Operating instructions

Maintenance instructions

BW 219 D-4 / PD-4

S/N 101 582 10 . . . . S/N 101 582 11 . . . .

Single drum roller

Catalogue number
008 042 01 11/2006

BOMAG machines are products from the wide
Forew ord
range of BOMAG compaction equipment.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your ma-
chine.
This manual comprises:
l Safety regulations
Operating instructions
l
l Maintenance instructions
l Trouble shooting
Using these instructions will
l help you to become familiar with the machine.
l avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
l enhance the reliability of the machine on con-
struction sites,
l prolong the lifetime of the machine,
l reduce repair costs and downtimes.
BOMAG GmbH will not assume liability for the
function of the machine
l if it is handled in a way not complying with the
usual modes of use,
l if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-
age resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and mainte-
nance instructions are part of the machine.
BW 219 D-4 / PD-4
Foreword
You should only operate the machine after you
have been instructed and in compliance with these
instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil En-
gineering Liability Association ”Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors” and all relevant accident prevention regula-
tions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Apart from that, the spare parts catalogue is avail-
able from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines in
soil and asphalt construction.
The above notes do not constitute an extension of
the warranty and liability conditions specified in the
general terms of business of BOMAG GmbH.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
BOMAG 3
Foreword

Please fill in
............................
Machine type (Fig. 1)
............................
Serial-number (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine number (Fig. 3)

i Note Fig. 1
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!

Fig. 2

Fig. 3

4 BOMAG BW 219 D-4 / PD-4

 Table of Contents

Technical Data 9
Safety regulations 13
Indicators and Controls 21
3.1 General notes 24
3.2 Description of indicators and control elements 24
3.3 Display and control elements BTM
34
3.4 Description of indicating and control elements
BTM 36
3.5 Line diagram (EVIB) 38
3.6 Description of line diagram (EVIB) 40
3.7 Bar diagram (EVIB) 41
Operation 43
4.1 General notes 44
4.2 Tests before starting to operate 44
4.3 Disarming the anti-theft protection 45
4.4 Starting the engine 46
4.5 Starting with jump wires 48
4.6 Driving the machine 48
4.7 Switching the vibration on and off 50
4.8 Operating the parking brake, stopping the machine 51
4.9 Shutting the engine down 52
4.10 Emergency exit 53
4.11 Adjusting the steering wheel 53
4.12 Adjusting the seat 54
4.13 Operating the hood 54
4.14 Towing in case of an engine failure 55
4.15 Transport 57
4.16 BTM 05 settings before start-up 59
4.17 Measuring pass with BTM 62
4.18 Finishing compaction of a track 65
4.19 Printing measuring data after completing compaction 66
4.20 Changing the paper roll in the measuring value printer 67
4.21 Changing the printer ribbon in the measuring value printer 68
Maintenance 69
5.1 General notes on maintenance 70
5.2 Fuels and lubricants 71
5.3 Table of fuels and lubricants 74
5.4 Running-in instructions 75
5.5 Maintenance chart 76
5.6 Check the engine oil level 79

BW 219 D-4 / PD-4 BOMAG 5

Table of Contents

5.7 Check, clean the water separator 79

5.8 Check the fuel level 80
5.9 Check the hydraulic oil level 81
5.10 Check the coolant level 81
5.11 Checking the dust separator on the oil bath air filter 82
5.12 Grease the articulated joint 83
5.13 Checking the tire pressure 83
5.14 Clean the cooling fins on engine and hydraulic oil cooler 84
5.15 Check the oil level in the drive axle 85
5.16 Check the oil level in the wheel hubs 85
5.17 Check the oil level in the axle reduction gear 86
5.18 Check the oil level in the drum reduction gear 86
5.19 Check the oil level in the vibration bearings 87
5.20 Changing engine oil and oil filter cartridges 88
5.21 Change the fuel filter cartridge 89
5.22 Draining the sludge from the fuel tank 90
5.23 Service the battery 91
5.24 Change the fuel pre-filter cartridge 92
5.25 Checking, replacing the refrigerant compressor V-belt 93
5.26 Service the air conditioning 94
5.27 Adjusting the valve clearance 97
5.28 Checking / replacing the ribbed V-belt 98
5.29 Check the engine mounts 99
5.30 Checking the engine pillow blocks 100
5.31 Change the oil in the drive axle 100
5.32 Change the oil in the wheel hubs 101
5.33 Changing the oil in the axle reduction gear 102
5.34 Change the oil in the drum reduction gear 103
5.35 Change the oil in the vibration bearings 104
5.36 Tightening the fastening of the axle to the frame 105
5.37 Tighten the wheel nuts 105
5.38 Check the ROPS 106
5.39 Cleaning the oil bath air filter 106
5.40 Changing hydraulic oil and breather filter 107
5.41 Changing the hydraulic oil filter 108
5.42 Change the coolant 109
5.43 Replacing the crank case pressure ventilation valve 110
5.44 Replacing the injector 111
5.45 Service the combustion air filter 112
5.46 Adjust the scrapers 115
5.47 Adjust the parking brake 116
5.48 Changing the tires 117

6 BOMAG BW 219 D-4 / PD-4

 Table of Contents

5.49 Change the fresh air filter in the cabin 117

5.50 Tightening torques 118
5.51 Engine conservation 118
Trouble shooting 119
6.1 General notes 120
6.2 Reading out faults BVC/BTM05 120
6.3 Engine 122
6.4 Reading out fault codes of the electronic engine control (EMR) 125
Cab assembly before initial start-up 127
7.1 Preparations 129
7.2 Cabin assembly 130
7.3 Final function tests and checks 136

BW 219 D-4 / PD-4 BOMAG 7

Table of Contents

8 BOMAG BW 219 D-4 / PD-4

 1 Technical Data

BW 219 D-4 / PD-4 BOMAG 9

 Technical Data

Fig. 4

Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 219 D-4 3255 2300 1600 2288 3022 450 6338 85 85 40 2130
BW 219 PD-4 3255 2300 1500 2288 3022 450 6338 85 85 35 2130

1 BW 219 D-4 BW 219 PD-4

Weights
Operating weight (CECE) kg 19050 19390
with ROPS and cabin
Axle load, drum (CECE) kg 12800 13140
Axle load, wheels (CECE) kg 6250 6250
Static linear load kg/cm 60,1 -
Travel characteristics
Travel speed 1 km/h 0 ... 3 0 ... 3
Travel speed 2 km/h 0 ... 4 0 ... 4
Travel speed 3 km/h 0 ... 7 0 ... 7
Travel speed 4 km/h 0 ... 11 0 ... 11
Max. gradability without/with % 50/48 52/50
vibration (soil dependent)

10 BOMAG BW 219 D-4 / PD-4

 Technical Data

1 BW 219 D-4 BW 219 PD-4

Engine
Engine manufacturer Deutz Deutz
Type TDC 2012 L06 2V TDC 2012 L06 2V
Cooling Water Water
Number of cylinders 6 6
Rated power ISO 3046 kW 150 150
Rated speed rpm 2200 2200
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Vibration
Vibrating drum
Drive system hydrostatic hydrostatic
Frequency 1 Hz 31 31
Frequency 2 Hz 26 26
Amplitude 1 mm 1,1 1,1
Amplitude 2 mm 2,0 1,7
Tires
Tire size 23.1-26/12 TL R3 23.1-26/12 TL R1
Air pressure bar 1,5 1,5
Filling capacities
Engine Litres 23,5 23,5
Coolant Litres 16 16
Fuel Litres 340 340
Hydraulic oil Litres 60 60
1 The right for technical modifications remains reserved

BW 219 D-4 / PD-4 BOMAG 11

Technical Data

The following noise and vibration data acc. to

- EC Machine Regulation edition (98/37/EC) and
- Noise Emission Regulation 2000/14/EC
were determined at nominal speed of the drive engine and with vibration running. The machine was
standing on an elastic base.
During operation these values may vary because of the existing operating conditions.
Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
sound pressure level at the work place of the operator (with cabin):
LpA = 78 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is
guaranteed sound capacity level of the machine:
LwA = 108 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO
11204 for sound pressure level (LpA) at the place of the operator.
Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined in accordance with ISO 7096 is γ ≤0.5 m/sec2.
Hand-arm vibration values
The weighted effective acceleration value determined in accordance with EN 500/ISO 5349 , is γ ≤2.5 m/
sec2.

12 BOMAG BW 219 D-4 / PD-4

 2 Safety regulations

BW 219 D-4 / PD-4 BOMAG 13

Safety regulations
General
This BOMAG machine is built in accordance
with the latest technical standard and the valid
technical rules and regulations. There is, how-
ever, a risk of danger for persons and property
if:
l the machine is used for purposes other than
those it is intended for
l the machine is operated by untrained person-
nel
the machine is modified or converted in an un-
l
professional way
the applicable safety regulations are not ob-
l
served.
Each person involved in operation, mainte-
nance and repair of the machine must there-
fore read and apply these safety regulations.
This should be confirmed by obtaining the sig-
natures of the customer, if necessary.
Furthermore the following regulations and instruc-
tions are obviously also valid:
l applicable accident prevention instructions
generally acknowledged safety and road traffic
l
regulations
l country specific safety regulations. It is the
duty of the operator to know and observe
these regulations. This applies also for local
regulations and the regulations for various
types of manual work. If the recommendations
in this manual differ from the regulations valid
in your country, you must strictly observe the
regulations in your country.
Intended use
This machine must only be used for:
l compaction of bituminous materials, e.g. road
surface layers. (AC and AD machines only)
l medium and heavy compaction tasks in earth
work (road sub-bases)
l This machine must only be operated with fully
functional safety equipment.
l The machine should be checked by an expert
once every year.
14
Unintended use
Dangers may, however, arise from the machine if
it is used by untrained personnel in an unprofes-
sional way or if it is used for purposes other than
those mentioned in these instructions.
Do not work with vibration on hard concrete, on a
cured concrete layer or heavily frozen ground.
Starting and operation of the machine in an explo-
sive environment is prohibited.
Who is allowed to work with the ma-
chine?
The machine must only be operated by trained
and authorized persons which are at least 18
years of age. The responsibilities for the operation
of the machine must be clearly specified and com-
plied with.
Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
the machine.
Maintenance and repair tasks require specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Conversions and alterations to the ma-
chine
Unauthorized conversions to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
pressly clear that we have not tested or authorized
any original parts or special equipment not sup-
plied by us. The installation and/or use of such
products can impair the active and/or passive driv-
ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
Safety notes in the operating and main-
tenance instructions:
Danger
!
Sections marked like this point out possible
dangers for persons.
BOMAG BW 219 D-4 / PD-4

! Caution
Sections marked like this point out possible
dangers for the machine or for parts of the ma-
chine.
i Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
Observe all environment protection regula-
tions.
Information and safety stickers/decals
on the machine
Keep stickers/decals complete (see spare parts
catalogue) and fully legible and observe their
meaning.
Replace damaged or illegible stickers/decals im-
mediately.
Loading the machine
Use only strong and stable loading ramps. The
ramp inclination must be lower than the gradability
of the machine.
Secure the machine against turning over or slip-
ping off.
Secure the machine on the transport vehicle
against rolling off, slipping and turning over.
Persons are highly endangered if
they step or stand under loads being lifted
l
l they remain in the drive range of the machine
during a demonstration or during loading.
The machine must not swing about when lifted off
the ground.
Use only safe lifting gear of sufficient load bearing
capacity.
Attach the lifting gear only to the specified lifting
points.
BW 219 D-4 / PD-4 BOMAG
Safety regulations
Towing the machine
Since the machine is not fitted with a towing hitch,
the machine cannot be towed with a tow bar.
If the machine has to be towed urgently out of the
danger zone because of other risks, this must only
be done on level ground or uphill using chains and
ropes. For this purpose towing ropes of sufficient
tensile strength must be fastened on the lifting
eyes.
After releasing the brake the machine can only be
braked by the towing vehicle.
Before releasing the brake block the machine with
chocks to prevent unintended rolling.
Checking the Roll Over Protection
Structure (ROPS)
i Note
On machines with cabin the ROPS is an integral
part of the cabin.
The machine frame must not be distorted, bent or
cracked in the area of the ROPS fastening points.
The ROPS must not show any signs of corrosion,
damage, hairline cracks or open fractures.
The ROPS must not rattle about during driving.
This would mean that it is not properly fastened.
All bolted connections must be in accordance with
the prescribed specifications and correctly tight-
ened (observe the tightening torque values).
Screws and nuts must not be damaged, bent or
deformed.
With the cabin installed check also the condition of
the cabin mounts (rubber elements and screws).
Neither must any additional parts be welded or
bolted on, nor must any holes be drilled without the
permission of the manufacturer, since this may im-
pair the strength of the structure.
Starting the machine
Before starting
Operation of the machine is only permitted when
sitting in the operator's seat.
Use only machines which have been properly
serviced at regular intervals.
15
Safety regulations
Become acquainted with the equipment, the con-
trol elements, the working mode of the machine
and the area you will be working in.
Use your personal protective outfit (hard hat, safe-
ty boots etc.).
Check before mounting the machine if:
l there are persons or obstructions beside or
under the machine
l the machine is free of any oily and combustible
material
l all handrails, steps and platforms are free of
grease, oils, fuels, dirt, snow and ice
l the engine compartment hood is closed and
locked
To climb onto the machine use steps and hand-
rails.
Check before starting, whether:
the machine shows any obvious defects
l
l all protective devices are properly secured in
their place
l steering, brakes, control elements, lighting
and warning horn are in order
the seat is correctly adjusted
l
l the mirrors (if available) are clean and correct-
ly adjusted.
Do not start the machine if any gauges, control
lights or controls are defective.
Do not take any loose objects with you or fasten
them to the machine.
On machines with ROPS you should always wear
your seat belt!
Starting
Start and operate the machine only from the oper-
ator's seat
For starting set all control levers to "neutral posi-
tion".
Do not use any starting aids such as Start Pilot or
ether.
After starting check all gauges.
Starting with jump leads
Connect plus with plus and minus with minus
(ground cable) - always connect the ground cable
last and disconnect it first! Wrong connections
may cause severe damage in the electric system.
16 BOMAG
Never start the engine by bridging the electrical
connections on the starter, because the machine
would probably start to move immediately.
Starting in closed rooms
Exhaust gases are toxic! Always ensure an ade-
quate supply of fresh air when starting in closed
rooms!
Driving the machine
Persons in the endangered area
If the machine has turned over and the cabin door
is jammed, use the right hand cabin window as an
emergency exit.
Before starting or resuming work and especially
when driving backwards, check that there are no
persons or obstructions in the endangered area.
If necessary give warning signals. Stop work im-
mediately if persons remain in the danger area de-
spite the warning.
Do not step or stand into the articulation area of
the machine while the engine is running. Danger of
squashing!
Driving
In events of emergency actuate the emergency
stop switch immediately. Do not use the emergen-
cy stop push button as service brake.
Restart the machine only after the danger, that has
caused the actuation of the emergency stop, has
been eliminated.
If the machine has come in contact with high-volt-
age power lines:
l do not leave the operator's stand
l warn others from coming too close to the ma-
chine or touching it
l if possible drive the machine out of the danger
zone
l have the power shut off.
Operate the machine only from the operator's
seat.
Keep the cabin doors closed.
Do not adjust the seat while driving.
Do not climb onto or off the machine while driving.
Change the travel direction only while the machine
is standing.
BW 219 D-4 / PD-4

