Factory service manual for the BOMAG BW 219 DH-5, BW 219 PDH-5, BW 226 DH-5 and BW 226 PDH-5 single drum rollers, covering serial ranges 101 586 33 / 37 / 40 / 42. These are Tier 4f machines with the Deutz TCD 6.1 L6 and full AdBlue/SCR exhaust aftertreatment, and the book treats them that way: you get the Deutz EMR4 DTC fault code list with remedies, SCR warning strategy, Common Rail and EGR coverage, plus complete hydraulics theory and troubleshooting for the travel and vibration circuits. Drum teardown is documented step by step for both smooth and padfoot drums, with bolt torques. Circuit diagrams 327 and 522 and hydraulic diagrams 479 and 480 are in the appendix.
What's Inside This Bomag BW 219 DH-5, BW 219 PDH-5, BW 226 DH-5, BW 226 PDH-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-62 | Concerning Your Safety, Basic Prerequisites, Definition of Responsible Persons, Fundamentals for Safe Operation, Handling Fuels and Lubricants, Load/Transport the Machine, Start-Up Procedure |
| Technical Data | 63-94 | Dimensions, Weights, Travel Characteristics, Exciter System, Padfoot Drum, Filling Capacities |
| Overview of Machine | 95-114 | General Information, Terrameter, Economizer, Bcm 05, BCM Start, BCM Net, BOMAG Telematic |
| Electric Systems | 115-312 | Basic Principles, Measuring Method, Understanding Circuit Diagrams, Telemecanique Switch, Deutsch Plug, Series DT and DTM, Overview of Electric System, Central Electrics |
| Hydraulic System | 313-388 | Basic Principles, Open and Closed Hydraulic Circuit, Swash Plate Principle, Pump, Motor, External Gear Pumps, Overview of Hydraulics, Description of Hydraulic Components |
| Machine Assemblies - Diesel Engine | 389-476 | Overviews, Lubrication Oil Circuit TCD 4.1 / 6.1, Coolant Circuit TCD 4.1 / 6.1, Common Rail System (CRS), Wastegate Charge Pressure Controller, Exhaust Gas Recirculation, EAT - Exhaust Aftertreatment System |
| Machine Assemblies - Drum | 477-555 | Repair Overview for Drum, Dismantling the Drum, Assembling the Drum, Smooth Drum Scraper; Installation and Removal, Pad Foot Scraper; Installation and Removal, Padfoot Shell; Installation and Removal, Inspection and Maintenance Work |
| Machine Assemblies - Articulated Joint and Drive Axle | 556-570 | Oscillating Articulated Joint, Overview, Dismantling the Oscillating Articulated Joint, Assembly of Oscillating Articulated Joint, Checks Prior to Start Up, Every 250 Operating Hours, Every 1000 Operating Hours |
| Machine Assemblies - Air Conditioning and Heating | 571-614 | Overview of Air Conditioning System, Physical Principles, Refrigerant R134a, Compressor Oil / Refrigeration Oil, Working Principle of the Air Conditioning System, Monitoring Devices, Description of Components |
| Machine Assemblies - Cabin and ROPS | 615-630 | Cabin Assembly, Preparations, Final Function Tests and Checks, ROPS/FOPS Assembly, Final Work |
| Troubleshooting - Emergencies and Electrics | 631-662 | Emergency Procedures, Actuating the Emergency Stop Switch, Disconnecting the Battery, Emergency Exit, Towing the Machine, After Towing, Troubleshooting, Electrical Systems |
| Troubleshooting - Diesel Engine (Deutz DTC List) | 663-729 | Trouble Shooting, Diesel Engine, Starting the Engine with Jump Leads, Engine Malfunctions, SCR System Warning Strategy, Deutz DTC Fault Code List, EMR4 |
| Troubleshooting - Hydraulics, a/C, Heating | 730-782 | Trouble Shooting, Hydraulics, Insufficient Hydraulic Power, Troubleshooting Axial Piston Pumps, Troubleshooting Axial Piston Motors, Troubleshooting Table for Hydraulic Components, Troubleshooting, Air Conditioning System, Trouble Shooting Procedure |
| Special Tools | 783-792 | Electrics, Hydraulic System, Tests and Adjustments, Special Tools for Flushing, Special Tools for Oscillating Articulated Joint, Drum, List of Special Tools |
| Index | 793-810 | - |
| Appendix - Circuit Diagrams | 811-1000 | Circuit Diagram 327, Circuit Diagram 522 |
| Appendix - Hydraulic Diagrams | 1001-1026 | Hydraulic Diagram 479, Hydraulic Diagram 480 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Deutz TCD 6.1 L6, Tier 4f | p. 65 |
| Operating weight with ROPS cabin (CECE), BW 219 DH-5 | 19400 kg (42770 lbs) | p. 65 |
| Max. operating weight, BW 219 DH-5 | 22000 kg (48502 lbs) | p. 65 |
| Static linear load, BW 219 DH-5 | 60.1 kg/cm (337 pli) | p. 65 |
