor side)p. 588
+Fig. 3p. 588
1. Unscrew both socket head cap screws from the flange (Fig. 3).p. 588
+Fig. 4p. 589
2. Mount bracket 1 (Fig. 11) for the lifting device to the flange.p. 589
3. Unscrew screws (2) from the flange.p. 589
+Fig. 5p. 589
4. Slide the lifting device over the bracket.p. 589
5. Force the exciter unit off with two forcing screws (Fig. 5).p. 589
+Fig. 6p. 589
6. Pull the exciter unit out of the drum (Fig. 6).p. 589
7. Take the coupling element off the coupling half.p. 589
+Disassembling the exciter unit (travel motor side)p. 590
+Fig. 7p. 590
1. Unscrew fastening screws 1 (Fig. 7) for the fan.p. 590
2. Loosen clamping screw (2).p. 590
3. Pull the coupling hub off the shaft.p. 590
+Fig. 8p. 590
4. Unscrew all other fastening screws 1 (Fig. 8) from the flange.p. 590
5. Press the flange off the flanged housing with forcing screws (2).p. 590
+Fig. 9p. 590
6. Lift the flange off the flanged housing (Fig. 9).p. 590
7. Take the O-ring out of the groove in the flanged housing.p. 590
+Fig. 10p. 591
8. Unclip the circlip from the groove in the flange (Fig. 10).p. 591
+Fig. 11p. 591
9. Press the cylinder roller bearing with forcing screws out of the flange (Fig. 11).p. 591
+Fig. 12p. 591
10. Lift the exciter unit out of the flanged housing(Fig. 12).p. 591
+Fig. 13p. 591
11. Knock the radial seal (Fig. 13) out of the flanged housing.p. 591
+Fig. 14p. 592
12. Unclip the circlip from the groove in the flanged housing (Fig. 14).p. 592
+Fig. 15p. 592
13. Press the cylinder roller bearing with forcing screws out of the flanged housing (Fig. 15).p. 592
+Fig. 16p. 592
14. Extract inner ring 1 (Fig. 16) for the radial seal and inner bearing races (2).p. 592
+Fig. 17p. 592
15. Unclip the circlip from the basic weight (Fig. 17).p. 592
+Fig. 18p. 593
16. To change shaft 1 (Fig. 18) knock out dowel pins (2 and 3) and press the shaft out of the basic weight.p. 593
+Disassembling the exciter unit (vibration motor side)p. 593
+Fig. 19p. 593
1. Unscrew fastening screw 1 (Fig. 19).p. 593
2. Take rectangular rubber buffer (2) with spacer block (3) off the side plate.p. 593
+Fig. 20p. 593
3. Unscrew fastening screws 1 (Fig. 20).p. 593
4. Force cover (2) together with the attached vibration motor off the side plate with forcing screws.p. 593
+Fig. 21p. 594
5. To change the vibration motor loosen clamping screw 1 (Fig. 21) and pull off coupling half (2).p. 594
+Fig. 22p. 594
6. Unscrew fastening screws 1 (Fig. 22).p. 594
7. Take the vibration motor off the cover.p. 594
+Fig. 23p. 594
8. Remove the coupling element (Fig. 23).p. 594
+Fig. 24p. 594
9. Fasten the lifting device.p. 594
10. Unscrew fastening screws 1 (Fig. 24).p. 594
+Fig. 25p. 595
11. Press the exciter unit out of the drum with forcing screws (Fig. 25).p. 595
+Fig. 26p. 595
12. Pull the exciter unit out of the drum (Fig. 26).p. 595
+Removing, dismantling the side platep. 595
+Fig. 27p. 595
1. Take off V-ring 1 (Fig. 27).p. 595
2. Unclip circlip (2).p. 595
+Fig. 28p. 595
3. Attach the disassembly device to the side plate (Fig. 28) and force off the side plate.p. 595
+Fig. 29p. 596
4. Lift the side plate of the flanged hub (Fig. 29).p. 596
+Fig. 30p. 596
5. Knock the grooved roller bearing out of the side plate (Fig. 30) and take out the spacer ring.p. 596
+Fig. 31p. 596
6. Unclip the circlip from the side plate (Fig. 31).p. 596
+Fig. 32p. 596
7. Take the mechanical seal off the flanged hub (Fig. 32).p. 596
+Dismantling the exciter unit (vibration motor side)p. 597
+Fig. 33p. 597
1. Unscrew the fastening from the coupling hub.p. 597