Do not use the machine to transport persons.
Stop the machine if you notice unusual noises or
the development of smoke. Investigate the cause
and have the fault corrected.
Keep a sufficient distance to excavations and em-
bankments and make sure that you work does not
impair the stability of the machine.
Do not work with vibration on hard concrete, on a
cured concrete layer or heavily frozen ground.
When passing under flyovers, bridges, tunnels,
electric power lines etc. keep a sufficient distance.
Driving on slopes and gradients
Do not drive up and down gradients, which exceed
the max. gradability of the machine.
On lopes always drive directly up or down. Change
to the lower speed range before approaching the
slope.
Wet and loose soils reduce the ground adhesion of
the machine and inclinations and slopes consider-
ably. Higher risk of accident!
Behaviour in traffic
Match the speed of the machine to the working
conditions.
Always allow loaded transport vehicles to pass.
Switch the lights on when the visibility is poor.
Keep clear of edges and embankments.
Check the effect of vibration
When compacting with vibration check the effect
of the vibration on nearby buildings and under-
ground supply lines (gas, water, sewage, electric
power supply), stop vibratory compaction if neces-
sary.
Do not work with vibration on hard (frozen, con-
crete) ground. Risk of bearing damage!
Parking the machine
Park the machine on level and firm ground.
Before leaving the machine:
l straighten the articulated joint to allow easy
access to and from the machine.
return the travel lever to neutral position
l
l apply the parking brake
l shut the engine down and pull the ignition key
out.
BW 219 D-4 / PD-4
Safety regulations
l lock the cabin
l secure the machine against unauthorized use.
Do not jump off the machine, use access steps
and hand rails.
Always secure parked machines, which could be
in the way, with appropriate measures.
Parking on slopes and gradients
Secure the machine against rolling, place metal
chocks in front of and behind the drums.
Filling the fuel tank
Do not inhale fuel fumes.
Refuel only after shutting the engine and the aux-
iliary heater down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Wipe off spilled fuel. Keep fuel free of dirt and wa-
ter.
Leaking fuel tanks can cause explosions. Ensure
tight fit of the fuel tank filling cover, replace it if nec-
essary.
Fire protection measures
Make yourself acquainted with the location and the
operation of fire extinguishers. Observe fire warn-
ing and fire fighting installations.
Maintenance
Observe the maintenance tasks described in the
operating and maintenance instructions, including
the exchange of parts.
For service and repair work in the engine compart-
ment support the engine compartment hood.
Maintenance work must only be carried out by
qualified and authorized personnel.
When performing maintenance work above body
height use the access steps on the machine or any
other safe ladders and working platforms. Do not
use machine parts as access steps.
Keep unauthorized persons away from the ma-
chine.
Do not perform maintenance work with the ma-
chine driving or the engine running.
BOMAG 17
Safety regulations
Park the machine on horizontal, level and stable
ground.
Pull the key out of the ignition switch.
Lock the articulated joint with the articulation lock.
Working on hydraulic lines
Always relieve the pressure in the hydraulic circuit
before working on hydraulic lines. Hydraulic oil es-
caping under pressure may penetrate through the
skin and cause severe injury. In case of being in-
jured by hydraulic oil you should immediately seek
medical advice, as otherwise this may lead to se-
rious infections.
When adjusting the hydraulic system do not stand
behind or in front of the drum/wheels.
Do not change the setting of high pressure relief
valves.
Drain hydraulic oil at operating temperature - dan-
ger of scalding!
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always catch and dispose of biological hydraulic
oils separately.
Do not start the engine after draining off the hy-
draulic oil.
Once all work is completed (with the system de-
pressurized!) check all connections and fittings for
tight and leak-free fit.
Changing hydraulic hoses
All hydraulic hoses must be inspected visually at
regular intervals.
Hydraulic hoses must be changed immediately if:
l the outer layer is worn down to the metal lining
(e.g. chafing, cuts, cracks)
l embrittlement of the outer layer (development
of cracks in the hose material)
deformation under pressurized and depressu-
l
rized condition, which are not in accordance
with the normal shape of the hydraulic hose
deformation in bends, e.g, squeezes, kinks,
l
layer separation, formation of blisters
l leakages.
l non-observance of the installation require-
ments
l separation of the hydraulic hose from the fit-
ting
18 BOMAG
l corrosion of the fitting, which impairs the func-
tion and the strength.
l Do not mix up hoses by mistake.
l damage or deformation of the fitting, which im-
pairs the function and strength of the hose/
hose connection.
Only genuine BOMAG hydraulic hoses ensure
that the correct type of hose (pressure range) is
used at the right place.
Working on the engine
Shut the engine down before opening the engine
compartment hood.
Drain the engine oil at operating temperature -
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oily materials in a sep-
arate, specially marked container and dispose of
environmentally.
Do not leave any tools or other objects, which
could cause damage, in the engine compartment.
Idle speed and full load speed must not be
changed, since this would have a negative effect
on the exhaust gas values and cause damage to
engine and drive.
Turbo chargers work with high speeds and high
temperatures. Keep hands, tools and materials
away from the intake and outlet openings of the
turbo charger and do not touch any hot surfaces.
Check and replace the coolant only when the en-
gine is cold.
Catch running out coolant and dispose of environ-
mentally.
Working on electrical equipment
Before working on electrical equipment disconnect
the battery and cover it with insulating material.
Do not use any fuses with higher ampere ratings
or repair a fuse with a piece of wire. Fire hazard!
Always disconnect the battery before starting to
wled on the machine.
Working on the battery
When working on the battery do not smoke, do not
use open fire.
BW 219 D-4 / PD-4
 Safety regulations

Do not let acid come in contact with skin and terials to the direct water jet, but cover them be-
clothes. If being injured by acid flush off with clear forehand.
water and seek for medical advice. l Do not guide the water jet into the exhaust or
Metal objects (e.g. tools, rings, wrist watches) into the air filter.
must not contact the battery poles - danger of
short circuit and burns! After maintenance work
When recharging maintenance free batteries re- Reinstall all protective devices after completing
move the plugs to avoid the accumulation of explo- the maintenance work.
sive gases.
When using an external battery to start the ma- Repair
chine follow the respective instructions. Attach a warning tag to the steering wheel if the
Dispose of old batteries environmentally. machine is defective.
Switch the charging current off before removing Repairs must only be performed by qualified per-
the charge clamps. sons who have been instructed for this purpose.
Ensure good ventilation, especially when charging Use our repair instructions.
the battery in a closed room. Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
Working on the fuel system in closed rooms!
Do not inhale fuel fumes. Test
No open fire, do not smoke, do not spill any fuel. Depending on the type of application and the op-
Catch running out fuel, do not let it seep into the erating conditions vibratory equipment has to be
ground and dispose of environmentally. examined by a specialist whenever required, but
at least once every year.
Working on wheels and tires
Explosion like bursting of tires and parts of rims
and tires can cause severe or even deadly injuries.
Assemble tires only with the appropriate knowl-
edge and tools. If necessary have the tires assem-
bled in a special workshop.
Ensure correct tire pressure and do not exceed the
highest specified pressure.
Check wheels and tires every day for specified
pressure, cuts, bulges, damaged wheel rims,
missing wheel studs and nuts. Do not drive with
damaged tires or wheels.
Anti-stick emulsions for tires must only be mixed
using water and concentrated anti-stick agent ac-
cording to the specifications of the manufacturer of
the anti-stick agent. Observe the regulations for
the protection of the environment.
Cleaning
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other combustible sub-
stances for cleaning purposes.
When using steam cleaning equipment do not
subject electrical components and insulating ma-

BW 219 D-4 / PD-4 BOMAG 19

Safety regulations

20 BOMAG BW 219 D-4 / PD-4

 3 Indicators and Controls

BW 219 D-4 / PD-4 BOMAG 21

 Indicators and Controls

Fig. 5

22 BOMAG BW 219 D-4 / PD-4


1 Ignition switch
2 Instrument cluster
3 Vent for heating and ventilation, driver
4 Vent for heating and ventilation, footwell
5 Push button vibration
6 Travel lever
7 Rotary switch vibration, high/low frequency
8 Potentiometer for speed limitation control
9 Emergency stop push button
10 Push button for warning horn
BW 219 D-4 / PD-4
Indicators and Controls
11 Rotary momentary contact switch for engine
speed
12 Rotary switch for direction indicators left/right1
13 Rotary switch for hazard light system 1
14 Rotary switch for light system (StVZO)1
15 Rotary switch for working lights 1
16 Steering wheel adjustment lever
17 Push button engine diagnose
1 Optional equipment
BOMAG 23
Indicators and Controls

3.1 General notes 3.2 Description of indicators

Please read this section thoroughly before operat-
and control elements
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise de-
scriptions of the individual operating steps.

Fig. 6
No. 1 = Ignition switch
Position "P"/"0" = ignition off, the key can be
pulled out, engine not running.
Position "I" = ignition on, all control and
warning lights on the fault
monitoring board light up for a
moment. The lighting can be
switched on.

i Note
The engine can only be started when the travel le-
ver is in braking position.
The ignition switch is provided with a lock against
repetitive starting. To repeat the starting proce-
dure you must first turn the ignition switch back to
"0"-position.
Position "II" = turn further against spring
pressure, the engine starts, re-
turn the ignition key to position
"I" when the engine starts

!Caution
Run the engine warm for a short while before
starting to work. Do not let the engine run at
idling speed for longer than 10 minutes.
Do not shut the engine down all of a sudden
from full speed, but let it idle for a while for
temperature equalization.

24 BOMAG BW 219 D-4 / PD-4


Fig. 7
No. 2 = Instrument cluster
i Note
With the ignition switch in position I all gauges and
instruments are switched on for 3 seconds.
a red = flashes when the engine overheats,
the warning buzzer sounds, the en-
gine is shut down after 2 minutes.
Switch off vibration, run engine with
idle speed or shut down engine if
necessary, clean engine oil cooler
and radiator, if necessary repair en-
gine.
b red = flashes if engine oil pressure too low,
engine is shut down after 10 sec-
onds. Check engine oil level, repair
the engine if necessary.
c yellow = Engine air filter, lights if air filter car-
tridge is soiled, clean or replace if
necessary.
d yellow = Charge control light, lights if battery is
not being charged.
Check V-belt, if necessary repair the
generator.
e yellow = lights if the hydraulic oil filter is con-
taminated, the engine is shut down
after 2 minutes.
Check hydraulic system, replace hy-
draulic oil filter.
f yellow = The seat occupation monitoring sys-
tem lights when the seat is not occu-
pied. If the machine is travelling the
warning buzzer will sound, engine is
shut down after 4 seconds.
BW 219 D-4 / PD-4
Indicators and Controls
g red = Parking brake, with lever shifted to
parking brake position, with driver’s
seat unoccupied.
h green = Direction indicator, flashes when the
direction indicator switch is actuated.
i yellow = Water separator in fuel pre-cleaner.
Lights when the water proportion in
the transparent section of the fuel fil-
ter reaches the contacts.
j red = flashes, when the coolant provision
(filling level) is too low, the engine is
shut down after 2 minutes.
k yellow = not used
l red = Hazard light, flashes when the haz-
ard light is activated
m = Operating hour meter, counts the op-
erating hours while the engine is run-
ning. All maintenance work must be
performed according to the indicated
operating hours.
n = Fuel tank filling level
When falling below the lowest filling
level the last green LED will light and
the red LED will additionally come on.
When the fuel tank is empty only the
red LED will flash.
No. 3 = Vents for air conditioning, heating
and ventilation, driver
No. 4 = Vents for air conditioning, heating
and ventilation, footwell1
1 Optional equipment
BOMAG 25
 Indicators and Controls

Fig. 8 Fig. 10
No. 5 = Push button for vibration No. 7 = Rotary switch for vibration
l Select or actuate the frequencies with the vi- Position "Mid-
bration selector switch. dle" = Vibration off
l Switch the vibration on or off by pressing the Position "Right" = low amplitude, high frequency
push button. Position "Left" = high amplitude, low frequency

Fig. 9 Fig. 11
No. 6 = Travel lever No. 8 = Rotary switch for speed ranges with-
Position "mid- out ASC
dle" = Braking position service brake Position "turtle" = Working speed range on level
Position "middle, ground
right" = Parking brake, to start the en- Position "Drum"= if the drum starts to slip
gine Position
Position "I" = Forward travel "Wheels" = if the wheels are slipping
Position "II" = Backwards travel Position "rab-
bit" = Transport speed range, e.g. to
i Note drive to the work location
If the engine speed drops under load when driving
on steep gradients, take the travel lever slightly
back towards neutral. This relieves the hydraulic
system and reduces the load on the diesel engine.

26 BOMAG BW 219 D-4 / PD-4

 Indicators and Controls

Fig. 12 Fig. 13
No. 9 = Emergency stop switch No. 10 = Push button for warning horn
The engine will be shut down and the brake will
close.

! Danger
Danger of accident!
Operate only in emergency situations during
operation, do not use as a service brake.
The machine should only be started again after
the danger, that caused the actuation of the
emergency stop switch, has been removed.
operate = push the button completely
down, it will automatically lock
in end position. Fig. 14
unlock = turn the button clockwise and No. 11 = Rotary momentary contact switch for
release it. engine speed
to drive = move the travel lever first to Electric engine speed adjustment
braking position, then start the Position left = Idle speed position
engine and choose the travel
direction.
i Note
For safety reasons the travel system of the ma- Normal position for engine start.
chine will only be enabled after the travel lever has
been shifted back to braking position. Position right = Full throttle position, operating
position for driving and vibra-
tion

Caution
!

Always drive and vibrate with max. engine

speed! Control the travel speed with the travel
lever.

BW 219 D-4 / PD-4 BOMAG 27

Indicators and Controls

Fig. 15 Fig. 17
No. 12 = Rotary switch for direction indicators No. 14 = Rotary switch for light system (StV-
left / right1 ZO)3
Position "mid- Position "left" = Light off
dle" = Direction indicators disabled Position "mid-
Position "left or dle" = Sidelights on, with ignition
right" = Front and rear direction indica- switch in position "I" or "P"
tors for the corresponding side Position "right" = Travel light on, with ignition
of the machine light up, the switch in position "I".
control light in the instrument
cluster flashes.

Fig. 18
Fig. 16
No. 15 = Rotary switch for working lights4
No. 13 = Rotary switch for hazard light system Position "left" = Light off
2 Position "right" = Working lights on, with ignition
Position "left" = Hazard light switched off, con- switch in position "I".
trol lights off.
Position "right" = Hazard light switched on, con-
trol light 1 in instrument cluster
lights up.

1 Optional equipment 3 Optional equipment

2 Optional equipment 4 Optional equipment

28 BOMAG BW 219 D-4 / PD-4

 Indicators and Controls

In this case the engine should be shut down,

as soon as this is possible without risk.
The fault light in the push button can have the fol-
lowing meanings:
l Shut-down request for the operator.

Caution
!

Loss of warranty if disregarded!

l Automatic engine shut-down after a short pre-
warning time, possibly in connection with a re-
starting prevention.
Fig. 19 l Forced engine operation at low idle speed to
No. 16 = Lever, steering wheel adjustment cool the engine, possible in connection with
automatic shut-down.
! Danger l Start prevention.
Danger of accident!
Do not adjust the steering wheel while driving. i Note
pull up = adjust height of steering wheel The light will go out after the fault has been recti-
fied. With some faults it is necessary to switch off
press down = adjust inclination of steering the ignition, then wait for 30 seconds before
wheel switching the ignition back on.
l The diagnostic button provides the possibility
to read out existing faults in form of flashing
codes.

i Note
Reading out fault codes, see section "Trouble
Shooting".

Fig. 20
No. 17 = Push button, engine diagnose
Under certain fault conditions the electronic en-
gine control (EMR) can protect the engine against
damage by monitoring important values and the
correct function during operation.
Depending on the severity of the fault the engine
may continue its operation with certain restrictions, Fig. 21
with the fault warning light permanently on, or the
fault warning light will be flashing to indicate a se- No. 18 = Lever, swivelling of driver’s seat
vere system fault.
Danger
!

Danger of accident!

BW 219 D-4 / PD-4 BOMAG 29

Indicators and Controls

Always lock the driver’s seat in one of the lock- F10, 10A = Rear parking light, right1
ing positions while driving. F11, 15A = Headlight, StVZO1
Do not swivel the driver’s seat while driving. F13, 30A = Starting
swivel = Stop the machine and apply F14, 15A = Engine solenoid
the parking brake. Pull the le-
ver up and swivel the driver’s F18, 10A = Working headlight, relay 1
seat to the desired position. F19, 15A = Working headlight, front left1
F22, 15A = Working headlight, rear1
i Note F23, 10A = Warning horn
Swivelling angle max. 20° to either side. F24, 10A = Monitoring, gauges
F25, 10A = Solenoid valve brake/travel
F39, 15A = Cabin1
F70, 15A = Indicator1
F105, 20A = Engine speed control

Danger
!

Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.

Fig. 22
No. 19 = 2-pole socket
Current only with the ignition switch in position "I"
or when the engine is running.

