Bomag Single Drum Rollers BW 216 DH / PDH -4, BW 219 DH / PDH-4, BW 226 DH / PDH -4* Factory Service / Repair/ Workshop Manual I

Service Training Single Drum Rollers BW 216 DH / PDH - 4 08/2005 Part-No. 008 097 20 BW 219 DH / PDH - 4 BW 226 DH / PDH - 4

Service Training BW 216 / 219 / 226 DH / PDH -4 Table of contents Foreword A 1 Documentation A 2 General A 3 New features A 5 Technical data and adjustment values B 1 Maintenance C 1 Maintenance chart and table of fuels and lubricants C2 DEUTZ diesel engine 2012C with EMR D 1 Service side D 2 Starter side D 3 Lubrication oil circuit D 4 Coolant circuit D 5 Fuel system D 6 EMR D10 Trouble shooting D22 Diagnostics SERDIA D24 Checking and adjusting the valve clearance D26 Assembly of plug-type injection pump D28 Engine components D44 Travel system E 1 Travel pump E 3 Control E 7 Charge pressure relief valve E 8 High pressure relief valve E 9 Pressure override valve E11 Axle drive motor E14 Drum drive motor E17 Test and adjustment points, travel system E19 Trouble shooting travel system E27

Service Training BW 216 / 219 / 226 DH / PDH -4 Vibration F 1 Vibration pump F 3 High pressure relief valves F 6 Control F 7 Vibration motor F 8 Drum F11 Test and adjustment points, vibration system F13 Trouble shooting vibration F15 Steering G 1 Charge pump G 2 Steering pump G 3 Steering valve G 5 Articulated joint G 7 Measuring and adjustment points G 9 Trouble shooting steering G10 Electrics H 1 Wiring diagram Hydraulic diagram

Service Training BW 216 / 219 / 226 DH / PDH -4 - A 1 - Foreword and new features Reliable construction equipment is of greatest advantage for all parties involved: • for the customer/user it is a basis for an exact calculation of utilization periods and the completion of projects as scheduled. • in the rental business it means that the equipment can be reliably used and planned without having to stock a large number of stand-by machines. • for the manufacturer it means that customers are satisfied, provides him with a good image and gives him a feeling of confidence. It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This aspect of simple and easy maintenance was one of the key issues when developing and designing the machine: • the location of components in the machine eases maintenance work, • the high quality standard of BOMAG is the basis for the considerable extension of the service and maintenance intervals. • the After Sales Service of BOMAG, including excellent operating and maintenance instruction manuals, high quality training courses and on-site machine demonstrations helps the customer to maintain their machines in good condition over a long period of time. Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service. This program of permanent training is only possible with appropriate and up-to-date training material for trainers as well as persons attending the training courses. This training manual has not only been written as a support for the professional work of the trainer, but also for the trainees attending these training courses. The different levels of product training demand, that the training performed by BOMAG, its Profit Centres or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in Boppard. For this reason we invested a lot of time in the preparation of these materials . The structure of this training manual enables us to change or up-date individual chapters in case of alterations to the machine.

Service Training BW 216 / 219 / 226 DH / PDH -4 - A 2 - Documentation This Service Training is valid for the following BOMAG single drum rollers of series 4: BW 216 DH / PDH -4 BW 219 DH / PDH-4 BW 226 DH / PDH-4 with Deutz diesel engine BF6M 2012C EMR For the BOMAG machines described in this training manual the following documentation is additionally available: 1. Operating and maintenance instructions 2. Spare parts catalogue 3. Wiring diagram * 4. Hydraulic diagram * 5. Repair instructions 6. Service Information * The document versions valid at the date of printing are part of this training manual. Attention! The currently valid part numbers for the documents can be taken from the Doclist or the Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial number of the machine.

Service Training BW 216 / 219 / 226 DH / PDH -4 - A 3 - General The new BOMAG single drum rollers of series 4 are mainly further developments of their predecessors of series 3. These machines have been successfully and reliably used for years on construction sites all over the world, especially in earth construction and on sanitary landfill sites. High compaction power and excellent traction are characteristics, which are of utmost importance for this type of machine. All components installed in these machines are manufactured in series production and are subjected to stringent quality tests. This guarantees a high level of reliability and safety. As with many other BOMAG products, and here especially with the large single drum rollers of the new generation, we have decided to use the same successful drive concept with diesel engine (water cooled) and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the engine directly to drum, drive wheels and steering. The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by slow running radial piston motors. On construction machines the work place of the operator is of utmost importance. Under such working conditions the health and safety of the operator must be the greatest concern. The cabin is very spacious and clearly arranged. The driver’s seat is very comfortable and can be individually adjusted for every operator, even for his weight. All control elements and gauges are within the reach and in the sight of the operator. A monitoring display with light emitting diodes and clear pictograms informs the operator about any operating faults. The operator is therefore always informed about the present condition of the machine. The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens, as well as a heated rear windscreen, offers clear vision to all sides.

Service Training BW 216 / 219 / 226 DH / PDH -4 - A 4 - Important characteristics of the new generation of single drum rollers are • strong ROPS/FOPS according to SAE-standard • wear free service brake by closed hydrostatic travel circuits • disc brakes in axle and drum drive motor serve as parking and emergency brakes • high stability due to low centre of gravity and the use of an articulated joint • operating safety due to the use of monitoring boards for all important system data • automatic engine shut down after 15 seconds, if the engine temperature is too high • automatic engine shut down after 10 seconds, if the coolant level is too low and the engine oil pressure is too low. The single drum rollers of series 4 are well designed down to the smallest detail, so that they can meet the toughest demands on large scale construction sites all over the world.

Service Training BW 216 / 219 / 226 DH / PDH -4 - A 5 - New features The multi-function travel lever and the display Back Front up down

Service Training BW 216 / 219 226 DH / PDH -4 - A - Control, operation, data collector,

Service Training BW 216 / 219 226 DH / PDH -4 - A - Translation Rückseite Back Vorderseite Front Rechts Right Auf Up Vibr. Taste Vibr. button Links Left Ab Down INFO Teste 1 INFO button 1 INFO Taste 2 INFO button 2 Translation: Fahrhebel Travel lever Datensammler Data collector Luftfilter Air filter Blink. L Indic. l Blink. R Indic. r Licht an Lights on D+ Signal D+ signal Hyd. Ölfilt. Hyd. oil filter Hyd. Temp. Hyd. temp. Klimaanl. Aircon Ampere Ampere Wasserab. Water separ. Kühl. Füll. Coolant level Fahrhebel Travel lever Stufenschalter Speed range switch Sitzkontaktschalter Seat contact switch Drucksensor Pressure sensor Verstellung Control Sensor Sensor Vorderrahmen Front frame Hinterrahmen Rear frame Verstellung Control Fahrmotor vorne Front travel motor Neigungssensor Inclination sensor Sensor Sensor Verstellung Control Fahrmotor hinten Rear vtravel motor Fahrpumpe Travel pump

Bomag Single Drum Rollers BW 216 DH / PDH -4, BW 219 DH / PDH-4, BW 226 DH / PDH -4* Factory Service / Repair/ Workshop Manual I

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