2. Pull coupling hub (2) off the shaft using a pulling device (Fig. 33).p. 597
+Fig. 34p. 597
3. Loosen hose clamp 1 (Fig. 34).p. 597
4. Pull coupling hub (2) off the shaft.p. 597
+Fig. 35p. 597
5. Unscrew all other fastening screws 1 (Fig. 35) and press the flanged hub off the flanged housing with forcing screws (2).p. 597
6. Take off the flanged hub.p. 597
7. Take the O-ring out of the groove in the flanged housing.p. 597
+Fig. 36p. 598
8. Unclip the circlip from the groove in the flanged hub (Fig. 36).p. 598
+Fig. 37p. 598
9. Knock the cylinder roller bearing out of the flanged hub (Fig. 37).p. 598
+Fig. 38p. 598
10. Lift the exciter unit out of the flanged housing (Fig. 38).p. 598
+Fig. 39p. 598
11. Knock the radial seal (Fig. 39) out of the flanged housing.p. 598
+Fig. 40p. 599
12. Unclip the circlip from the groove in the flanged housing (Fig. 40).p. 599
+Fig. 41p. 599
13. Press the cylinder roller bearing with forcing screws out of the flanged housing (Fig. 41).p. 599
+Fig. 42p. 599
14. Extract inner rings 1 (Fig. 42) for the radial seals and inner bearing races (2) from the shaft.p. 599
+Fig. 43p. 599
15. Unclip the circlip from the basic weight and remove the cover (Fig. 43).p. 599
+Assembling the exciter unit (vibration motor side)p. 600
+Fig. 44p. 600
1. Cool the shaft down in liquid nitrogen.p. 600
2. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 44).p. 600
+Fig. 45p. 600
3. Secure shaft 1 (Fig. 45) with dowel pins (2 and 3).p. 600
+Fig. 46p. 600
4. Cool the shaft down in liquid nitrogen.p. 600
5. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 46).p. 600
+Fig. 47p. 601
6. Secure shaft 2 (Fig. 47) with dowel pins (1 and 3).p. 601
+Fig. 48p. 601
7. Insert the fitting key into the keyway in the respective shaft (Fig. 48).p. 601
+Fig. 49p. 601
8. Insert the circlip into the groove in the basic weight and on the cover (Fig. 49).p. 601
+Fig. 50p. 601
9. Heat the inner bearing race up to approx. 100˚ C and press it onto the basic weight against the shoulder with the larger outer diameter forward (Fig. 50).p. 601
+Fig. 51p. 602
10. Heat the inner ring up to approx. 50˚ C and slide it onto the short shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 51).p. 602
+Fig. 52p. 602
11. Heat the inner bearing race up to approx. 100˚ C and press it onto the cover against the shoulder with the larger outer diameter forward (Fig. 52).p. 602
+Fig. 53p. 602
12. Heat the inner ring up to approx. 50˚ C and slide it onto the longer shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 53).p. 602
+Fig. 54p. 602
13. Press cylinder roller bearing 1 (Fig. 54) with pressing plate (2) into the flanged housing until it bottoms.p. 602
+Fig. 55p. 603
14. Insert the circlip into the groove in the flanged housing (Fig. 55).p. 603
+Fig. 56p. 603
15. Fit the new radial seal with some grease into the groove in the flanged housing (Fig. 56).p. 603
16. Fill engine oil SAE-15W/40 into the flanged housing, filling capacity see table of fuels and lubricants.p. 603
+Fig. 57p. 603
17. Insert the exciter unit with the longer shaft forward into the flanged housing (Fig. 57).p. 603
+Fig. 58p. 603
18. Press cylinder roller bearing 1 (Fig. 58) with pressing plate (2) into the flanged hub until it bottoms.p. 603
+Fig. 59p. 604
19. Insert the circlip into the groove in the flanged hub (Fig. 59).p. 604
+Fig. 60p. 604
20. Attach the flanged hub to the flanged housing (Fig. 60).p. 604
21. Unscrew eye bolts (1) and replace them with short screws.p. 604
22. Turn short screws (2) into the tapped bores in the flanged housing (four screws) and tighten them.p. 604