Fig. 24
a = toggle switch for flashing beacon
b = toggle switch for front windscreen wiper/
washer
up = windscreen wiper moves to
Fig. 23 end position and stops.
No. 20 = Fuses in electric installation box down = Switches on wiping of front
F03, 15A = Vibration windscreen.
F05, 15A = Socket Push button = Front windscreen is sprayed
during wiping.
F07, 15A = Hazard light1
F09, 10A = Rear parking light, left1
1 Optional equipment

30 BOMAG BW 219 D-4 / PD-4

 Indicators and Controls

c = toggle switch for rear windscreen wiper/

washer
up = windscreen wiper moves to
end position and stops.
down = Switches on wiping of rear
windscreen.
Push button = Rear windscreen is sprayed
during wiping.
d = toggle switch for rear windscreen heating

Fig. 26
No. 22 = Control panel for ventilator, air condi-
tioning, heating
e = Rotary switch for cabin ventilator
Position ’’Off“ = cabin ventilator switched off.
Position 1, 2 and
3 = ventilator stages of different
strengths
f = Push button for air conditioning1
Fig. 25 press = air conditioning switched on.
No. 21 = Fuse box, cabin
i Note
! Danger The lights above the push buttons light up.
Fire hazard! With rotary switch (g) the air conditioning unit can
Do not use fuses with higher ampere ratings be regulated within the blue range.
and do not bridge fuses. press again = air conditioning switched off.
(1), 15A = (F43) wiper/washer, rear
(2), 15A = (F44) wiper/washer, front i Note
(3), 10A = (F130) relay for rear windscreen The light goes out.
heating, reading light g = Rotary switch for cabin heater (tempera-
(4), 25A = (F31) cabin fan ture selector switch)
(5), 10A = (F41) flashing beacon Position ’’Off“ = cabin heater switched off.
(6), 15A = (F144) cab socket Position blue
(7), 15A = (F143) rear windscreen heating range = temperature selection for air
(8), 5A = (F42) potential 30, cab light conditioning.
Position red
range = Temperature selection for cab-
in heater.

1 Optional equipment

BW 219 D-4 / PD-4 BOMAG 31

Indicators and Controls

Fig. 27 Fig. 29
No. 23 = Cabin light No. 25 = Anti-theft protection1
i = reading and dashboard light prevents unauthorized starting of the engine.
Keypad = Input of user and service code (main-
j = toggle switch for reading and dashboard tenance).
light
k = toggle switch for cabin light i Note
l = cabin light Enter the user code with the ignition switched

off!
After entering the user code you should start the
engine within 30 seconds.
After entering the service code the anti-theft pro-
tection remains switched off.
red LED
display
flashes
slowly = anti-theft protection active.
LED dis-
play lights
green = every time a digit of the user or serv-
ice code is entered.
Fig. 28
No. 24 = Main fuse for battery i Note
125A = (F00) After shutting down the engine it can be restarted
within a period of 12 seconds, in any other case
i Note the user code needs to be entered again.
Battery with main fuse is located in the engine
compartment

1 Optional equipment

32 BOMAG BW 219 D-4 / PD-4

 Indicators and Controls

Fig. 30
No. 26 = EVIBdisplay1
is a compaction measuring unit for continuous dis-
play of the load bearing characteristics (MN/m2)
during the compacting pass.
EVIB value
Increase = higher load bearing capacity
Constant = end of compaction

i Note
Modular upgrading to BTM plus / BTM prof and/or
BCM 05 possible.

1 Optional equipment

BW 219 D-4 / PD-4 BOMAG 33

Indicators and Controls

3.3 Display and control ele-

ments BTM1

1 Optional equipment

Fig. 31

34 BOMAG BW 219 D-4 / PD-4

 Indicators and Controls

1 EVIBdisplay 11 not used

2 Display for jump operation 12 not used
3 Push button F5 START 13 not used
4 Push button F6 STOP 14 not used
5 Push button F7 PRINT (only BTM prof) 15 not used
6 Push button F8 DELETE 16 not used
7 Vibration frequency display 17 Travel speed display
8 Rotary switch setting of nominal value 18 Amplitude display
9 Push button F14 nominal value increase 19 Printer for measuring values (only BTM prof)
10 Push button F13 nominal value decrease 20 Fault light

BW 219 D-4 / PD-4 BOMAG 35

Indicators and Controls

To print out the measuring data saved during the

3.4 Description of indicating last pass press button F7 PRINT.
and control elements short actuation = Line diagram
BTM long actuation ≥5
sec. = Bar chart
Control field F7 goes out and the measuring value
i Note printer starts to print out measuring data.
The BTM plus can be upgraded to BTM prof and/
or BCM 05. i Note
After the printing process has finished any amount
Surface covering dynamic compaction of diagrams can be printed out by pressing the
control (SCCC) same button F7 (PRINT).
The BOMAG compaction measuring systems No. 6 = Button F8 DELETE
EVIB-meter (BEM) and Terrameter BTM plus/prof press = All stored faults are deleted.
are integrated in the work process for continuous
and surface covering evaluation of compaction
and load bearing capacity of soils and non-bonded ! Caution
bearing courses. If the increase of the measuring value is to be
The EVIB-value, designated as vibration modulus, calculated on a track press button F8 DELETE
with the unit MN/m2 is directly linked with the de- only when changing the track.
formation modules EV1 or EV2 known from the No. 7 = Frequency display
plate load test acc. to DIN 18134.
No. 1 = EVIB -display with vibration switched on this instrument shows
the frequency (rotating speed) of the exciter shaft.
Display of the dynamic soil stiffness in MN/m2. No. 8 = Rotary switch P3 pre-setting of nomi-
No. 2 = Display for jump operation nal values
yellow The desired maximum dynamic stiffness modulus
symbol = Drum jumps EVIB [MN/m2] can be pre-selected in 6 stages (45,
red 80, 100, 120,150 and Max.).
symbol = Drum jumps excessively or The selected value is shown on the screen in field
tumbles „P3“
Select a smaller amplitude, if necessary! No. 9 = Button F14 increase of nominal value
No. 3 = Button F5 START With each actuation of the button the presetting is
press = Starts recording of measuring raised by one stage.
values The selected value is shown on the screen in field
Control field "F5" flashes green on the screen. „P3“
No. 4 = Button F6 STOP No. 10 = Button F13 reduction of nominal val-
press = Stops recording of measuring ue
values With each actuation of the button the presetting is
The green control field "F7" PRINT on the screen reduced by one stage.
lights up.

i Note
Depending on the measuring result the green con-
trol field "F5" CONTINUE or the red control field
"F6" FINISHED will light up.
No. 5 = Button F 7 Print1 1 only with BTM prof

36 BOMAG BW 219 D-4 / PD-4

 Indicators and Controls

The selected value is shown on the screen in field

„P3“
No. 11 = Button F11 is not used
No. 12 = Button F12 is not used
No. 13 = Button F11 is not used
No. 14 = Rotary switch P1 is not used
No. 15 = Button F10 is not used
No. 16 = Button F9 is not used
No. 17 = Travel speed display
Shows the travel speed of the machine.
No. 18 = Amplitude display
This gauge shows the current vertical amplitude of
the machine.
No. 19 = Printer for measuring values*
To print out the measuring data saved during the
last pass press button (7) "PRINT".
No. 20 = Fault light
Infor the BOMAG After Sales Service if it lights up.

BW 219 D-4 / PD-4 BOMAG 37

Indicators and Controls

3.5 Line diagram1 (EVIB)

1 only BTM prof

Fig. 32

38 BOMAG BW 219 D-4 / PD-4

 Indicators and Controls

1 Pass-No. 11 EVIB-change
2 Travel direction 12 Medium frequency
3 Machine equipment (BTM 05/BTM-E) 13 Mean travel speed
4 Software status of the measuring equipment 14 Track length
5 Machine number 15 Raster division in longitudinal direction
6 Machine type 16 Marking (thick line) excessive jumping, tum-
7 Amplitude bling of the drum
8 Maxiumum EVIB value 17 Longitudinal raster line
9 Miniumum EVIB value 18 Measuring value raster line
10 Mean EVIB-value 19 Diagram line
20 Marking (thin line) jumping of the drum

BW 219 D-4 / PD-4 BOMAG 39

Indicators and Controls

Graduation of the measuring track (track length in

3.6 Description of line diagram printout) into fixed sections.
1 (E ) No. 16 = Marking of jump information
VIB
Indicates excessive jumping/tumbling of the drum
No. 1 = Pass on the marked track section (thick line).
Total number of measured passes on this track.
No. 2 = Travel direction i Note
Select a smaller amplitude, if necessary!
No. 3 = Machine equipment
No. 4 = Software status of the measuring No. 17 = Longitudinal raster line
equipment No. 18 = Measuring value raster line
No. 5 = Machine number No. 19 = Diagram line
No. 6 = Machine type Shows the EVIB-value at any point of the rolled
No. 7 = Amplitude track. The raster line enables the location related
This gauge shows the vertical amplitude the ma- assignment of the EVIB-value and the location of a
chine has worked with on this track. fault (over or under compaction).
No. 8 = Maxiumum EVIB value No. 20 = Marking of jump information
No. 9 = Miniumum EVIB value Indicates jumping of the drum on the marked track
section (thin line).
No. 10 = Mean EVIB -value
This gauge shows the vertical amplitude the ma-
chine is currently working with on this track.
No. 11 = EVIB -change
EVIB-change in %. This always refers to the previ-
ous pass in the same direction of travel.
No. 12 = Medium frequency
No. 13 = Mean travel speed
shows the mean value of speed driven during this
pass.

i Note
Always shows the same travel speed in order to
avoid a falsification of the measuring results.
No. 14 = Track length
Measured track length between START and
STOP.
No. 15 = Raster division in longitudinal direc-
tion
Is used to pinpoint individual measuring values on
the measuring curve.

i Note
The raster lines mark measuring track sections of
5 m length.

1 only BTM prof

40 BOMAG BW 219 D-4 / PD-4

 Indicators and Controls

3.7 Bar diagram1 (EVIB)

The bar diagram differs from the line diagram only
by the graphic representation of measuring val-
ues. In the bar diagram the mean values of 5 m
sections are shown as bars. In addition, the EVIB
changes of the individual 5 m sections are speci-
fied in percent after the second pass in the same
travel direction.

1 only BTM prof

BW 219 D-4 / PD-4 BOMAG 41

Indicators and Controls

42 BOMAG BW 219 D-4 / PD-4

 4 Operation

BW 219 D-4 / PD-4 BOMAG 43

Operation
4.1 General notes
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
you are not yet fully familiar with the indicators and
control elements of the machine.
All indicators and control elements are described
in detail in this chapter.
44
4.2 Tests before starting to op-
erate
The following tests must be performed before
each work day or before a longer work period.
!Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of these operating and mainte-
nance instructions!
l Park the machine on level ground.
Check:
l Fuel tank and fuel lines for leaks
l Bolted connections for tight fit
l Function of the steering
l Check the machine for cleanliness and dam-
age
l availability of the appropriate operating and
maintenance instructions,
l check if the machine has been properly serv-
iced.
i Note
For a description of the following work refer to the
section "maintenance every 10 operating hours"
l engine oil level
i Note
Hydraulic systems, which are filled with Panolin
HLP Synth. 46, the same oil must be used for fill-
ing up. In case of any other ester based oil consult
the lubrication service department of the respec-
tive oil manufacturer.
l Check the hydraulic oil level, top up if neces-
sary.
l Check the coolant level, top up if necessary.
Danger
!
Fire hazard!
Do not refuel in closed rooms
l Check the fuel level, top up if necessary.
BOMAG BW 219 D-4 / PD-4
 Operation

Check water separator in the fuel system,

4.3 Disarming the anti-theft1
l
drain if necessary.
l Adjust the scrapers if necessary protection
l Tire pressure. Pressure see technical data.
Before starting the engine the anti-theft protection
Caution must be disarmed by entering a code while the ig-
!
nition is still off.
Ensure equal pressure in both tires.
! Caution
If the anti-theft protection is disarmed with the
ignition switched on, the diesel engine will run
in limp home program!

Fig. 33

i Note
With the anti-theft protection armed light emitting
diode a (Fig. 33) flashes slowly in red.
l Slowly enter the six-digit user code while the
ignition is switched off.

i Note
With each digit of the code the light emitting diode
lights green.
l Press the confirmation key ’’VAL“.
l The anti-theft protection is now disarmed and
the engine must be started within the next 30
seconds.

i Note
After the engine has been shut down restarting is
possible within 12 seconds. After this the anti-theft
protection will be armed again. The red LED flash-
es at intervals of one second.
1 Optional equipment

BW 219 D-4 / PD-4 BOMAG 45

Operation

After entering the service code (for maintenance

work) the anti-theft protection remains disarmed. 4.4 Starting the engine
Danger
!

Danger of accident!
Always wear your seat belt.

Fig. 34
l Check, whether the travel lever (Fig. 34) is en-
gaged to the right in brake position.

Fig. 35
l Turn the rotary vibration selector switch (Fig.
35) to position "0", vibration off.

46 BOMAG BW 219 D-4 / PD-4

 Operation

Fig. 36 Fig. 39
l Check, whether the emergency stop switch All control and warning lights (Fig. 39) in the fault
(Fig. 36) is unlocked. monitoring board light up for a moment.
The battery control (d) and brake warning lights (g)
light up, the engine oil pressure warning light (b)
flashes.

! Caution
Perform the starting process for maximum 20
seconds without interruption and pause for a
minute between starting attempts.
If the engine has not started after two attempts
perform trouble shooting.

Fig. 37
l Turn rotary switch (Fig. 37) to position "Min"
(idle speed).

Fig. 40
l Turn the ignition key to position "II" (Fig. 40),
the starter will crank the engine.
l As soon as the engine ignites return the igni-
tion key to position "I".
Fig. 38
l Turn the ignition key (Fig. 38) to position "I". Caution
!

Do not allow the engine to run longer than 10

minutes with idle speed.

BW 219 D-4 / PD-4 BOMAG 47

Operation
4.5 Starting with jump wires
Fig. 41
! Caution
A wrong connection will cause severe damage
in the electric system.
l Bridge the machine only with a 12 Volt auxilia-
ry battery.
l When jump starting with an external battery
connect both plus poles first.
l Then connect the ground cable first to the mi-
nus pole of the current supplying auxiliary bat-
tery and then to engine or chassis ground, as
far away from the battery as possible (Fig. 41).
l Start as described under 'Starting the engine'.
l Once the engine is running switch on a power-
ful consumer (working light, etc.).
! Caution
If no powerful consumer is switched on volt-
age peaks may occur when separating the con-
necting cables between the batteries, which
could damage electrical components.
After starting disconnect the negative poles
l
(ground cable) first and the positive poles af-
ter.
l Switch off the consumer.
48 BOMAG
4.6 Driving the machine
Danger
!
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclina-
tions and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive up and down inclinations exceed-
ing the maximum gradability of the machine
(see technical data).
Do not drive without wearing your seat belt.
Always give way to loaded transport vehicles!
Before starting to drive make sure that the
drive range is absolutely safe.
!Caution
Always keep the cabin door closed while driv-
ing with the machine. With the door opened
and the machine fully articulated extreme os-
cillations of the machine may damage the
door.
i Note
"Start engine", see previous sections.
The machine is equipped with a seat contact
switch (safety feature).
If the travel lever is actuated with the engine run-
ning, but the driver's seat is not occupied, the sig-
nal horn is triggered and the engine shut down.
If the driver gets up from his seat while driving, the
signal horn is activated and the engine shut down
after four seconds.
If the driver occupies the seat again within this pe-
riod of four seconds, the machine will continue
travelling.
BW 219 D-4 / PD-4
 Operation

Fig. 42 Fig. 45
l Close the cabin door (Fig. 42). l Select the desired travel speed range (Fig.
45).

Fig. 43
l Sit down on the seat (Fig. 43). Fig. 46
l Turn the rotary switch (Fig. 46) to "Max" posi-
tion (full throttle).

Fig. 44
l Fasten your seat belt (Fig. 44).
Fig. 47
l Push the travel lever (Fig. 47) to the left out of
braking position and move it slowly to the de-
sired travel direction.

BW 219 D-4 / PD-4 BOMAG 49

Operation

i Note 4.7 Switching the vibration on

Shift the travel lever out of "0"-position slowly to
forward or reverse, the machine will drive forward and off
or reverse at a speed which corresponds with the
displacement of the travel lever.
Returning the travel lever towards neutral will Danger
!

brake the machine and in "0"-position of the travel Risk of damage!

lever the machine will stop. When compacting with vibration you must
check the effect of nearby buildings and un-
Danger derground supply lines (gas, water, sewage,
electric power), if necessary stop compaction
!