| Engine speeds (low idle / ECO / high idle) | 800 / 1800 / 2300 rpm | p. 79 |
| Valve clearance (angle method, intake / exhaust) | 75° ±15° / 120° ±15° | p. 79 |
| Charge pressure relief valve (high idle, travel pump 1) | 25 bar | p. 79 |
| Fuel capacity | 235 litres | p. 92 |
| AdBlue/DEF tank | 20 litres | p. 92 |
| Hydraulic oil capacity | 75 litres, HV 46 (ISO) | p. 92 |
| Engine oil capacity | 15.5 litres | p. 92 |
| Drum half shell bolts torque | 463 Nm (341 ft·lbf) | p. 533 |
Bomag BW 219 DH-5, BW 219 PDH-5, BW 226 DH-5, BW 226 PDH-5 Common Problems This Manual Covers
Engine warning lamp, derate, or repeated SCR/AdBlue faults on a Tier 4f machine
Pull the code and match it against the Deutz DTC fault code list in section 7.4.4, which pairs each EMR4 code with a description and remedy. The same chapter explains the SCR warning strategy so you know how far the machine is from a hard derate.
Manual Section: Troubleshooting - Diesel Engine (Deutz DTC List) p. 670Machine crawls, loses power on grades, or vibration will not come up to full amplitude
Start with the charge circuit: the book specifies 25 bar at the travel pump charge pressure relief valve at high idle, and the hydraulics troubleshooting chapter includes dedicated procedures for axial piston pumps, axial piston motors, and an insufficient hydraulic power diagnostic path.
Manual Section: Troubleshooting - Hydraulics, A/C, Heating p. 730Inconsistent compaction, drum knock, or suspected exciter bearing trouble, especially on padfoot machines worked in wet cohesive soil
The drum chapter gives a full repair overview with dismantling and assembly of the drum and exciter, plus the inspection and maintenance schedule. Keep the exciter housings at their 1.6 liter fill per side, and use the documented exciter simulation mode to test the vibration system.
Manual Section: Machine Assemblies - Drum p. 477Intermittent electrical faults, dead gauges, or functions that drop out over bumps
The electric systems chapter teaches the measuring method, how to read the circuit diagrams, and how to service Deutsch DT and DTM connectors, which are the usual culprits on these machines. Trace the circuit on diagrams 327 and 522 in the appendix.
Manual Section: Electric Systems p. 643Frequently Asked Questions
The display is throwing engine fault codes and the dealer wants a day rate just to plug in. Does this manual decode them?
Yes. Section 7.4.4 carries the full Deutz DTC fault code list for the EMR4 engine controller, laid out as code / description / remedy tables. You can look up exactly what the machine is complaining about before you decide whether it is a sensor, wiring, or something that genuinely needs dealer software. p. 663
My machine is derating and showing AdBlue warnings. Is the SCR system covered?
Covered properly. The troubleshooting chapter explains the SCR warning strategy, so you know which lamp stage means a nag and which one means an actual torque derate is coming. Filling and checking the 20 liter AdBlue tank is in section 6.1.9.2.2, and the EAT exhaust aftertreatment system has its own description in the engine chapter. p. 449
Travel or vibration feels weak. Can I actually test the hydraulics with this book?
Yes, with real numbers. The spec tables give you 25 bar charge pressure at the travel pump relief valve at high idle, and the troubleshooting chapter walks through axial piston pump and motor diagnosis, insufficient hydraulic power, and a component by component fault table. The hydraulic system chapter explains the closed circuit and swash plate principle so the tests make sense. p. 313
I need to pull the drum or swap padfoot shells and scrapers. Are torques and procedures in here?
The drum chapter has a repair overview plus step by step dismantling and assembly, scraper installation for both smooth and padfoot drums, and padfoot shell replacement. Torques are printed, not guessed: 463 Nm on the scraper half shell bolts, 578 Nm on the padfoot shell segment bolts. p. 477
What service specs does it give for routine maintenance?
The capacities table lists 235 l fuel, 15.5 l engine oil, 26 l coolant, 75 l hydraulic oil (HV 46), 20 l AdBlue and 1.6 l per exciter housing. Valve clearance is set by the angle method: intake 75 degrees, exhaust 120 degrees, both plus or minus 15. Engine speeds are 800 low idle, 1800 ECO, 2300 high idle. p. 92
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