+Fig. 61p. 604
23. Apply some grease to the sealing lip of radial seal 1 (Fig. 61).p. 604
24. Insert the radial seal into the flanged hub with the sealing lip facing down and press it down against the stop with pressing bushing (2).p. 604
+Fig. 62p. 604
25. Heat the coupling hub up to approx. 80 ˚C and slide it onto the shaft against the stop (Fig. 62).p. 604
+Fig. 63p. 605
26. Apply some grease to the sealing lip of radial seal 1 (Fig. 63).p. 605
27. Slide the radial seal with the sealing lip forward over the shaft and drive it completely into the flanged housing, using a suitable tube (2).p. 605
+Fig. 64p. 605
28. Cover the thread of screw 1 (Fig. 64) with a screw retention agent (Loctite CVX strong, blue, 582).p. 605
29. Slide on the new U-seal ring (2), turn in and tighten the screws.p. 605
+Fig. 65p. 605
30. Heat coupling hub 1 (Fig. 65) with marking letter “L“ up to approx. 80˚ C and slide it over the shaft against the shoulder.p. 605
31. Turn in and tighten clamping screw (2).p. 605
+Assembling and installing the side platep. 606
+Fig. 66p. 606
1. Fill grooved ball bearing 1 (Fig. 66) on both sides with grease.p. 606
2. Press the grooved ball bearing completely in using pressing plate (2).p. 606
+Fig. 67p. 606
3. Insert the circlip into the groove in the side plate (Fig. 67).p. 606
+Fig. 68p. 606
4. Apply a thick coat of grease to the spacer ring on both sides and insert it into the side plate (Fig. 68).p. 606
+Fig. 69p. 607
5. Fill grooved ball bearing 1 (Fig. 69) on one sides with grease.p. 607
6. Insert the grooved ball bearing with the grease side forward and press it completely in with pressing plate (2).p. 607
+Fig. 70p. 607
7. Insert the oiled loop-ring into the mechanical seal (Fig. 70).p. 607
8. Clean the sliding surfaces of the mechanical seal and cover them with oil.p. 607
+Fig. 71p. 607
9. Lay one half of the radial seal on the flanged hub with the sliding surface pointing up (Fig. 71).p. 607
+Fig. 72p. 607
10. Lay the second half of the mechanical seal down with the sliding face pointing down (Fig. 72).p. 607
+Fig. 73p. 608
11. Bolt the threaded section of the assembly device to the flanged hub (Fig. 73).p. 608
+Fig. 74p. 608
12. Lay the side plate on the flanged hub (Fig. 74).p. 608
+Fig. 75p. 608
13. Attach bushing 2 (Fig. 75) of the assembly device and turn on nut (1).p. 608
+Fig. 76p. 608
14. Pull the side plate with the assembly device onto the flanged hub.p. 608
+Fig. 77p. 609
15. Remove the assembly device.p. 609
16. Insert the circlip into the groove in the flanged hub (Fig. 77).p. 609
+Assembling the exciter unit (travel motor side)p. 609
+Fig. 78p. 609
1. Cool the shaft down in liquid nitrogen.p. 609
2. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 78).p. 609
+Fig. 79p. 609
3. Secure shaft 1 (Fig. 79) with dowel pins (2 and 3).p. 609
+Fig. 80p. 610
4. Insert the circlip into the groove in the basic weight and on the cover (Fig. 80).p. 610
+Fig. 81p. 610
5. Heat the inner bearing race up to approx. 100˚ C and press it onto the basic weight against the shoulder with the larger outer diameter forward (Fig. 81).p. 610
+Fig. 82p. 610
6. Heat the inner ring up to approx. 50˚ C and slide it onto the shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 82).p. 610
+Fig. 83p. 610
7. Heat the inner bearing race up to approx. 100˚ C and press it onto the cover against the shoulder with the larger outer diameter forward (Fig. 83).p. 610
+Fig. 84p. 611
8. Press cylinder roller bearing 1 (Fig. 84) with pressing plate (2) into the flanged housing until it bottoms.p. 611