Danger of accident! with vibration.

When stopping on inclinations and slopes pull Do not activate the vibration on hard (frozen,
the travel lever to the right and lock it in brak- concrete) ground. Danger of bearing damage!
ing position.
Important notes on travel operation
! Caution
When changing the travel direction hold the
travel lever for a moment in "0"-position, until
the machine has stopped, before actuating to
the new travel direction.
Do not operate jerkily!
When driving up and down inclinations move
the travel lever slowly back towards neutral to
brake the machine. Fig. 48
If the engine speed drops when driving up ex- Switch to working speed (Fig. 48) (turtle).
treme inclinations move the ravel lever slightly l

back, if necessary change to the lower speed

range. Pre-selecting the vibration

Fig. 49
l Pre-select amplitude/frequency with the rotary
switch (Fig. 49).

50 BOMAG BW 219 D-4 / PD-4

 Operation

Switch the vibration on 4.8 Operating the parking

brake, stopping the ma-
chine

Fig. 50
l Turn the rotary switch (Fig. 50) to position
"Max" (full throttle).
Fig. 52
Caution
Return the travel lever (Fig. 52) slowly to "neu-
!

Switch the vibration on only at max. engine l

tral"-position and engage it to the right parking
speed. brake position.
The machine is automatically braked by the hydro-
static drive and parking brake closes.

i Note
The parking brake also closes automatically when
shutting the engine down.

Fig. 51
l Press the push button (Fig. 51) in the travel le-
ver while driving, the drum will vibrate.
Switching the vibration off
l Press the push button again and after work
switch the rotary vibration switch to position
"0".

BW 219 D-4 / PD-4 BOMAG 51

Operation

4.9 Shutting the engine down

!Caution
Straighten the articulated joint to provide easi-
er access to the machine.

Fig. 55
l Turn the ignition switch (Fig. 55) to position "0"
or "P" and pull the ignition key out.

i Note
The parking brake closes automatically when
shutting the engine down.
Fig. 53
l Return the travel lever (Fig. 53) slowly to "neu- Danger
!

tral"-position and engage it to the right in brak- Danger of accident!

ing position.
Secure the machine against unauthorized use,
pull the ignition key out, lock the cabin door.

Fig. 54
l Turn rotary switch (Fig. 54) to position "Min"
(idle speed).

i Note
Do not shut the engine down all of the sudden from
full speed, but let it idle for a while for temperature
equalization.

52 BOMAG BW 219 D-4 / PD-4

 Operation

4.10 Emergency exit 4.11 Adjusting the steering

If the machine should turn over and the cabin door
wheel
is closed, the right hand side cabin window can be
used as an emergency exit.

Fig. 56
l Adjustment of steering wheel in height, pull le-
ver (Fig. 56) up and move the steering wheel
to the desired height.
l Adjustment of steering wheel inclination, press
lever down and adjust the inclination of the
steering wheel.

Danger
!

Danger of accident!
After the adjustment make sure that the steer-
ing wheel adjustment is securely locked in
place.

BW 219 D-4 / PD-4 BOMAG 53

Operation

4.12 Adjusting the seat 4.13 Operating the hood

!Danger
Danger of accident!
If the hood needs to be opened further for
maintenance or repair work, support it safely.
Bottom position

Fig. 57
l To adjust the seat in longitudinal direction dis-
engage lever e (Fig. 57) upwards and push the
seat forward or back.
l To adjust the weight turn lever (d) and read the
weight in sight glass (c).
l To adjust the inclination of the backrest oper-
ate lever (a) and tilt the backrest forward or Fig. 59
back.
Unlock the lock (Fig. 59).
To swivel the seat pull lever (b) up and turn the
l
l
seat to the desired direction. l To open the hood press in the button and turn
the handle.

Fig. 58
Fig. 60
l To adjust the height of the seat lift the seat up
(Fig. 58) until it engages at the desired level. l Pull the support out of the bracket and support
the hood (Fig. 60).
When lifting the seat completely it will sink down to
lowest position.
Top position
l Push the hood to top position.

54 BOMAG BW 219 D-4 / PD-4

 Operation

4.14 Towing in case of an engine

failure
Danger
!

Secure the machine with wheel chocks against

unintentional rolling.
Danger of accident!
When using towing ropes or chains tow the
machine only uphill.
Fig. 61 When towing downhill you must use a rigid
towing device.
Pull the spring pin (Fig. 61) out of the bracket.
The machine cannot be steered.
l

l Secure the hood i´n the protection tube with

spring plug.

Fig. 62
l Attach chains (Fig. 62) or towing ropes secure-
ly to the lifting eyes.

Caution
!

Towing speed 1 km/h, max. towing distance

500 m.
l Open the tailgate.

BW 219 D-4 / PD-4 BOMAG 55

Operation

Fig. 63 Fig. 65
l Slacken the middle hexagon on both valves l Turn both screws (Fig. 65) for releasing the
(Fig. 63) for approx. 2 to 3 turns. drum brake evenly in clockwise direction, until
the drum can turn freely.
Caution
After towing
!

Do not turn the valves out completely.

! Caution
Before detaching the tow bar block the ma-
chine with chocks to prevent unintended roll-
ing.
l Turn the high pressure relief valve cartridges
tightly back in.
l Turn both screws for releasing the drum brake
(Fig. 65) anti-clockwise against the stop.
l Turn all brake releasing screws of the axle
evenly back out, until they are light moving
again.
Fig. 64
l To release the brake turn counter nuts 1 (Fig.
64) approx. 8 mm back.
l Turn the brake releasing screws (2) complete-
ly in against the stop.

!Caution
From this stop turn the screw in for maximum
another turn to release the brake!
Turn the screws in evenly on both sides.
l Turn the screws in alternately for ¼ turn at a
time. Fig. 66
l Repeat this measure on the opposite wheel l Turn the brake releasing screws (Fig. 66) back
side. in again, until they abut against the brake pis-
ton.

56 BOMAG BW 219 D-4 / PD-4


Fig. 67
l Unscrew the brake releasing screws (Fig. 67)
for two turns and tighten the counter nuts.
l Repeat this adjustment procedure on the op-
posite wheel side.
i Note
If necessary replace the seal ring under the coun-
ter nut if it is leaking.
For this purpose completely unscrew the brake re-
leasing screw, replace the seal ring and lubricate
the screw with silicone grease.
Reinstall the screw with a new seal ring and adjust
the protrusion as described above.
BW 219 D-4 / PD-4 BOMAG
Operation
4.15 Transport
!Danger
Danger of accident!
Use only stable loading ramps of sufficient
load bearing capacity. Make sure that persons
are not endangered by the machine tipping or
sliding off.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
Do not stand or step under loads being lifted.
Always use shackles on the lifting points for
loading, tying or lifting the machine.
Fig. 68
l Pull the spring pin (Fig. 68) out.
l Engage the articulation lock and secure it with
the spring pin.
Fig. 69
l Engage the articulation lock and secure it with
the spring pin (Fig. 69).
57
Operation

Fig. 70 Fig. 72
l Lash the machine on the transport vehicle l Position of centre of gravity (Fig. 72).
(Fig. 70), use the four lashing eyes on front
and rear frame for this purpose. Machine L H
Support the front frame to avoid overstressing
BW 219-4 1020±80 900±40
l
of the rubber buffers.
i Note
The tolerances account for all possible options,
such as cabin, additional weight etc.
Weights: See technical data
l After transport release the articulation lock
again and store it in the receptacle.

Fig. 71
l For lifting use also the four lifting eyes (Fig. 71)
and appropriate lifting gear.

58 BOMAG BW 219 D-4 / PD-4

 Operation

4.16 BTM 051 settings before

start-up
Changing the units system

Fig. 75
l Press key "F4" (Fig. 75).

i Note
The screen page to select the unit system appears
on the screen.
Fig. 73
l Turn the ignition key (Fig. 73) to position "I".

i Note
The control unit shows the start screen.

Fig. 76
l Press key "F5" (Fig. 76) and choose the units
system.
Imperial 0 = metric units
Imperial 1 = imperial units
Fig. 74
l Press key ’’?“ (menu) (Fig. 74).

i Note
The menu appears on the screen.

1 Optional equipment

BW 219 D-4 / PD-4 BOMAG 59

Operation

Fig. 77 Fig. 79
l After the desired change press key "F14" (Fig. l Turn the ignition key to position "I" (Fig. 79).
77). The "Save" symbol on the screen lights up
green for a moment as confirmation.
i Note
The control unit shows the start screen.
i Note
After releasing key "F14" the system returns auto-
matically to the start screen and restarts.

Fig. 80
l Press key ’’?“ (menu) (Fig. 80).
Fig. 78
l Switch the ignition off and on again (Fig. 78). i Note
The menu appears on the screen.
i Note
Both Asphalt Manager control unit and printer
have been set to the new units system.

Setting the printer language1

i Note
With a printer* connected the language in the
printout can be changed via the Asphalt Manager
control unit.
1 Optional equipment

60 BOMAG BW 219 D-4 / PD-4

 Operation

Fig. 81 Fig. 83
l Press key "F6" (Fig. 81). l Press key "F14" to save the language setting
(Fig. 83). The "Save" symbol on the screen
lights up green for a moment as confirmation.
i Note
The printer language screen page appears.

Fig. 84
Fig. 82 l Press key "ESC" (Fig. 84) to return to the start
screen.
l Use keys "F11" or "F12" to choose the desired
printer language (Fig. 82).

i Note
The screen shows country flags, which represent
the associated language.

BW 219 D-4 / PD-4 BOMAG 61

Operation

4.17 Measuring pass with BTM1

General notes
i Note
The soil measuring values (EVIB) recorded during
different passes can only be compared if the re-
cording of measuring values took place in operat-
ing mode "Manual" with the same amplitude,
frequency and travel speed and on exactly the
same track. Fig. 86
Measuring values must only be compared for l Control field F5 (Fig. 86) lights green.
passes performed in the same direction.
The following description describes an measuring
pass in forward. Measuring passes in reverse
must be performed accordingly.

Measuring pass

Fig. 87
l Turn the ignition key (Fig. 87) to position „II en-
gine start.

Fig. 85
l Turn the ignition key (Fig. 85) to position "I"
The BTM plus/prof performs a self-test.

1 Optional equipment

62 BOMAG BW 219 D-4 / PD-4

 Operation

Fig. 89
l Pre-select working speed (Fig. 89).

Fig. 88
l Mark the track to be compacted (Fig. 88).

! Caution
Since the transducer unit is mounted on the
left hand side of the drum, it is necessary to ar-
range the tracks so that track 1 is processed
first, followed by further tracks offset to the
left.
Fig. 90

i Note l Turn the rotary switch (Fig. 90) for engine

speed to position "MAX".
Maximum track length 150 m.
Forward:
Mark 1 = Start of track
Mark 2 = End of track

i Note
The operator may also remember the start and the
end of the track by means of distinct points.

Fig. 91
l Shift the travel lever (Fig. 91) fully to position
„I“.
The machine accelerates up to the preadjusted
travel speed.

BW 219 D-4 / PD-4 BOMAG 63

Operation

!Caution
Differences in the travel speeds falsify the
measuring result!

Fig. 94
l When the end of the track, mark 2, is reached,
press the button F6 “STOP” (Fig. 94).
l Stop the machine.
Fig. 92
l Switch the vibration on (Fig. 92). i Note
The first forward pass is finished.
Caution
Control field F5 lights green. This means, that the
!

Before reaching mark 1 the nominal exciter compaction is not yet completed. One or several
shaft speed must have been reached and a val- passes are still required.
id Evib-value should be displayed.

Fig. 93
l When mark 1 is reached, press button F5
“START” (Fig. 93).
Control field to the left of F5 lights green.
The EVIB- display shows the present value.

64 BOMAG BW 219 D-4 / PD-4

 Operation

4.18 Finishing compaction of a

track

Fig. 95
l Drive forward and reverse passes on a track Fig. 96
until the green control field to the left of F5 (Fig. Repeat the complete compaction process on
95) goes out and the red control field F6 below l
the next track (Fig. 96) to record measuring
lights up after pressing the stop button F6. values.
The compaction process on this track is finished.
Criterion for a finished track:
Compared with the previous track the increase of
the EVIB-value in the same travel direction was
less than 10%. This criterion is also fulfiled if the
EVIB decreases.

i Note
Another pass on this track does not make any
sense, because an increase in load bearing ca-
pacity is hardly possible with this machine.
l If necessary print out the measuring data for
this track (see following section).

BW 219 D-4 / PD-4 BOMAG 65

Operation

4.19 Printing measuring data af-

ter completing compaction1
i Note
Measuring data can be printed after completion of
any pass.
Always check the paper provision before starting
work.
Change the paper roll if a red stripe appears on the
paper. Fig. 98
l If no further printouts of this track are needed,
press the button F8 “DELETE” (Fig. 98) when
the red control lamp F6 “FINISHED” lights up.
The red control field F6 “FINISHED” goes out and
the green control field F5 “CONTINUE” lights up.
BTM plus/prof is ready to compact the next track.

Fig. 97
l At the end of the measurement press push
button F7 "PRINT" (Fig. 97).
short actuation = Line diagram
long actuation ≥5
sec. = Bar chart
Control field F7 goes out and the measuring value
printer starts to print out measuring data.

i Note
After the printing process has finished any amount
of diagrams can be printed out by pressing the
same button F7 (PRINT).

1 only BTM prof

66 BOMAG BW 219 D-4 / PD-4

 Operation

4.20 Changing the paper roll in

the measuring value print-
er1
i Note
Use a new paper roll if a red stripe appears on the
paper.

Fig. 101
l Insert a new paper roll (Fig. 101).
l Feed the paper into the guide (1) on the print-
er.
l Actuate the toggle switch (2) in direction of ar-
row, until the paper comes out of the printer.
l Reassemble the cover.

Fig. 99
l Unscrew the star handles (Fig. 99) and re-
move the cover.

Fig. 100
l Remove shaft 1 (Fig. 100) with the rest of the
paper roll (2).

1 only BTM prof

BW 219 D-4 / PD-4 BOMAG 67

Operation

4.21 Changing the printer ribbon

in the measuring value
printer1
i Note
In case of faint or poorly legible diagrams the print-
er ribbon needs to be replaced.

Fig. 102
l Unscrew the star handles (Fig. 102) and re-
move the cover.

