From the Deutz 2012C diesel with EMR through the hydrostatic travel drive, vibration circuit, steering and electrics, this 255-page Bomag BW 216, BW 219 and BW 226 Service Training PDF (OEM 008 097 20) walks the DH-4 and PDH-4 versions of all three single drum rollers end to end. Wiring diagrams and hydraulic schematics close out the book, behind an electrics section filling roughly the last third with fault code and signal descriptions. Travel pump, drum drive motor and exciter each get their own test and adjustment points, so you chase a weak drive or dead vibration against measured pressures instead of hunches. Set charge pressure at port X near 26 bar on your 216, and pull the plug-type injection pump screws down in stages from 5 Nm to 30 Nm. A roller sitting between passes for want of one valve setting bleeds a whole shift. Bookmarked and text-searchable, the download hands you that figure in seconds.
What's Inside This Bomag BW 216 to 226 DH/PDH-4 Manual
| System | Pages | Key Topics |
|---|---|---|
| Documentation | 5 | Index of Related Bomag Publications (Each Sold Separately) |
| General | 6-7 | Drive Concept, Hydrostatic Drives, Hydraulic Motors, Cabin, Monitoring Display, Windscreen Wiper and Washer Systems |
| New Features | 8-12 | Multi-Function Travel Lever, Display, Control, Operation, Data Collector |
| Technical Data and Adjustment Values | 13-19 | Engine, Travel Pump, Reduction Gear, Travel Motor, Drum Drive, Vibration Pump, Vibration Motor, Steering and Charge Pump |
| Maintenance | 20-30 | Maintenance Chart |
| Deutz Diesel Engine 2012C with Emr | 31-76 | Service Side, Starter Side, Lubrication Oil Circuit, Coolant Circuit, Fuel System, Emr, Trouble Shooting, Diagnostics Serdia |
| Travel System | 77-119 | Travel Pump, Control, Charge Pressure Relief Valve, High Pressure Relief Valve, Pressure Override Valve, Axle Drive Motor, Drum Drive Motor, Test and Adjustment Points |
| Vibration | 120-140 | Vibration Pump, High Pressure Relief Valves, Control, Vibration Motor, Drum, Test and Adjustment Points, Vibration System, Trouble Shooting Vibration |
| Steering | 141-153 | Charge Pump, Steering Pump, Steering Valve, Articulated Joint, Measuring and Adjustment Points, Trouble Shooting Steering |
| Electrics | 154-255 | Description of Errors, Description of Signals, Fault Codes |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Injection pump screws tightening torque (initial) | 5 Nm | p. 71 |
| Injection pump screws tightening torque (final stages) | 7 Nm, 10 Nm and 30 Nm | p. 72 |
| Flushing quantity | 10 to 16 l/min | p. 99 |
| Flushing quantity limitation valve pressure | 16 bar | p. 99 |
| Port X pressure | approx. 26 bar | p. 110 |
| Prop. solenoid voltage/current | 12V / 0,4-1,2 A | p. 110 |
| Main fuse | 125A | p. 222 |
| Starter holding current | 10A | p. 222 |
| Starter pull-in current | 50A | p. 222 |
| Battery capacity | 103A | p. 234 |
| Engine Power (ISO 9249) | 147 kW | p. 14 |
| Valve Clearance (Inlet) | 0.3 mm | p. 14 |
Bomag BW 216 to 226 DH/PDH-4 Common Problems This Manual Covers
Bomag BW 216 DH-4 shutoff timer relay fault code active, machine shuts down or will not restart
Read the active code on the display and match it in the fault code list starting. Pull the shutoff timer relay and check contact continuity; a relay that drops out kills the machine mid-pass. Verify the 125A main fuse and trace the relay circuit on the wiring diagram at page 222 before condemning parts.
Manual Section: Fault Codes of the ESX ControlEngine cranks slowly or will not start at all, worse on cold mornings
Load-test the battery against its 103A rating listed on page 234, then clean and tighten both starter cable connections. Verify the starter draws about 50A pull-in and 10A holding current using the wiring diagram on page 222. Check oil level too: the engine holds 12.5 L without the filter, and overfilled oil drags cold cranking speed down.
Manual Section: Deutz Diesel Engine 2012C with Emr p. 234Roller creeps in neutral and loses travel power on one side after warm-up
Check the flushing valve first: flushing flow should run 10 to 16 l/min through the spool with a 16 bar limitation valve, both shown on page 99. If one side still lags, swap the drum drive motor hoses side to side to isolate a bad motor, then work through the test and adjustment points in the Travel System section from page 77.
Manual Section: Travel System p. 99Hydraulic oil overheats and travel speed drops after an hour of steady passes
Clean the hydraulic oil cooler inside and out; a soiled core or jammed thermostat sends hot oil straight back to the travel pump. Trace the cooler and thermostat circuit on the hydraulic schematic. If the oil has cooked, drain and refill the 60 L hydraulic system per the capacities on page 15, then recheck temperature under load.
Manual Section: Travel System p. 77Engine oil pressure warning and buzzer come on during full-throttle vibration passes
Shut the engine down now; do not finish the pass on a low-pressure warning. Check the oil level and correct viscosity, topping toward the 12.5 L capacity listed on page 15. Inspect the lubrication circuit for leaks per the Deutz engine section starting on page 31, and prove oil pressure is good before you put it back on the mat.
Manual Section: Deutz Diesel Engine 2012C with Emr p. 31Frequently Asked Questions
What does error code 5140 mean on a BOMAG BW 219 DH-4?
Error code 5140 indicates an unknown fault within the Deutz EMR system. Fault diagnostics for this specific code are only possible using the DEUTZ diagnostics tool, SERDIA. p. 202
How do I delete all stored fault codes on the ESX control?
To delete all stored faults, ensure the engine is not running, enter code number 0710, and then switch the ignition off and on again. p. 171
What is the specified valve clearance for the Deutz engine in the Bomag BW 216 to 226 DH/PDH-4?
The valve clearance for the Deutz engine must be checked and adjusted when the engine is cold. The intake valve clearance is 0.3 mm and the exhaust valve clearance is 0.5 mm. p. 56
What is the tightening torque for the multi-function valves on the travel pump of the Bomag BW 216 to 226 DH/PDH-4?
The multi-function valves must be tightened with a torque of 89 Nm when being screwed into the pump. p. 90
What is the engine oil capacity for the BW 216 DH-4?
The engine oil capacity for the BW 216 DH-4 is approximately 12.5 litres without the oil filter. p. 21
How quickly can I access this Bomag BW 216 DH-4 manual after buying?
Instant PDF download. You get the full 255-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Can I print this Bomag BW 216 DH-4 manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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