+Fig. 85p. 611
9. Insert the circlip into the groove in the flanged housing (Fig. 85).p. 611
+Fig. 86p. 611
10. Fit the new radial seal with some grease into the groove in the flanged housing (Fig. 86).p. 611
11. Fill engine oil SAE-15W/40 into the flanged housing, filling capacity see table of fuels and lubricants.p. 611
+Fig. 87p. 611
12. Insert the exciter unit into the flanged housing (Fig. 87).p. 611
+Fig. 88p. 612
13. Press cylinder roller bearing 1 (Fig. 88) with pressing plate (2) into the flange until it bottoms.p. 612
+Fig. 89p. 612
14. Insert the circlip into the groove in the flange (Fig. 89).p. 612
+Fig. 90p. 612
15. Lift the flange onto the flanged housing and align it the bores (Fig. 90).p. 612
+Fig. 91p. 612
16. Turn the screws into the tapped bores of the flanged housing and tighten them (Fig. 91).p. 612
+Fig. 92p. 613
17. Apply some grease to the sealing lip of radial seal 1 (Fig. 92).p. 613
18. Slide the radial seal with the sealing lip forward over the shaft and drive it completely into the flanged housing, using a suitable tube (2).p. 613
+Fig. 93p. 613
19. Cover the thread of screw 1 (Fig. 93) with a screw retention agent (e.g. Loctite CVX strong, blue, 582).p. 613
20. Slide on the new U-seal ring (2), turn in and tighten the screws.p. 613
+Fig. 94p. 613
21. Insert the fitting key into the keyway of the shaft (Fig. 94).p. 613
+Fig. 95p. 613
22. Slide the fan with assembly disc over the shaft.p. 613
23. Heat coupling hub 1 (Fig. 95) with marking letter “R“ up to approx. 80˚ C and slide it over the shaft against the shoulder.p. 613
24. Turn in and tighten clamping screw (2).p. 613
25. Assemble the fan to the coupling hub.p. 613
+Assembling the exciter unit (travel motor side)p. 614
+Fig. 96p. 614
1. Check coupling elements , replace if necessary.p. 614
2. Insert the coupling element into the coupling hub (Fig. 96).p. 614
3. Fasten the lifting device to the exciter unit.p. 614
+Fig. 97p. 614
4. Insert the vibrator unit into the drum (Fig. 97).p. 614
Fig. 98p. 614
+Fig. 99p. 615
5. Turn in and tighten screws 2 (Fig. 99).p. 615
6. Remove bracket (1) for the lifting device.p. 615
+Fig. 100p. 615
7. Cover the thread of screws (Fig. 100) with a screw retention agent (e.g. Loctite green 270).p. 615
8. Slide on the new U-seal ring, turn in and tighten the screws.p. 615
+Installing the travel motorp. 615
+Fig. 101p. 615
1. Assemble drive disc 2 (Fig. 101) and support (4) with screws (3).p. 615
+Fig. 102p. 615
2. Attach the drive disc 2 (Fig. 102) with the assembled travel drive (3) to the rubber buffers. Turn on and tighten the nuts (1).p. 615
+Installing the exciter unit (vibration motor side)p. 616
+Fig. 103p. 616
1. Fasten the lifting gear to the exciter unit and insert it into the drum (Fig. 103).p. 616
Fig. 104p. 616
+Fig. 105p. 616
2. Turn in and tighten screws 1 (Fig. 105).p. 616
3. Remove the lifting gear.p. 616
4. Fit cover (2) to the drum.p. 616
+Fig. 106p. 617
5. Check the end float of the exciter shafts (Fig. 106).p. 617
+Fig. 107p. 617
6. Attach disc 1 (Fig. 107), turn in and tighten the fastening screws (2).p. 617
+Fig. 108p. 617
7. Lay a new V-ring over the journal of the flanged hub (Fig. 108).p. 617
8. Fill the grooved ball bearing with grease.p. 617
+Fig. 109p. 617
9. Check coupling element, replace if necessary.p. 617
10. Insert the coupling element into the coupling hub (Fig. 109).p. 617
+Fig. 110p. 618
11. Fasten the vibration motor 1 (Fig. 110) to the cover (5) so that the hydraulic connections and the ventilation bore are opposite each other.p. 618