Fig. 103
l Lift the tongue at point 1 (Fig. 103) and take
the printer ribbon (2) out of the printer.
l Insert the new printer ribbon into the printer,
then press in the tongue (1) on the right.
l Tension the printer ribbon by turning the rotary
button (3) in direction of arrow.
l Reassemble the cover.
1 only BTM prof

68 BOMAG BW 219 D-4 / PD-4

 5 Maintenance

BW 219 D-4 / PD-4 BOMAG 69

Maintenance
5.1 General notes on mainte-
nance
When servicing the machine pay careful attention
to all applicable safety instructions.
Thorough maintenance of the machine ensures
maximum reliability and prolongs the lifetime of im-
portant components. The necessary effort can by
no means be compared with the problems and
malfunctions that could occur if this is not ob-
served.
The terms left/right are always related to travel di-
rection forward.
l Clean machine and engine thoroughly before
starting maintenance work.
l For maintenance work park the machine on
level ground.
Maintenance work must generally be carried
l
out with the engine shut down.
Depressurize hydraulic lines before working
l
on them.
l Disconnect the battery and cover it with insu-
lation material before starting to work on elec-
trical components.
l Always attach the articulation lock (transport
lock) before starting to work in the articulation
area of the machine.
Environment
Catch running out oils, coolant and fuel and do
not let them seep into the ground or into the
sewage system. Dispose of oils, coolant and
fuels environmentally.
Notes on the fuel system
The lifetime of the diesel engine is decisively de-
pending on the cleanliness of the fuel.
l Keep the engine free of dirt and water as this
could damage the injection elements of the en-
gine.
l Zinc lined drums are not suitable for storing fu-
el.
l The fuel drum should rest for a longer period
of time before drawing off fuel.
70 BOMAG
Do not let the suction hose disturb the sludge
l
on the bottom of the drum.
l Do not draw off fuel from near the bottom of
the fuel drum.
Fuel left in the fuel drum is not suitable for the
l
engine and should only be used for cleaning
purposes.
Notes on the engine performance
Combustion air and fuel injection rates of the die-
sel engine have been carefully adjusted and deter-
mine the engine's performance and temperature
level as well as the quality of the exhaust gas.
If your machine has to operate permanently in
"thin air" (at high altitudes) and with full power, you
should consult the after sales service of BOMAG
or the service department of the engine manufac-
turer.
Notes on the hydraulic system
During maintenance work in the hydraulic system
cleanliness is of utmost importance. Make sure
that no dirt or other impurities can enter into the
system. Small particles can flute valves, cause
pumps to seize and block restrictors and pilot
bores, thereby causing costly repairs.
l If during the daily oil level check the oil level is
found to have dropped, check all lines, hoses
and components for leakages.
l Seal external leaks immediately. If necessary
inform the responsible service department.
Do not store drums with hydraulic oil outside,
l
or at least keep them under a cover. During
weather changes water may penetrate
through the bunghole.
l Always fill the hydraulic system using the filling
and filtering unit (BOMAG part-no.
007 610 01). This unit is equipped with a fine
filter, which filters the hydraulic oil and pro-
longs the lifetime of the system filter.
l Clean fittings, filler caps and their immediate
surrounding area before removing them, so
that no dirt can fall in.
l Do not leave the tank opening unnecessarily
open, cover it so that no dirt can fall in.
BW 219 D-4 / PD-4

Notes on the cooling system
On water cooled engines the preparation and
monitoring of the coolant is of utmost importance,
as otherwise engine failures caused by corrosion,
caviation and freezing may occur.
The coolant is a mixture of water and a cooling
system protection agent.
The cooling system must be permanently moni-
tored. Apart from the coolant level inspection this
includes also the inspection of the concentration of
cooling system protection agent.
The concentration of the cooling system protection
agent can be checked with commercially available
test instruments (glycomat).
! Danger
Health hazard!
The mixing of nitride based cooling system
protection agents with amine based agents will
cause the generation of highly toxic nitro-
samines.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
BW 219 D-4 / PD-4
Maintenance
5.2 Fuels and lubricants
Engine oil
Quality
Lubrication oils are classified according to their
performance and quality class. Oils according to
other comparable specifications may be used.
Approved engine oils
Deutz DQC II-05 DQC II-05
ACAE E3/96/E5-02/E07/-04 E4-99/E6-04
API CH-4/CG-4/CI-4 -
DHD DHD-1 -
The exact assignment of the approved oil qualities
and oil change intervals can be taken from the fol-
lowing section "Lubrication oil change intervals".
Consult your local service station if in doubt.
Oil viscosity
Multi-purpose oils should be generally used.
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class).
Optimal operating conditions can be achieved by
using the opposite oil viscosity chart (Fig. 104) as
a reference.
Occasionally falling short of the temperature limits
will impair the cold starting ability, but will not
cause any engine damage. In order to keep the
occurring wear as low as possible, occasional ex-
ceeding of the limits should not happen over a
longer period of time.
BOMAG 71
Maintenance

Fig. 104
With their better temperature and oxidation stabil-
ity synthetic lubrication oils offer quite a few bene-
fits.
Oil change intervals
The longest permissible time a lubrication oil
!Caution
These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight
and for ambient temperatures higher than -10
°C.
When using fuels with a sulphur content of
more than 0.5% to 1% or under ambient tem-
peratures below -10 °C the oil change intervals
specified in the table must be halved. For fuels
with a sulphur content of more than 1% you
should consult the responsible service agen-
cy.
Fuels
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and
ensure strict cleanliness when filling in. A higher
sulphur content has a negative effect on the oil
change intervals. Use only winter-grade diesel fuel
under low ambient temperatures. The fuel level
should always be topped up in due time so that the
fuel tank is never run dry, as otherwise filter and in-
jection lines need to be bled.
When using fuels with a Cetan number < 49 poor
starting and white smoke can be expected, in par-
ticular in connection with low ambient tempera-
tures.
The following fuel specifications are permitted:
DIN/EN 590
l

should remain in an engine is 1 year. If the follow- l ASTM D 975, Grade No. 1-D and 2-D.
ing oil change intervals are not reached over a pe- Winter fuel
riod of 1 year, the oil change should be performed
at least once per year, irrespective of the operating
hours reached. ! Danger
ACEA 1 Fire hazard!
E3-96/E5-02/ Diesel fuels must never be mixed with gaso-
E07-04 = 500 operating hours line.
E4-99/E6-04 = 500 operating hours For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At
API2 very low temperatures disturbing paraffin separa-
CG-4/CH-4/CI- tion can also be expected when using winter diesel
4 = 500 operating hours fuel.
In most cases a sufficient cold resistance can also
be achieved by adding flow enhancing fuel addi-
tives. Consult the engine manufacturer.
1 Association des Constructeurs European d’Automobiles
2 American Petroleum Institute

72 BOMAG BW 219 D-4 / PD-4


Operation with rape seed oil methyl ester (RME
„Bio Diesel“)
Due to the extreme quality differences of RMEW-
fuels available on the market, which are caused by
the non-existence of a standardization, BOMAG
does generally not approve any RME-fuels. If this
is neglected the warranty will become null and
void!
However, if you still intend to operate the machine
with RME-fuels you should observe the following
information:
l Reduced engine power (approx. 7%), higher
fuel consumption.
l The quality of RME-fuel should be in compli-
ance with DIN draft 51606.
l Avoid longer periods of standstill (formation of
resin, corrosion in injection system)
l RME-fuel can damage the paint finish of the
machine.
l Fuel dilution of engine oil, therefore shortening
of oil change intervals to half.
Rubber parts, such as leak fuel return lines,
l
seats will be damaged in the long run and
need to be replaced on a regular basis or
should be replaced by parts made of fluorinat-
ed rubber. However, fluorinated rubber is not
resistant against normal diesel fuel.
l If the fuel filter is clogged the filter change in-
tervals must be shortened accordingly.
Coolant, anti-freeze agent
Use only soft tap water (drinking water) to prepare
the coolant mix.
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any
climatic conditions.
The proportion of cooling system protection agent
must be between min. 35% and max. 45% to the
water.
! Caution
Do not mix different coolants and additives of
any other kind.
BW 219 D-4 / PD-4
Maintenance
Environment
Cooling system protection agents must be dis-
posed of environmentally.
Hydraulic oil
The hydraulic system is operated with hydraulic oil
HV 46 (ISO) with a kinematic viscosity of
46 mm2/s at 40°C. For topping up or for oil chang-
es use only high-quality hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils
type HV according to ISO 6743/3. The viscosity in-
dex (VI) should be at least 150 (observe informa-
tion of manufacturer).
Bio-degradable hydraulic oil
On request the hydraulic system can also be filled
with ester based biodegradable hydraulic oil (Pan-
olin HLP Synth. 46). The biologically quickly de-
gradable hydraulic oil meets all demands of a
mineral oil based hydraulic oil according to DIN
51524.
In hydraulic systems filled with Panolin HLP Synth.
46 always use the same oil to top up. When
changing from mineral oil based hydraulic oil to an
ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manu-
facturer for details.
Check the filter more frequently after this change.
!Caution
Oil change bio-degradable hydraulic oil:
Perform regular oil analyses for content of wa-
ter and mineral oil.
Replace the hydraulic oil filter element every
500 operating hours.
Oil for drive axle and drum drive reduc-
tion gear
For the drive axle use only multi-purpose transmis-
sion oil of API-class GL5 with viscosity class SAE
90.
The additives in this oil ensure low wear lubrication
under all operating conditions.
Lubrication grease
For lubrication use only EP-high pressure grease,
lithium saponified (penetration 2).
BOMAG 73
Maintenance

5.3 Table of fuels and lubri-

cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention
Observe the level marks
Engine Engine oil ACEA: E3-96/E5-02E07-4/ approx. 23,5 litres without
E4-99/E6-04 or oil filter
API: CG-4/CH-4/CI-4
SAE 10W/40
(-20 °C to +40 °C)
SAE 15W/40
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 340 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm2/s at 40 °C
Vibration bearings Engine oil SAE 15W/40 approx. 2 x 1,8 litres
Drive axle Gear oil SAE 90, API GL5 approx. 11 litres
Wheel hubs Gear oil SAE 90, API GL5 approx. 2 per side
Axle reduction gear Gear oil SAE 90, API GL5 approx. 1,9 litres
Drum drive gear Gear oil SAE 90, API GL5 approx. 3,2 litres
Articulated joint / lubrica- lithium saponified multi-purpose grease, penetration as required
tion points 2
Air conditioning system Refrigerant R134A 1400
Engine cooling system Cooling system protection agent approx. 16 litres
Tires Water approx. 295 litres
Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg
(MgCl2)

74 BOMAG BW 219 D-4 / PD-4

 Maintenance

5.4 Running-in instructions

The following maintenance work must be per-
formed when running in new machines or
overhauled engines:

! Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes
l Retighten the V-belt
After 250 operating hours
l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.
l Retighten all wheel fastening screws with the
specified tightening torque.
l Oil change diesel engine and engine oil filter
l 1. Oil change vibration bearings
l Oil change in drive axle
l Oil change in wheel hubs
l Oil change, axle reduction gear
l 1. Oil change, drum drive reduction gear
After 500 operating hours
l 2. Oil change vibration bearings
l 2. Oil change, drum drive reduction gear

BW 219 D-4 / PD-4 BOMAG 75

Maintenance

5.5 Maintenance chart

y
l
i
a
d s s s
, s s r r r
s s r r u u u
r r u u o o o
s
u u o o h h h
n
o o h h
o g g g
i h h
t g g n n n
c g g i i i
n n t t t
No. Maintenance work Remark u n i i
i n t t a a a
r t i r r r
t t a a
s a a r r e e e
r r e e p p p
n e
i e p p o o o
p p o o d
n 0 0 0
i o o e
- 0 0 0 0 0 r
g 0 0 5 0 0 0 0 i
n 5 1 2 5 1 2 6 u
i 2 q
n y y y y y y
r r r r r r r e
n e r
t e e e e e e
u f v v v v v v s
R a e e e e e e a

5.6 Check the engine oil level Dipstick mark X

5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Check the dust separator X
5.12 Grease the articulated joint X
5.13 Check the tire pressure X
5.14 Clean the cooling fins on engine and X
hydraulic oil cooler
5.15 Check the oil level in the drive axle X
5.16 Check the oil level in the wheel hubs X
5.17 Check the oil level in the axle reduc- X
tion gear
5.18 Check the oil level in the drum reduc- X
tion gear
5.19 Check the oil level in the vibration X
bearings
5.20 Change engine oil and oil filter car- min. 1x per year X X
tridge1
5.21 Change the fuel filter cartridge X
5.22 Drain the sludge from the fuel tank X
5.23 Battery maintenance Pole grease X
5.24 Change the fuel pre-filter cartridge X

76 BOMAG BW 219 D-4 / PD-4

 Maintenance

y
l
i
a
d s s s
, s s r r r
s s r r u u u
r r u u o o o
s
u u o o h h h
n
o o h h
o g g g
i h h
t g g n n n
c g g i i i
n n t t t
No. Maintenance work Remark u n i i
i n t t a a a
r t i r r r
t t a a
s a a r r e e e
r r e e p p p
n e
i e p p o o o
p p o o d
n 0 0 0
i o o e
- 0 0 0 0 0 r
g 0 0 5 0 0 0 0 i
n 5 1 2 5 1 2 6 u
i 2 q
n y y y y y y
r r r r r r r e
n e r
t e e e e e e
u f v v v v v v s
R a e e e e e e a

5.25 Check, replace the refrigerant com- X

pressor V-belt
5.26 Service the air conditioning X
5.27 Check, adjust the valve clearance Intake = 75° (0,3 X
mm)
Exhaust = 120° (0,5
mm)
5.28 Check, replace the ribbed V-belt X
5.29 Check the engine mounts X X
5.30 Check the engine pillow blocks X
5.31 Oil change in drive axle min. 1x per year X X
5.32 Oil change in wheel hubs min. 1x per year X X
5.33 Oil change, axle reduction gear min. 1x per year X X
5.34 Oil change in drum drive reduction min. 1x per year X X
gear2
5.35 Oil change vibration bearings2 see foot note, min. 1 X X
x per year
5.36 Retighten the fastening of the axle on X
the frame
5.37 Tighten the wheel nuts X X
5.38 Check the ROPS X
5.39 Clean the oil bath air filter min. 1x per year X
5.40 Change hydraulic oil and breather fil- at least every 2 X
ter3 years
5.41 Change the hydraulic oil filter3 at least every 2 X
years
5.42 Change the coolant at least every 2 X
years

BW 219 D-4 / PD-4 BOMAG 77

Maintenance

y
l
i
a
d s s s
, s s r r r
s s r r u u u
r r u u o o o
s
u u o o h h h
n
o o h h
o g g g
i h h
t g g n n n
c g g i i i
n n t t t
No. Maintenance work Remark u n i i
i n t t a a a
r t i r r r
t t a a
s a a r r e e e
r r e e p p p
n e
i e p p o o o
p p o o d
n 0 0 0
i o o e
- 0 0 0 0 0 r
g 0 0 5 0 0 0 0 i
n 5 1 2 5 1 2 6 u
i 2 q
n y y y y y y
r r r r r r r e
n e r
t e e e e e e
u f v v v v v v s
R a e e e e e e a

5.43 Crankcase pressure ventilation valve at least every 2 X

years
5.44 Replacing the injector X
5.45 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2 years
5.46 Adjusting the scrapers X
5.47 Adjust the parking brake X
5.48 Change the tires X
5.49 Change the fresh air filter in the cabin X
5.50 Tightening torques X
5.51 Engine conservation X
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h.
3 Also in case of repair in the hydraulic system.

78 BOMAG BW 219 D-4 / PD-4

 Every 10 operating hours

5.6 Check the engine oil level 5.7 Check, clean the water sep-
E very 1 0 ope ra ti ng hou rs

arator
Danger
!

Danger of injury! Danger

!

Support the engine hood for all maintenance Danger of injury!

and repair work. Support the engine hood for all maintenance
and repair work.
i Note
The machine must be parked horizontally with the i Note
engine shut down. The service intervals for the water separator de-
pend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should therefore
check the water separator every day for signs of
water.
If a to high quantity is drained off, the filter must be
refilled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.

Environment
Catch running out fuel and dispose of environ-
mentally.
Fig. 105
l Pull the dipstick (Fig. 105) out, wipe it off with
a lint-free, clean cloth and reinsert it until it bot-
toms.
l Pull the dipstick back out again.
l If the oil level is below the "MAX" mark fill in oil.
l If the oil level is above the “Max” mark deter-
mine the cause and drain the oil off.

Caution
!

Before longer work periods you should always

top the oil up to the "MAX"-mark. Fig. 106
For quality and quantity of oil refer to the table l Slacken the drain plug (Fig. 106) for a few
of fuels and lubricants. turns and catch running out fuel / water.
l Tighten the drain plug again and check for
leaks, if necessary replace the seal ring.

BW 219 D-4 / PD-4 BOMAG 79

Every 10 operating hours

5.8 Check the fuel level !Caution

Contaminated fuel can cause malfunction or
even damage of the engine.
Danger
! If necessary, fill in fuel through a funnel with
Fire hazard! screen.
When working on the fuel system do not use l If necessary top up with fuel (diesel or winter
open fire, do not smoke, do not refuel in closed diesel).
rooms, do not inhale any fuel fumes. For quality of fuel refer to the table of fuels and
lubricants.

Fig. 107
l Check the fuel level on the fuel level gauge
(Fig. 107) with the ignition switched on.

i Note
Do not drive the fuel tank dry, as otherwise the fuel
system needs to be bled.
l Clean the area around the filler opening.

Fig. 108
l Open the fuel tank cover (Fig. 108).

80 BOMAG BW 219 D-4 / PD-4

 Every 10 operating hours

5.9 Check the hydraulic oil level 5.10 Check the coolant level
!Caution !Danger
In hydraulic systems filled with Panolin HLP Danger of scalding!
Synth. 46 always use the same oil to top up. Fill up coolant only when the engine is cold.
With other ester based oils consult the lubrica-
tion oil service of the respective oil manufac-
turer.

Fig. 110
l Check the coolant level (Fig. 110).
Fig. 109
l Check the hydraulic oil level in the inspection ! Caution
glass (Fig. 109). If, during the daily inspection the coolant level
Normal level is found to have dropped, check all lines, hos-
es and engine for leaks.
approx. 3 cm below the top edge of the inspection
glass. l To top up unscrew the filler cap and fill in cool-
ant up to the MAX-mark.
Minimum level
Middle of inspection glass. For quality of coolant refer to the chapter 5.2,
fuels and lubricants.
! Caution
If, during the daily inspection of the oil level
the hydraulic oil level is found to have
dropped, check all lines, hoses and compo-
nents for leaks.
l If necessary fill in hydraulic oil through the filler
neck.
For quality and quantity of oil refer to the table
of fuels and lubricants.

BW 219 D-4 / PD-4 BOMAG 81

Every 10 operating hours

5.11 Checking the dust separa-

tor on the oil bath air filter1

Fig. 111
l If the dust reaches the mark loosen the clamp
(Fig. 111), take the cover off and clean the
bowl.

1 Option

82 BOMAG BW 219 D-4 / PD-4

 Every 250 operating hours

5.12 Grease the articulated joint 5.13 Checking the tire pressure
E very 2 5 0 oper ating hours

!Caution
Since the tires are filled with water, you should
always turn the inflation valve to top position
to check the tire pressure!
Always close the valves with the dust cap.

Fig. 112
l Clean the grease nipples (Fig. 112) and lubri-
cate with approx. 5 shots from the grease gun.
For quality of grease refer to the section on fu-
els and lubricants.
Fig. 113
l Check the tire pressure with a pressure gauge
and the tire inflation valve 1 (Fig. 113) in top
position.
Nominal value see "technical data".

i Note
Ensure even pressure in all tires.
l Screw the valve caps back on.

BW 219 D-4 / PD-4 BOMAG 83

Every 250 operating hours

5.14 Clean the cooling fins on Cleaning with cold cleansing agent
engine and hydraulic oil Caution
cooler
!

Protect electrical equipment such as genera-

tor, regulator and starter against the direct wa-
ter jet.
Danger
!
l Spray the engine with a suitable cleansing
Danger of injury! agent, e.g. cold cleanser, let it soak in for a
Perform cleaning work only after the engine while and spray it off with a strong water jet.
has cooled down and with the engine stopped. l Run the engine warm for a while to avoid cor-
rosion.
Caution
!

Do not damage any cooling fins on the cooler

core when cleaning.

i Note
Dirt on fan blades and oil cooler reduce the cooling
effect. Dirt deposits in these areas are substantial-
ly supported by oil and fuel on these surfaces. For
this reason you should always seal any oil or fuel
leaks in the vicinity of the cooling fan or the oil
cooler and clean the cooling surfaces after.

Cleaning with compressed air

Fig. 114

i Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 114) out with com-
pressed air.

84 BOMAG BW 219 D-4 / PD-4

 Every 250 operating hours

5.15 Check the oil level in the 5.16 Check the oil level in the
drive axle wheel hubs
l Park the machine on level ground.

Fig. 116
Fig. 115 l Move the drive wheel so that the oil level mark
l Unscrew the oil level inspection plug (Fig. 115) on the plug (Fig. 116) is in horizontal position.
and check the oil level. l Unscrew the plugs
The oil level must reach the bottom edge of the
i Note level bore.
The second level inspection plug as at the back. l Top up oil, if necessary.
After filling in oil wait until the oil has evenly distrib- For quality of oil refer to the table of fuels and
uted inside the axle. lubricants.
The oil level must reach the bottom edge of the Turn the plug tightly back in.
level bore.
l

Repeat this inspection on the other side.

Top up oil, if necessary.
l
l

For quality of oil refer to the table of fuels and

lubricants.
l Turn the level inspection plug tightly back in.

BW 219 D-4 / PD-4 BOMAG 85

Every 250 operating hours

5.17 Check the oil level in the 5.18 Check the oil level in the
axle reduction gear drum reduction gear
Check

Fig. 117
l Unscrew the filler and oil level inspection plug
(Fig. 117) and check the oil level. Fig. 118
The oil level must reach the bottom edge of the l Unscrew the oil level inspection plug (Fig. 118)
bore, top up oil if necessary. and check the oil level.
For quality of oil refer to the table of fuels and The oil level must reach the bottom edge of the
lubricants. bore, top up oil if necessary.
l Retighten the filler and level inspection plug. Filling up
l Move the drum until drain and filler plugs are
exactly vertically in line.

Fig. 119
l Unscrew the filler plug at the top (Fig. 119) and
fill in oil, until it reaches the bottom edge of the
inspection bore.

86 BOMAG BW 219 D-4 / PD-4

 Every 250 operating hours

! Caution
Investigate the cause for the oil loss, if neces-
sary seal the gearbox
For quality of oil refer to the table of fuels and
lubricants.
l Retighten the filler and level inspection plug.
5.19 Check the oil level in the vi-
bration bearings
i Note
Check only at operating temperature after running
the machine approx. 1/2 hour with vibration.
l Park the machine on level ground.

Fig. 120
l Move the drum, until oil level inspection plug 1
(Fig. 120) on the left hand side of the drum is
in bottom position.
l Unscrew level inspection plug (1).
Some oil should run out of the inspection bore.
l If necessary unscrew oil filler plug (2) and fill in
some oil through the oil filler bore (2), until oil
starts to drip out through the inspection bore.
For quality of oil refer to the table of fuels and
lubricants.
l Screw oil filler (2) and level inspection plug (1)
back in tightly.
l Repeat this inspection on the other side.

! Caution
If a loss of oil is found perform trouble shoot-
ing, repair the drum if necessary.

BW 219 D-4 / PD-4 BOMAG 87

 Every 500 operating hours

Every 500 operating h ours

5.20 Changing engine oil and oil

filter cartridges

! Caution
The oil change at 500 operating hours refers to
the use of oils of oil quality class API CG-4/CH-
4 or ACAE E3-96/E5-02 respectively.
Refer also to the chapter 5.2, fuels and lubri-
cants.
Drain the engine oil only when the engine is
warm. Fig. 122

l Thoroughly clean the outside of the filter car-

tridge (Fig. 122).
Danger
!

Danger of scalding! l Unscrew the filter cartridges using an appro-

priate filter wrench.
When draining off hot oil.
l Clean the sealing face on the filter carrier from
By hot oil when unscrewing the engine oil fil- any dirt.
ter.
l Slightly oil the rubber seal on the new filter car-
tridges.
Environment
Catch running out oil and dispose of environ-
mentally together with the engine oil filter car-
tridge.

Fig. 123

l Turn the new filter cartridges (Fig. 123) on by

hand, until the seal contacts.

Fig. 121 l Tighten the filter cartridges for another half

turn.
l Unscrew the drain plug (Fig. 121) and catch
running out oil.
l Turn the drain plug tightly back in.

88 BOMAG BW 219 D-4 / PD-4

 Every 500 operating hours

5.21 Change the fuel filter car-

tridge

! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.
Catch running out fuel, do not let it seep into
the ground.
Fig. 124
Do not inhale any fuel fumes.
l Fill in new engine oil (Fig. 124).

For quality and quantity of oil refer to the table

of fuels and lubricants.
l Tighten the oil filler cap properly.

! Caution
Before starting crank the engine with the start-
er motor until the oil pressure warning light
goes out.
l After a short test run check the oil level on the
dipstick, if necessary top up to the top dipstick
mark.
Fig. 125
l Check filter cartridge and drain plug for leaks
after a short test run. l Loosen and unscrew the fuel filter cartridge
l Shut the engine down and wait for about 15 (Fig. 125) using an appropriate filter wrench.
minutes, so that all oil can flow back into the oil l Clean the sealing face on the filter carrier from
sump. any dirt.
l Check the oil level again, if necessary fill up to
the Max.-mark.

Fig. 126

l Slightly oil the rubber seal (Fig. 126) on the

new filter cartridge.

BW 219 D-4 / PD-4 BOMAG 89

Every 500 operating hours

l Fill the filter cartridge with clean diesel fuel.

5.22 Draining the sludge from
l Turn the new filter cartridge on by hand, until
the seal contacts. the fuel tank
l Tighten the filter element for another half turn.
l Check the filter cartridge for leaks after a short ! Danger
test run.
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke!
Do not spill any fuel.
Catch running out fuel, do not let it seep into
the ground.
Do not inhale any fuel fumes.

Fig. 127

l Unscrew the cap (Fig. 127) and drain off ap-

prox. 5 litres of fuel.
l Turn the cap tightly back in.

90 BOMAG BW 219 D-4 / PD-4

 Every 500 operating hours

Caution
5.23 Service the battery !

Exhausted batteries (batteries with formation

of sulphate on thge plates are not covered un-
der warranty!
! Danger
Danger of cauterisation ! Danger of explosion! l Open the engine hood and remove the cover-
ing.
When working on the battery do not use open
fire, do not smoke!
The battery contains acid. Do not let acid come
in contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!

Environment
Dispose of the old battery environmentally.

i Note
Maintenance free batteries also need care. Main-
tenance free only means that the fluid level does Fig. 128
not need to be checked. Each battery suffers un- l Remove the battery (Fig. 128) and clean the
der self-discharge, which may, in not checked oc- battery compartment.
casionally, even cause damage to the battery as a
result of exhaustive discharge. l Clean the outside of the battery.
l Clean battery poles and pole clamps and
The following therefore applies for the service grease them with pole grease (Vaseline).
life:
l Check the fastening of the battery.
l Switch off all consumers (e.g. ignition, light, in-
side light, radio). l On serviceable batteries check the acid level,
if necessary top up to the filling mark with dis-
l Check open-circuit voltage of the battery at
tilled water.
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V = Charging voltage recommendation
50% discharged.
l Recharge the battery immediately after an
open-circuit voltage of 12.25 V or less is
reached. Do not perform boost charging.
The open-circuit voltage of the battery occurs ap-
prox. 10 hours after the last charging process or
one hour after the last discharge.
l After each charging process allow the battery
to rest for one hour before taking it into service.
l For resting periods of more than one month
you should always disconnect the battery. Do
not forget to perform regular open-circuit volt-
age measurements. Fig. 129

BW 219 D-4 / PD-4 BOMAG 91

Every 500 operating hours

5.24 Change the fuel pre-filter

cartridge

! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.
Catch running out fuel, do not let it seep into
the ground.
Fig. 131
Do not inhale any fuel fumes.
l Unscrew the water separator from the filter
cartridge (Fig. 131).

Fig. 130

l Pull off the cable and unscrew the fuel filter
cartridge (Fig. 130) using an appropriate filter
wrench.
l Clean the sealing face on the filter carrier from
any dirt.
Fig. 132
l Apply a thin coat of oil to the rubber seal of the
water separator 1 (Fig. 132).
l Screw the water separator on by hand (2), until
the seal contacts.
l Tighten the water separator for another half
turn (3).
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter el-
ement (5) and screw it on by hand, until the
seal contacts.
l Tighten the filter element for another half turn
(6).
l Plug the water sensor cable back on.
l Check the filter cartridge for leaks after a short
test run.

92 BOMAG BW 219 D-4 / PD-4

 Every 500 operating hours

i Note
5.25 Checking, replacing the re-
Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the en- frigerant compressor V-
gine and makes starting impossible. belt1
Therefore bleed the fuel system after changing the
fuel pre-filter.
Danger
!

Environment Danger of injury!

Catch running out fuel and dispose of environ- Work on the V-belt must only be performed
mentally. with the engine shut down.

Check the V-belt

Fig. 133

l Slacken the bleeding screw (Fig. 133) on the

fuel pre-filter for 2 to 3 turns. Fig. 134

l Operate the hand pump manually, until fuel
flows out of the slackened bleeding screw (Fig.
133) without air bubbles.
l Then tighten the bleeding screw while pump-
ing.
l Inspect the entire circumference of the V-belt
(Fig. 134) visually for damage and cracks. Re-
place damaged or cracked V-belts.
l Check with thumb pressure whether the V-belt
can be depressed more than 10 to 15 mm (0.4
– 0.6 inches) between the V-belt pulleys,
retighten if necessary.

1 Optional equipment

BW 219 D-4 / PD-4 BOMAG 93

Every 500 operating hours
Tighten the V-belt.
Fig. 135
l Slightly slacken fastening screws 1, 2 and 3
(Fig. 135).
l Press the compressor in direction of arrow, un-
til the correct V-belt tension is reached.
l Retighten all fastening screws.
Changing the V-belt
l Slightly slacken the fastening screws 1, 2 and
3.
l Press the compressor against the direction of
arrow completely against the engine.
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
! Caution
Check the V-belt tension after a running time of
30 minutes.
94
5.26 Service the air condition-
ing1
Cleaning the condenser
Caution
!
A soiled condenser results in a considerable
reduction of air conditioning power.
Under extremely dusty conditions it may be
necessary to clean the condenser several
times per day.
If, during operation of the air conditioning sys-
tem, the warning buzzer sounds switch the air
conditioning off and clean the condenser.
In case of formation of foam have the air con-
ditioning system inspected by the service de-
partment.
Danger
!
Danger of accident!
Do not clean with a hot water jet. Heat will
cause extreme overpressure, which could
cause damage or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 136
l Unscrew the condenser fastening screws (Fig.
136) and fold the condenser forward.
l Clean the condenser fins on front and back
with compressed air or cold water .
1 Optional equipment
BOMAG BW 219 D-4 / PD-4
 Every 500 operating hours

Checking the refrigerant level

l Start the engine.

Fig. 139

l Check whether the white float (Fig. 139) inside

the inspection glass of the drier/collector unit
Fig. 137 floats right at the top.
l Switch the air conditioning (Fig. 137) on.
i Note
The refrigerant level is correct.

Fig. 138

l Choose a cooling temperature with the rotary

switch for cabin heater (Fig. 138) in the blue
section.
l Open the air outlet nozzles.
l Check, whether the outflowing air is noticeably
cooler.
i Note
The adjusted temperature must be below the actu-
al temperature inside the cabin, so that the com-
pressor will be switched on.
l Open the hood.
Fig. 140
l If the white float (Fig. 140) inside the inspec-
tion glass of the drier/collector unit floats at the
bottom, inform the service department.
i Note
The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary
check the air conditioning system for leaks.

BW 219 D-4 / PD-4 BOMAG 95

Every 500 operating hours

Checking the moisture level of the dry- arising from the handling and operation of
ing agent pressure reservoirs.

! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be re-
placed, to avoid bursting and further damage.

Fig. 141

l Check the moisture indication pearl (Fig. 141)

inside the inspection glass of the drier/collec-
tor unit.
orange = drying agent o.k.
colorless = moisture level of drying agent too
high. Fig. 142

l Inform the service department. Replace drier/ l Check the drier/collector unit (Fig. 142) for me-
collector unit, check air conditioning system. chanical damage or rust.

!Caution
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.

Checking the condition of the drier/col-

lector unit

!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeated-
ly inspected by a specialist. In this sense
repeated inspections are external examina-
tions, normally on pressure reservoirs in oper-
ation. In connection with this inspection the
drier/collector unit must be visually examined
twice every year. During these inspections
special attention must be paid to corrosion
and mechanical damage. If the reservoir is not
in proper condition it must be replaced for
safety reasons, as a precaution to protect op-
erators and third parties against any danger

96 BOMAG BW 219 D-4 / PD-4

 Every 1000 operating hours

5.27 Adjusting the valve clear-

Every 1000 operating hours

ance
Caution
!

We recommend to have this work carried out

by trained personnel or our after sales service.
Before checking the valve clearance let the en-
gine cool down for at least 30 minutes. The en-
gine oil temperature must be less than 80 °C.
After a short test run check the engine for
leaks. Fig. 144

l Attach the cranking device over the V-belt pul-

ley fastening screws.
l Remove the valve cover (2).
l Crank the engine, until the valves on cylinder
1 overlap.
l The individual cylinder positions can be taken
from the section "valve adjustment schemat-
ic".
Adjusting the valve clearance
Fig. 145

l Attach the rotation angle disc 3 (Fig. 145) and

the spanner socket (4) to the valve adjustment
screw 2 (Fig. 144).
l Fix the magnet (5) of the rotation angle disc.
l Turn the rotation angle disc counter-clockwise
against the stop (rocker arm no clearance) and
set the scale to zero.
l Turn the rotation angle disc clockwise, until the
specified angle is reached.
Fig. 143
Intake valve IN = 75° (0,3 mm)
Loosen counter nut 1 (Fig. 143). Exhaust valves
EX = 120° (0,5 mm)
l

l Hold the rotation angle disc tight, so that it

does not turn, and tighten counter nut 1 (Fig.
143).
l Repeat this adjustment procedure an all other
cylinders, after cranking the crankshaft ac-
cordingly.
l Assemble the cylinder head cover with a new
gasket.