12. Turn in fastening screw (2) with ball disc (3) and ball socket (4) and tighten.p. 618
+Fig. 111p. 618
13. Slide on coupling half 2 (Fig. 111) and secure with clamping screw (1).p. 618
+Fig. 112p. 618
14. Attach the cover 2 (Fig. 112) with the installed vibration motor, turn in and tighten the screws (1).p. 618
+Fig. 113p. 618
15. Install rectangular rubber buffers 2 (Fig. 113) with attached spacer block (3) and screws (1) to the side plate.p. 618
+14.5 Dismantling, assembling the change- over weightsp. 619
+Dismantling the change-over weightp. 619
+Fig. 1p. 619
1. Unscrew all screws (Fig. 3).p. 619
+Fig. 2p. 619
2. Force the cover off the basic weight with forcing screws (Fig. 5).p. 619
+Fig. 3p. 619
3. Take the change-over weight out of the basic weight (Fig. 6).p. 619
+Fig. 4p. 620
4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.p. 620
+Assembling the change-over weightsp. 620
+Fig. 5p. 620
1. Install new O-rings 1 and 2 (Fig. 5) with grease.p. 620
+Fig. 6p. 620
2. Insert the change-over weight into the basic weight (Fig. 6).p. 620
+Fig. 7p. 620
3. Fill silicon oil 47 V 1000 cst up to the upper edge of the change-over weight (approx. 2,5 litres) into the basic weight (Fig. 13).p. 620
+Fig. 8p. 621
4. Attach the cover (Fig. 14), so that the raised areas are in line.p. 621
5. Turn in screws with screw retention agent (e.g. Loctite blue 243) and tighten with 120 Nm.p. 621
6. Check the end float of the shaft.p. 621
+14.6 Changing the rubber buffers and adjusting the pretensionp. 622
+Fig. 1p. 622
1. Lift the frame up by both sides, until rubber buffers and rectangular buffers are relieved of any load (Fig. 1).p. 622
2. Loosen all fastening screws.p. 622
+Fig. 2p. 622
3. Turn one screw each into the welded nuts (Fig. 2) on the spacer blocks.p. 622
+Fig. 3p. 622
4. Remove the compensation shims (Fig. 3).p. 622
+Fig. 4p. 623
5. Unscrew the screws (Fig. 4) from the welded nuts.p. 623
+Fig. 5p. 623
6. Unscrew nut 1 (Fig. 3) and remove the washer.p. 623
7. Unscrew screws (2).p. 623
8. Take off rubber buffer (3).p. 623
9. Attach the new rubber buffer to the drive disc and align the bores to the tapped bores in the drum.p. 623
10. Turn in and tighten the fastening screws.p. 623
11. Assemble the washer, turn on and tighten the nut.p. 623
+Fig. 6p. 623
12. Measure distance „X“ between spacer piece and side plate (Fig. 6).p. 623
13. Calculate the thickness of the compensation plates. Nominal value: Distance „X“ + 2 mmp. 623
+Fig. 7p. 623
14. Turn in screws into each welded nut and provide sufficient space to insert the compensation plates (Fig. 7).p. 623
+Fig. 8p. 624
15. Assemble the compensation shims (Fig. 8).p. 624
+Fig. 9p. 624
16. Unscrew the screws (Fig. 9) from the welded nuts.p. 624
+Fig. 10p. 624
17. Tighten the fastening screws (Fig. 10).p. 624
18. Lower the frame again.p. 624
15 Oscillating articulated jointp. 625
+15.1 Special toolsp. 626
+Fig. 1p. 626
1. Assembly mandrel for rocker bearings (console of articulated joint).p. 626
+Fig. 2p. 626
2. Assembly mandrel for rocker bearings (steering cylinders).p. 626
+Repair overview oscillating articulated joint
Fig. 1 Oscillating articulated jointp. 628
+Fig. 2 Cross-sectional drawingp. 629
1 Four-point bearingp. 629
2 Console, frontp. 629
3 Centring discp. 629
4 O-ringp. 629
5 Console, rearp. 629
6 Self-aligning bearingp. 629
7 Spacer ringp. 629
8 Washerp. 629
9 Boltp. 629
Fig. 3p. 630
Fig. 4 electric steeringp. 631
+15.3 Removing and installing the oscillating articulated jointp. 632
+Fig. 1p. 632