BW 219 D-4 / PD-4 BOMAG 97

Every 1000 operating hours

Valve adjustment schematic 5.28 Checking / replacing the

Firing sequence 1-5-3-6-2-4
l
ribbed V-belt
Valves Cylinder
overlapping 1 5 3 6 2 4 Danger
!

adjustment 6 2 4 1 5 3 Danger of injury!

Overlapping of valves: Work on the V-belt must only be performed
with the engine shut down.
Exhaust valve not yet closed,
intake valve starts to open. Checking the wear limit of the ribbed V-
belt
Caution
!

With the intake valve opened, the exhaust

valve will temporarily open for about 2 mm.
This is no valve overlap condition!

Fig. 146

l Check the distance between the tongue of the

moveable tensioner arm and the fixed tension-
er housing (Fig. 146).
l If measurement "a" is smaller than 3 mm, re-
place the ribbed V-belt.

98 BOMAG BW 219 D-4 / PD-4

 Every 1000 operating hours

Changing the ribbed V-belt 5.29 Check the engine mounts

Fig. 147

l Unscrew the fastening screws (Fig. 147) and

slide the fan forward.
Fig. 149

l Tighten fastenings of intake and exhaust man-

ifolds (Fig. 149) on the cylinder heads.
l Check sockets and clamps between air filter,
exhaust turbocharger and charge air line as
well as the lubrication air line for tight fit and
leaks.
l Retighten the fastening screws for oil sump
and engine mounts.

Fig. 148

l Press idling pulley 1 (Fig. 148) in direction of

arrow using a socket wrench (3), until the lock-
ing pin (4) engages in the assembly bore.
The ribbed V-belt (2) is thus relieved from tension.
l Remove the ribbed V-belt first from the small-
est roller or from the idling pulley.
l Check the condition of the idling pulley, re-
place if necessary.
l Install the new ribbed V-belt.
l Counter the idling pulley with the socket
wrench and remove the locking pin.
l Relieve the idling pulley and tension the ribbed
V-belt.

BW 219 D-4 / PD-4 BOMAG 99

Every 1000 operating hours

5.30 Checking the engine pillow 5.31 Change the oil in the drive
blocks axle
i Note
On other axle versions drain and filler plugs are of
slightly different design. Perform the oil change ac-
cordingly.

Caution
!

Drain oil only at operating temperature.

Environment
Catch old oil and dispose of environmentally.
Fig. 150
l Park the machine on level ground.
l Check state of engine pillow blocks (Fig. 150),
replace if necessary.

Fig. 151

l Clean and unscrew all level inspection and

drain plugs (Fig. 151).
l Drain and catch all oil.
l Clean the drain plug and turn it back in with a
new seal ring.

100 BOMAG BW 219 D-4 / PD-4

 Every 1000 operating hours

5.32 Change the oil in the wheel

hubs
Caution
!

Drain oil only at operating temperature.

Change the oil on both sides of the axle.

Environment
Catch old oil and dispose of environmentally.
Fig. 152

l Fill in oil through the oil level inspection bores

(Fig. 152), until it has reached the bottom edge
of the bore.

i Note
The second level inspection plug as at the back.
After filling in oil wait until the oil has evenly distrib-
uted inside the axle.
For quality and quantity of oil refer to the table
of fuels and lubricants.
l Retighten the filler and level inspection plug. Fig. 153

l Move the drive wheel, until the plug (Fig. 153)

is in bottom position.
l Clean and unscrew the plug.
l Drain and catch all oil.

Fig. 154

l Move the drive wheel, until the plug (Fig. 154)

is in horizontal position on the housing.
l Fill in oil, until it reaches the bottom edge of the
bore .

BW 219 D-4 / PD-4 BOMAG 101

Every 1000 operating hours

For quality and quantity of oil refer to the table

of fuels and lubricants. 5.33 Changing the oil in the axle
l Turn the plug tightly back in. reduction gear
Caution
!

Drain the oil only at operating temperature.

Environment
Catch the old oil and dispose of environmetal-
ly.

Fig. 155

l Unscrew the filler plug (Fig. 155).

l Unscrew the oil drain plug and catch the run-
ning out oil.
l Once the oil has run out clean the drain plug
and screw it tightly back in.
l Fill in oil through the filler and control bore until
it reaches the lower edge of the control bore.
For quality and quantity of oil refer to the table
of fuels and lubricants.
l Clean the filler plug and screw it back in tightly
with a new sealing ring.

102 BOMAG BW 219 D-4 / PD-4

 Every 1000 operating hours

5.34 Change the oil in the drum

reduction gear
Caution
!

Drain oil only at operating temperature.

Environment
Catch old oil and dispose of environmentally.
l Move the drum until drain and filler plugs are
exactly vertically in line. Fig. 158

l Fill in oil through the filler bore (Fig. 158), until

it reaches the bottom edge of the inspection
bore.
For quality and quantity of oil refer to the table
of fuels and lubricants.
l Clean filler and level control plugs and screw
them tightly back in with new sealing rings.

Fig. 156

l Unscrew the filler plug at the top (Fig. 156).

l Unscrew the drain plug at the bottom and
catch running out oil.
l Turn the oil drain plug back in tightly after all oil
has run out.

Fig. 157

l Unscrew the level inspection plug (Fig. 157).

BW 219 D-4 / PD-4 BOMAG 103

Every 1000 operating hours

5.35 Change the oil in the vibra-

tion bearings
!Caution
Change the oil at operating temperature. For
this purpose run the machine approx. half an
hour with vibration.

Environment
Catch running out oil and dispose of environ-
mentally. Fig. 160

Park the machine on level ground. l Unscrew oil level inspection plug 1 (Fig. 160)
on the drum and fill in oil through the filler
l

opening (2), until it starts to drip out from the

level inspection bore.
For quality and quantity of oil refer to the table
of fuels and lubricants.
l Screw oil filler (2) and level inspection plug (1)
back in tightly.
l Repeat the oil change on the opposite side.
l Check the oil level once again at operating
temperature (after running the machine for
about half an hour with vibration).

Fig. 159 !Caution

l Move the drum, until the drain plug 1 (Fig. 159) Overfilling causes overheating and destruc-
is in bottom position. tion of the vibration bearings!
l Unscrew the drain plug, let the oil run out and
catch it.
l Turn the oil drain plug back in tightly after all oil
has run out.

104 BOMAG BW 219 D-4 / PD-4

 Every 1000 operating hours

5.36 Tightening the fastening of 5.37 Tighten the wheel nuts

the axle to the frame

Fig. 162

Fig. 161 l Tighten the wheel nuts (Fig. 162) cross-wise

l Check all fastening nuts for the axle retaining Tightening torques: 550 Nm (405 ft-lb)
bolts (Fig. 161) for tight fit. (M22x1.5)

BW 219 D-4 / PD-4 BOMAG 105

Every 1000 operating hours

5.38 Check the ROPS 5.39 Cleaning the oil bath air fil-
ter 1
i Note
On machines with cabin the ROPS (roll over pro-
tection structure) is an integral part of the cabin.
Please observe also the corresponding section in
the safety regulations in this manual.

Fig. 164

l Loosen the quick locks (Fig. 164), take the fil-

ter bowl off and empty it.
l Clean the filter mesh by repetitive dipping into
diesel fuel.
Clean the filter bowl with diesel fuel and fill in
Fig. 163

Inspect the cabin, especially the ROPS (Fig.

l
l
engine oil up to the level mark.
163), for cracks, corrosion, damage and miss-
ing fastening parts. l reinstall the filter bowl.

i Note
Unusual movements and noises (vibrations) dur-
ing operation are signs for damage or loosened
fastening elements.
l Check the fastening screws for the cabin
(ROPS) to the operator’s stand for tight fit.
l Check the rubber buffers of the operator’s plat-
form suspension for condition and tight fit.
l Check the condition and fastening of the seat
belts.

1 Optio n

106 BOMAG BW 219 D-4 / PD-4

 Every 2000 operating hours

5.40 Changing hydraulic oil and

Every 2000 operating hours

breather filter
i Note
See also chapter 5.1 "Notes on the hydraulic sys-
tem".

Caution
!

Apart from the normal oil change intervals, the

hydraulic oil must also be changed after major
repairs in the hydraulic system. Fig. 165

Perform the oil change when the hydraulic oil l Unscrew the plug (Fig. 165) and drain off all
is warm. hydraulic oil.
Clean the area round hydraulic oil tank, filler l Turn the plug tightly back in.
opening and breather filter.
Do not use any detergents to clean the system.
Do not start the engine after draining the hy-
draulic oil.
Replace the hydraulic oil filter element with
every hydraulic oil change.

Danger
!

Danger of scalding!
Danger of scalding by hot oil.

Environment Fig. 166

Catch running out oil and dispose of environ- l Remove the filler cap (Fig. 166).
mentally.
l Fill in new hydraulic oil through the screen.
i Note
Generally replace the hydraulic oil filter element i Note
after the test run. We recommend to use the filling and filtering unit
(BOMAG part-no. 079 930 35) with fine filter to fill
the hydraulic system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the hy-
draulic oil filter and protects the hydraulic system.
l Check the oil level in the inspection glass.
Nominal value:
approx. 3 cm below the upper edge of the inspec-
tion glass

BW 219 D-4 / PD-4 BOMAG 107

Every 2000 operating hours

For quality and quantity of oil refer to the table

of fuels and lubricants. 5.41 Changing the hydraulic oil
filter
i Note
The breather filter for the hydraulic oil tank is inte-
grated in the filler cap, you must therefore replace Danger
!

the complete filler cap. Danger of scalding!

l Close the tank with a new filler cap. There is a danger of scalding by hot oil when
unscrewing the filter.

! Caution
If the filter has to be changed together with the
hydraulic oil, the filter should in any case be
changed after the oil change and the test run.
Do not use the oil in the filter bowl.

Environment
Catch running out oil, dispose of oil and filter
element environmentally.

i Note
The filter element must be changed with every hy-
draulic oil change and after major repairs in the hy-
draulic system.

Fig. 167

l Unscrew the cap nut 4 (Fig. 167) and take the

filter bowl (5) with the filter element (3) off.
l Examine the sealing face on the filter element
thoroughly for any visible dirt.

! Caution
Visible impurities may be an early indicator for
a failure of system components and predict the

108 BOMAG BW 219 D-4 / PD-4

 Every 2000 operating hours

possible malfunction of important parts. In

such a case you should perform trouble shoot- 5.42 Change the coolant
ing and replace or repair the defective compo-
nents. Nonobservance may lead to total
damage of the hydraulic system. Danger
!

Do not clean or reuse the filter element. Danger of scalding!

l Take the old filter element (3) out and clean Change the coolant only when the engine is
the filter bowl and the thread. cold.
l Reinstall the filter bowl with the new filter ele-
ment, check the condition of the O-rings (1) Environment
and (2), replace if necessary. Catch running out coolant and dispose of envi-
l After a test run check the filter for leaks. ronmentally.

Fig. 168

l Set the cock valve for the cabin heater to posi-

tion "warm".

Fig. 169

l Unscrew the plug, let the coolant run out and

catch it.
l Screw the plug back in once all coolant has run
out.

BW 219 D-4 / PD-4 BOMAG 109

Every 2000 operating hours

5.43 Replacing the crank case

pressure ventilation valve

Fig. 170

l Unscrew the cap and fill in coolant up to the

MAX-mark (Fig. 170).
For quality of coolant refer to the chapter 5.2,
fuels and lubricants. Fig. 171

l Start the diesel engine and run it warm to op- l Replace the crank case ventilation valve (Fig.
erating temperature. 171).
l Let the engine cool down and check the cool-
ant level again, top up if necessary.

110 BOMAG BW 219 D-4 / PD-4

 Every 6000 operating hours

5.44 Replacing the injector

Every 6000 operating hours

i Note
This work must only be performed by authorized
service personnel.

BW 219 D-4 / PD-4 BOMAG 111

 As required

5.45 Service the combustion air i Note

As required

Once the air filter service indicator lights up, work

filter may be continued until the end of the day.

Caution
!

Perform cleaning, maintenance and repair

work only with the engine shut down. Do not
start the engine after removing the filter ele-
ment.
Do not use gasoline or hot fluids to clean the
filter element.
After cleaning the filter element must be in-
spected for damage using a torch.
Air filter elements with damaged paper bellows
or seal lips must be replaced in any case.
The main filter element must be replaced after
Fig. 173

3 times cleaning, but at the latest after one l Open the engine hood (Fig. 173) completely
year, irrespective of the operating hours. and secure it.
Each cleaning interval must be marked with a
cross on the cover of the filter element. Removing the main filter element
Cleaning does not make sense if the air filter
element is covered with a sooty deposit. Use a
new filter element.
Incorrectly handled filter elements may be-
come ineffective because of damage (e.g.:
cracks) and cause engine damage.

Fig. 174

l Loosen both locking hooks (Fig. 174) on the

housing cover and take the cover off.

Fig. 172

Maintenance of the dry air filter is due when con-

trol light “c” (Fig. 172) in the instrument cluster
lights permanently when the engine is running, but
at the latest after one year.

112 BOMAG BW 219 D-4 / PD-4

 As required

Fig. 175 Fig. 176

l Pull out the main filter element (Fig. 175) with l Blow the filter cartridge out from inside to out-
light turning movements. side with dry compressed air (max. 5 bar) (Fig.
176), until all dust has been removed.
Cleaning the main filter element
! Caution
If necessary, the main filter element may be
cleaned up to five times. It must be renewed at
the latest after a maximum utilization period of
two years.
The number of cleaning intervals of the main
filter element can be marked on the safety ele-
ment with a ball pen or a felt pen.
Cleaning does not make sense if the main filter
element is covered with a sooty deposit. Use a
new filter cartridge. Fig. 177

Incorrectly handled inserts may be ineffective l Examine the filter cartridge with a torch for
because of damage (e.g. cracks) and cause cracks and holes in the paper bellows (Fig.
damage to the engine. 177).
Replace the safety cartridge if the main filter el-
ement is defective! Caution
!

Additional cleaning intervals between two fil- Do not continue to run the machine with a
ter services signalized by the fault monitoring damaged main filter element. If in doubt use a
board are not necessary. new main filter element.

BW 219 D-4 / PD-4 BOMAG 113

As required

Cleaning the dust bowl if the warning light comes on again after serv-
icing the main filter cartridge.
l Remove the housing cover and pull the main
filter element off.

Fig. 178

l Pull the internal part (Fig. 178) out and remove

the dust from the cover.
l Reinsert the inner part. Fig. 179

l Pull the safety element (Fig. 179) out by slight

turning movements.
Caution
Push in a new safety filter element.
!

When assembling the inner part make sure l

that the notch in the cover engages in the l Reassemble main filter element and cover.
opening of the inner part.
Caution
Installing the main filter element
!

Make sure that the cover locks engage correct-

l Slide the main filter element carefully into the ly.
housing.
When closing the housing cover the main filter el-
ement is automatically forced in the correct posi-
tion.
Changing the safety filter element
! Caution
The safety filter element must not be cleaned
and should not be used again after it has been
removed.
Break the seal only to replace the safety filter
element.
The safety filter element must be replaced:
If the main filter element is defective.
after five service intervals of the filter car-
tridge,
at the latest after 2 years,

114 BOMAG BW 219 D-4 / PD-4

 As required

5.46 Adjust the scrapers

Smooth drum
l Check adjustment and condition of front and
rear scrapers, if necessary adjust or replace
the scraper rubber.

Fig. 181

l Check adjustment and condition of scrapers

(Fig. 181), adjust or replace the teeth if neces-
sary.
l To adjust the scrapers slacken the clamping
screws and push the scrapers towards the
drum, leaving a gap of about 25 mm.
l Retighten the clamping screws.
Fig. 180

l In order to adjust the scrapers 2 (Fig. 180),

slacken the fastening screws (1) in the slots
and push the scraper towards the drum to con-
tact.
l Retighten the fastening screws.
Padfoot drum
l Check adjustment and condition of front and
rear scrapers, if necessary adjust or replace
the scraper rubber.