1. Jack the back of the frame (Fig. 1) up and secure it with trestles or wooden blocks.p. 632
2. Jack the front frame up and secure it with trestles or wooden blocks.p. 632
3. Block drums and wheels with suitable chocks .p. 632
+Fig. 2p. 632
4. Unscrew fastening screws 1 (Fig. 2) and take off axle holder (2).p. 632
5. Knock out bearing bolt (3).p. 632
6. Retract steering cylinder (4).p. 632
+Fig. 3p. 632
7. Support the oscillating articulated joint in the middle with a suitable jack or a similar device.p. 632
8. Unscrew fastening screws 1 (Fig. 3).p. 632
+Fig. 4p. 633
9. Unscrew fastening screws 1 (Fig. 4).p. 633
10. Pull out the oscillating articulated joint.p. 633
+Fig. 5p. 633
11. Insert the bolt for the steering cylinder so that groove 2 (Fig. 5) is in line with tapped bores (1).p. 633
+15.4 Dismantling the oscillating articulated jointp. 634
+Fig. 1p. 634
1. Unscrew fastening screws 1 (Fig. 1) and take off axle holder (2).p. 634
2. Take out bolt (3).p. 634
+Fig. 2p. 634
3. Unscrew fastening screws 1 (Fig. 2) and take off axle holder (2).p. 634
+Fig. 3p. 634
4. Turn out bolt 1 (Fig. 3) and separate consoles (2 and 3).p. 634
+Fig. 4p. 635
5. Take spacer ring 1 (Fig. 2) out of the centring disc.p. 635
+Fig. 5p. 635
6. Unscrew fastening screws 1 (Fig. 3) and take off the centring disc (2).p. 635
+Fig. 6p. 635
7. Take the O-ring out of the rocker bearing (Fig. 4).p. 635
+Fig. 7p. 635
8. Knock both rocker bearings 1 (Fig. 5) out of console (2).p. 635
+Fig. 8p. 636
9. Knock rocker bearings 1 (Fig. 8) out of the steering cylinder receptacles.p. 636
+Fig. 9p. 636
10. Unscrew fastening screws 1 (Fig. 9) and lift the front console (2) off the four point bearing (3).p. 636
11. Check four point bearing for wear , replace if necessary.p. 636
+15.5 Assembling the oscillating articulated jointp. 637
+Fig. 1p. 637
1. Lay the four point bearing 3 (Fig. 1) on a level surface, insert console (2) and fasten with screws (1) and washers.p. 637
+Fig. 2p. 637
2. Spray the rocker bearings 1 (Fig. 2) with sliding lacquer OKS 571 and knock them into the corresponding boreholes in the steering cylinder.p. 637
+Fig. 3p. 637
3. Slightly lubricate the bearings seats and knock rocker bearings 1 (Fig. 3) into console (2).p. 637
+Fig. 4p. 638
4. Grease the new O-rings and insert them into the rocker bearings (Fig. 2).p. 638
8. Join both consoles (2 and 3) together and knock in bolt (1).p. 638
+Fig. 8p. 639
9. Assemble disc 2 (Fig. 8) with screws (1) and washers.p. 639
+Fig. 9p. 639
10. Spray bolt 3 (Fig. 9) with sliding lacquer OKS 571 and insert it so that groove (2) is in line with tapped bores (1).p. 639
+Fig. 10p. 639
11. Secure bolt 3 (Fig. 10) with axle holder (2), screws (1) and washers.p. 639
16 Suppliers documentationp. 641
16.1 Travel pump / vibration pump series 90Rp. 643
16.2 Vibration motor A2FMp. 733
16.3 Travel drive series 51p. 763
16.4 Transmission CRp. 845
+16.5 Axle DANA 193p. 871
17 Circuit diagramsp. 959
17.1 Wiring diagramp. 961
17.2 Wiring diagramp. 1005
17.3 Wiring diagramp. 1047
17.4 Hydraulic diagramp. 1089
Chapters Covered
General — Introduction, safety regulations, general repair instructions, tightening torques
Maintenance — General notes, fuels and lubricants, running-in instructions, maintenance chart
Technical Data — Dimensions, weights, travel characteristics, brake and steering data, engines
Connection Overview — Travel/vibration pump connections and layout
Tests and Adjustments — Special tools, service mode, driving against the closed brake, pressure tests (travel, vibration, steering circuits), neutral position adjustment, leakage rate checks
Flushing and Bleeding — Flushing tools, general procedure, travel circuit flushing, vibration circuit flushing, bleeding procedures
Put together, this BOMAG service manual is not just a list of parts — it is a full technical reference for the entire machine. The travel system chapter alone walks through the 90R100 EP travel pump, the 51C110 drum drive motor, the 51D110 axle drive motor, multi-function valves, charge pressure relief, pressure override and flushing valves, complete with fault tables and adjustment values. The vibration section covers the 90R075 EP vibration pump, the A2FM fixed displacement motor, high-pressure relief valves, flushing circuits and exciter shaft speed checks. The steering chapter covers the HY/ZFFS11/16 charge/steering pump, steering valve block, shock valves and the oscillating articulated joint. On top of that, the Deutz engine chapters document the TCD 2012 and TCD 2013 engines with their Deutz Common Rail (DCR) injection system, EDC16/EMR3 control unit, sensor specifications, fault-code lists and valve adjustment procedures.
What This Manual Lets You Do
With this manual on hand you can carry out the same work a BOMAG workshop would: find the correct tightening torques, set the travel pump neutral position, teach travel system surge currents, adjust the steering end stops, check charge pressure and high-pressure readings against nominal values, flush and bleed the hydraulic circuits after a component change, diagnose ESX control fault codes, troubleshoot the EMR3 engine controller, adjust valve clearance on the Deutz engine, service the air conditioning system, replace cab window panes, remove and rebuild the drum, and recondition the oscillating articulated joint. Every procedure is backed by the actual BOMAG specification values, port connections, test points and diagrams, so you are not guessing at pressures, torques or settings.
IMAGES PREVIEW
Getting the procedures and specs right matters on a machine this size. A wrongly set pressure override, a miscalibrated travel pump, or an ignored fault code can lead to premature hydraulic wear, poor compaction performance or an expensive breakdown on site. This manual removes that risk by giving you the correct nominal values, adjustment screws, taught function codes and test sequences directly from the manufacturer.
Why Buy This BOMAG Service Manual
This BOMAG BW 219 DH/PDH-4 and BW 226 DH/PDH-4 service manual is an invaluable reference for any owner, fleet workshop, independent technician or service company maintaining these single drum rollers. Instead of relying on generic hydraulic or diesel knowledge, you get the BOMAG-specific values, diagrams and step-by-step repair instructions for exactly these two machine families and their Deutz power units. The appendix reprints the original supplier documentation for the Sauer-Danfoss 90R pumps, Bosch Rexroth A2FM vibration motor, Sauer series 51 travel motors, CR transmission and DANA 193 axle, so you can also service the major bought-in components using the makers’ own repair instructions.
Instant PDF Delivery
Your copy is delivered as an instant-download PDF after checkout. There is no shipping, no waiting for a parcel and no risk of a lost book. The file can be opened on a laptop, tablet or smartphone in the workshop, and you can print the pages you actually need for the job at hand — whether that is a single torque table, a hydraulic schematic or an entire chapter on the drum repair.
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