BW 219 D-4 / PD-4 BOMAG 115

As required

5.47 Adjust the parking brake

!Caution
Have adjustment work on the brakes only car-
ried out by a specialist! Always adjust both
sides.
l Secure the machine with wheel chocks
against rolling.
l Start the diesel engine to relieve the brake.
Fig. 184

l In order to adjust the brake clearance turn the

square 1 (Fig. 184) three turns back in clock-
wise direction.
l Fasten the locking plate again.
l Pull the plug off the brake solenoid valve and
perform the drive test.
The machine must be braked.

Fig. 182

l Disengage the travel lever (Fig. 182) to the

left, but do not move to position "I" or "II".
The parking brake is released

Fig. 183

l Unscrew locking plate 2 (Fig. 183).

l Turn the square (1) in anti-clockwise direction
against the stop.

116 BOMAG BW 219 D-4 / PD-4

 As required

5.48 Changing the tires 5.49 Change the fresh air filter in
the cabin
Danger
!

Danger of accident!
Observe all safety notes for the lifting of loads.
l Place a jack (min. 5 t bearing capacity) under
the rear frame and jack the machine up so that
the wheel can turn freely.
l Unscrew the wheel nuts and take the wheel
off.

Fig. 186

l Unscrew fastening screws for the ventilation

grid (Fig. 186) and remove the filter.
l Insert a new filter and reassemble the ventila-
tion grid.

Fig. 185

l Attach the wheel (Fig. 185) and tighten the

wheel nuts crosswise with 550 Nm (405 ft. lb.).
l Check the tire pressure, see technical data.

BW 219 D-4 / PD-4 BOMAG 117

As required

5.50 Tightening torques 5.51 Engine conservation

If the engine is to be shut down for a longer period
of time (e.g. over winter), please consult the serv-
ice department of the engine manufacturer for fur-
ther details.

Fig. 187

* Strength classes for screws with untreated, non-

lubricated surface. Screw quality designations are
stamped on the screw heads.
8.8 = 8G
10.9 = 10K
12.9 = 12K
l Axle - frame
M 24x2 = 800 Nm
l Wheel nuts
M 22x1.5 = 550 Nm
The values result in a 90% utilization of the screw
yield point at a coefficient of friction μ total = 0,14.
When using lubricant MOS the specified tighten-
2

ing torques do not apply.

i Note
Self-locking nuts must always be replaced once
they have been unscrewed.

118 BOMAG BW 219 D-4 / PD-4

 6 Trouble shooting

BW 219 D-4 / PD-4 BOMAG 119

Trouble shooting

6.1 General notes 6.2 Reading out faults BVC/

BTM05
The following work must only be carried out by
qualified and trained personnel or by the sales
service.
Please observe strictly the safety regulations
in chapter 2 of these operating and mainte-
nance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serv-
iced. Therefore, whenever a fault occurs, read
through these instructions on correct operation
and maintenance. If you cannot locate the cause
of the fault or eliminate it yourself by following the
trouble shooting charts, you should contact our
customer service departments at our branch office
or dealers. Fig. 188

l Turn the ignition key (Fig. 188) to position "I".

! Danger
Danger of injury!
Keep away from rotating parts of the engine.

Fig. 189

l Press key ’’?“ (menu) (Fig. 189).

i Note
The menu appears on the screen.

120 BOMAG BW 219 D-4 / PD-4

 Trouble shooting

Fig. 190

l Press key "F5" (diagnostics) (Fig. 190).

i Note
The screen with the currently available fault codes
is displayed.

Fig. 191

l Currently present faults are indicated by a cor-

responding fault code in the field "Actual Er-
rors".
l Press key "ESC" (Fig. 191) to leave the screen
page with the actual fault codes.

BW 219 D-4 / PD-4 BOMAG 121

Trouble shooting

6.3 Engine
Faults Possible cause Remedy
The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank
Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.
Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.
Fuel lines leaking Check all line connections for leakages
and tighten the fittings.
Battery discharged or not connected Tighten the pole clamps, check the cable
connections
Injection valves or injection pump defec- Have examined by a specialist
tive
The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature
Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Incorrect valve clearance Adjust the valve clearance
Injection valve defective Have examined by a specialist
Injection lines leaking Check the lines for leakages
Turbo charger defective Have examined by a specialist
Dry air filter dirty clean, replace if necessary
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary

122 BOMAG BW 219 D-4 / PD-4

 Trouble shooting

Faults Possible cause Remedy

Excessive ex- Engine oil level too high
haust smoke
Dry air filter dirty
Exhaust gas turbo-charger defective
Poor compression due to burned or bro-
ken compression rings or incorrect valve
clearance
Incorrect valve clearance
Engine over- Cooling fins on radiator extremely soiled
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Injection valve defective
Engine oil level too low
Filling capacity of the injection pump not
correctly adjusted
Cooling air flow restricted
V-belt loos or broken
Poor engine Engine oil level too high
power
Dry air filter dirty
Exhaust gas turbo-charger defective
Charge air hose leaking
Incorrect valve clearance
Injection valve defective
Engine oil pres- Engine oil level too low (control light "en-
sure too low gine oil pressure" lights, the warning
buzzer sounds)
Leakages in the lubrication system
The charge con- Generator speed too low
trol light lights
during opera-
tion, the warning The generator does not charge the bat-
buzzer sounds tery, because generator or regulator is de-
fective
Drain the oil to the upper dipstick mark
clean, replace if necessary
Have examined by a specialist
Have compression rings and pistons ex-
amined by a specialist, adjust the valve
clearance
Adjust the valve clearance
Clean the cooling fins
Have examined by a specialist
Top up engine oil to the upper dipstick
mark
Have adjusted by a specialist
Clean the cooling air duct
Tension or replace the V-belt
Drain the engine oil down to the upper dip-
stick mark
clean, change if necessary
Have examined by a specialist
Check fastening and connections
Adjust the valve clearance
Have examined by a specialist
Top up oil
Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
Check the V-belt tension, replace the V-
belt if necessary
Have examined by a specialis

BW 219 D-4 / PD-4 BOMAG 123

Trouble shooting

124 BOMAG BW 219 D-4 / PD-4

 Trouble shooting

after another 2
6.4 Reading out fault codes of seconds = 1 x long flash of 0.8 second of
the electronic engine con- the second digit for the stored
fault
trol (EMR) after another 2
seconds = 1 x short flash of 0,4 second of
the third digit for the stored
!Caution fault
In case of a fault make a note of the fault code Write down the fault code and transmit it to the
and inform the BOMAG customer service or l
customer service department.
the customer service of the engine manufac-
turer. After output of
The diagnostic button provides the possibility to fault code = 5 seconds pause, the display
read out existing faults in form of flashing codes. by flashing and permanent
light.)
Example fault code 211 l If necessary repeat as described above to
read out the next fault code.

Fig. 192

l Press the diagnose button (Fig. 192) for ap-

prox. 1 to 3 seconds, then release the button.

Fig. 193

After 2 seconds = 2 x short flashes of 0.4 sec-

onds of the first digit (recogni-
tion of the EMR 2) (Fig. 193).
1

1 Ele ctronic e ngine contro l

BW 219 D-4 / PD-4 BOMAG 125

Trouble shooting

126 BOMAG BW 219 D-4 / PD-4

 7 Cab assembly before initial start-up

BW 219 D-4 / PD-4 BOMAG 127

Cab assembly before initial start-up
General safety regulations for assem-
bly
When installing the cabin to your BOMAG ma-
chine you must strictly comply with the valid
accident prevention instructions or the coun-
try specific regulations. However, dangers for
persons and property may still arise, if:
l the lifting gear used has a too low bearing ca-
pacity
l damaged or worn lifting tackle is used
l unqualified personnel is entrusted with the in-
stallation
l the safety instructions are not observed
Each person involved in the installation of the
cabin must therefore read and comply with
these safety regulations. If necessary, the cus-
tomer must demand a written confirmation
with signature.
Moreover, the following instructions and regula-
tions must obviously also be complied with:
applicable accident prevention instructions
l
l generally accepted safety and road traffic reg-
ulations
l country specific safety regulations. It is the
duty of the operator to be acquainted with
these instructions and to apply these accord-
ingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instruc-
tions be different from the regulations valid in
your country, you must comply with the safety
regulations valid in your country.
Changes and conversions to the cabin/
machine
Unauthorized changes to the cabin are prohibited
for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
plicitly clear that we have not tested or approved
any parts or accessories not supplied by us. The
installation and/or use of such products may have
an adverse effect on the active and/or passive
driving safety.
128 BOMAG
The manufacturer explicitly excludes any liability
for damage caused by the use of non-original
parts or accessories.
Notes on safety in the assembly in-
structions
Danger
!
Paragraphs marked like this highlight possible
dangers for persons.
Caution
!
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
i Note
Paragraphs marked like this contains technical in-
formation and hints for optimal assembly.
Environment
Paragraphs marked like this point out practic-
es for safe and environmental disposal of fuels
and lubricants as well as replacement parts.
Strictly observe the national regulations for
the protection of the environment.
Information and safety stickers/decals
on the cabin
Keep stickers/decals in good and legible condition
(see spare parts catalogue) and comply with their
meaning.
Replace damaged stickers/decals
Work on heating lines
Before starting work on heating pipes relieve any
pressure and let them cool down - danger of scald-
ing!
After completing work on the heating system of the
machine check all connections and fittings for
leaks.
Working on electric parts of the ma-
chine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
BW 219 D-4 / PD-4
 Cab assembly before initial start-up

Do not use fuses with higher ampere ratings and

do not repair fuses with a piece of wire. Fire haz- 7.1 Preparations
ard.
!Danger
Danger of accident!
For transport purposes the driver's seat must
be tied down with cable straps thus to operate
the seat contact switch. Before resuming oper-
ation of the machine these cable straps must
strictly be removed to ensure safe and reliable
function of the seat contact switch.
Check the 4 lifting eyes on the cabin roof for
tight fit.
Fasten the lifting gear to all four lifting eyes.
Use lifting gear (chains or ropes) of sufficient
load bearing capacity. The minimum load bear-
ing capacity of the crane must be 1000 kg.
Do not stand or step under loads being lifted.

Fig. 194

l Make sure that all fastening screws, washers,

spacers and nuts to fasten the cabin are avail-
able (Fig. 194).
l Check whether rear rack, foot mat, step plate
and fastening kit are available.

BW 219 D-4 / PD-4 BOMAG 129

Cab assembly before initial start-up

7.2 Cabin assembly

!Danger
Danger of accident!
Use lifting gear (chains or ropes) of sufficient
load bearing capacity. The minimum load bear-
ing capacity of the crane must be 1000 kg.
Do not stand or step under loads being lifted.
l Clean the operator's stand of dirt, oil and mois-
ture.
Fig. 195

l Fasten the lifting gear to the four lifting eyes 1

(Fig. 195).
l Loosen possible fastening on the transport
pallet.
l Slowly list the crane with a crane.

Danger
!

Danger of accident!
Do not stand or step under loads being lifted.

Fig. 196

l Stick the supplied sealing tape 1 (Fig. 196)

along the edge of the operator's stand.

Caution
!

Only unroll and stick the sealing tape on just

before mounting the cab to the operator's
stand. The sealing tape will swell a few min-
utes after being unrolled. In this case the cabin
can no longer be mounted!

130 BOMAG BW 219 D-4 / PD-4

 Cab assembly before initial start-up

Fig. 197 Fig. 199

l Stick the sealing tape 1 (Fig. 197) all around l Slowly lower the cabin vertically to the opera-
the operator's stand. tor's stand (Fig. 199).
l Do not run the sealing tape across the front re-
cess in the operator's stand (2), since this is Caution
!

the air inlet for the cabin ventilation. The cabin must be lowered vertically onto the
operator's stand.
i Note
Mount the cabin immediately after sticking on the
sealing tape, because the sealing tape will swell.

Fig. 200

Caution
!

Fig. 198
l Spray the sealing tape with soapsuds (Fig.
198), to be able to slide the cabin on the oper-
ator's stand.
Take care that none of the hoses and electric
cables become squashed (Fig. 200).
Run cables and hoses from inside the cabin
l
through the operator's stand to the outside.

BW 219 D-4 / PD-4 BOMAG 131

Cab assembly before initial start-up

Fig. 201 Fig. 203

l Turn both fastening screws (Fig. 201) at the l Tighten the bottom fastening screw on the ac-
rear of the cabin in hand tight. cess side (Fig. 203) with 578 Nm.

Fig. 202 Fig. 204

l Loosen both fastening screws (Fig. 204) at the

i Note rear of the cabin again.
If the bores do not match the cabin can be moved
into position by means of a crow bar (Fig. 202). i Note
The cabin will now slide into final assembly posi-
tion.
l Tighten both fastening screws (Fig. 204) at the
rear of the cabin with 578 Nm.

132 BOMAG BW 219 D-4 / PD-4

 Cab assembly before initial start-up

Fig. 205 Fig. 208

l Tighten the rear lateral fastening screw on the l Turn nuts with washers onto both studs and
left hand side with 578 Nm (Fig. 205). tighten with 200 Nm (Fig. 208).

Fig. 206 Fig. 209

l Tighten the rear lateral fastening screw on the l Tighten the front lateral fastening screw on the
right hand side with 578 Nm (Fig. 206). right hand side with 578 Nm (Fig. 209).

Fig. 207 Fig. 210

l Tighten the rear inside fastening screw on the l Tighten the front lateral fastening screw on the
right hand side with 578 Nm (Fig. 207). left hand side with 578 Nm (Fig. 210).

BW 219 D-4 / PD-4 BOMAG 133

Cab assembly before initial start-up

Fig. 211 Fig. 214

l Cover all lateral fastening screws with plastic l Insert the dashboard and fasten it with four
caps (Fig. 211). fastening screws (Fig. 214).

Fig. 212 Fig. 215

l Insert the foot mat 1 (Fig. 212). l Remove all cable straps from the seat console
(Fig. 215) to activate the seat contact switch.

Fig. 213

l Attach the step plate 1 (Fig. 213) and tighten Fig. 216

the three fastening screws (2). l Insert the rear rack and knock both plastic fas-
teners carefully into the bores with a hammer
(Fig. 216).

134 BOMAG BW 219 D-4 / PD-4

 Cab assembly before initial start-up

Fig. 217 Fig. 219

l Connect the feed 1 (Fig. 217) and the return
flow (2) for the air conditioning system with
quick release couplings.
l Connect the feed (4) and the return flow (3) of
the heating. (Observe the marks on the hos-
es).
l Plug on the hoses for the washing water sup-
ply to front and rear windscreens 1 (Fig. 219).
i Note
Check the function of the washing water system
within the scope of the function test.

i Note
Run the connecting lines for the heating parallel to
each other (do not cross).

i Note
Check the function of air conditioning and heating
within the scope of the function test.
Observe identical hose diameters when connect-
ing.

Fig. 220

l Insert the plug 1 (Fig. 220) into the socket (2).

l Close the bayonet catch by turning the corru-
gated cap nut in clockwise direction against
the stop.

Danger
!

Before starting to work on electric parts of the

machine disconnect the battery and cover it
with insulating material.
Fig. 218

l Plug on both connecting plugs for the washing

water pumps (Fig. 218).

BW 219 D-4 / PD-4 BOMAG 135

Cab assembly before initial start-up

7.3 Final function tests and

checks
Caution
!

Make sure that all screws have been tightened

with the specified torque.

i Note
After the cabin assembly the following tests must
be performed to assure that all cables and lines
Fig. 221 are correctly connected.
l Connect the plug connection of the air condi- Insert the ignition key and turn clockwise to po-
tioning system (Fig. 221).
l
sition "1".
l Operate the switches for headlights, direction
indicators and interior light to check their func-
tion.
l Operate the switches for front and rear wind-
screen washer system and check their correct
function.

i Note
If the function of the windscreen washer system is
reversed, the two washing water hoses must be in-
terchanged.
l Start the engine.
l Switch the air conditioning on by the switch.
After a five minute operation the cabin must
become noticeably cooler.
l Switch the air heater on by the switch. After a
five minute operation the cabin must become
noticeably warmer.
l Function of the seat contact switch.

Caution
!

The machine must not be operated if the seat

contact switch is not functioning correctly.

136 BOMAG BW 219 D-4 / PD-4