OMM BW219D-4 BF6M2012C 00812981.a05

Operating instructions
Maintenance instructions
BW 219 D-4 / PD-4

S/N 101 582 72 .... S/N 101 582 73 ....
Single drum roller
Catalogue number
008 129 81 01/2005
Foreword
BOMAG machines are products from the wide You should only operate the machine after you
F oreword
range of BOMAG compaction equipment. have been instructed and in compliance with these
instructions.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth- Strictly observe the safety regulations.
ods, such as lifetime tests of all important Please observe also the guidelines of the Civil En-
components and highest quality demands gineering Liability Association ”Safety Rules for
guarantee maximum reliability of your ma- the Operation of Road Rollers and Soil Compac-
chine. tors” and all relevant accident prevention regula-
tions.
This manual comprises:
For your own personal safety you should only
l Safety regulations use original spare parts from BOMAG.
l Operating instructions
In the course of technical development we re-
l Maintenance instructions serve the right for technical modifications
l Trouble shooting without prior notification.
These operating and maintenance instructions are
Using these instructions will also available in other languages.
l help you to become familiar with the machine. Apart from that, the spare parts catalogue is avail-
l avoid malfunctions caused by unprofessional able from your BOMAG dealer against the serial
operation. number of your machine.
Your BOMAG dealer will also supply you with in-
Compliance with the maintenance instructions will formation about the correct use of our machines in
l enhance the reliability of the machine on con- soil and asphalt construction.
struction sites, The above notes do not constitute an extension of
l prolong the lifetime of the machine, the warranty and liability conditions specified in the
general terms of business of BOMAG GmbH.
l reduce repair costs and downtimes.
We wish you successful work with your BOMAG
BOMAG GmbH will not assume liability for the machine.
function of the machine BOMAG GmbH
l if it is handled in a way not complying with the Printed in Germany
usual modes of use,
Copyright by BOMAG
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/BW 219 PD-4 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/BW 219 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 37
3.5 Line diagram (EVIB) 39
3.6 Description of line diagram (EVIB) 41
3.7 Bar diagram (EVIB) 42
Operation 43
4.2 Tests before starting to operate 44
4.3 Starting the engine 45
4.4 Starting with jump wires 47
4.5 Driving the machine 47
4.6 Switching the vibration on and off 49
4.7 Operating the parking brake, stopping the machine 50
4.8 Shutting the engine down 51
4.9 Emergency exit 52
4.10 Adjusting the steering wheel 52
4.11 Adjusting the seat 53
4.12 Operating the hood 53
4.13 Towing in case of an engine failure 54
4.14 Transport 56
4.15 Measuring pass with BTM 58
4.16 Finishing compaction of a track 61
4.17 Printing measuring data after completing compaction 62
4.18 Changing the paper roll in the measuring value printer 63
4.19 Changing the printer ribbon in the measuring value printer 64
Maintenance 65
5.1 General notes on maintenance 66
5.2 Fuels and lubricants 67
5.3 Table of fuels and lubricants 70
5.4 Running-in instructions 71
5.5 Maintenance chart 72
5.6 Check the engine oil level 75
5.7 Check, clean the water separator 75
5.8 Check the fuel level 76

Table of Contents
5.9 Checking the hydraulic oil level 77

5.10 Check the coolant level 77
5.11 Checking the dust separator on the oil bath air filter 78
5.12 Checking the tire pressure 79
5.13 Clean the cooling fins on engine and hydraulic oil cooler 79
5.14 Check the oil level in the drive axle 80
5.15 Check the oil level in the wheel hubs 81
5.16 Check the oil level in the axle reduction gear 81
5.17 Check the oil level in the drum reduction gear 82
5.18 Check the oil level in the vibration bearings 83
5.19 Changing engine oil and oil filter cartridges 84
5.20 Change the fuel filter cartridge 85
5.21 Draining the sludge from the fuel tank 86
5.22 Service the battery 87
5.23 Change the fuel pre-filter cartridge 88
5.24 Checking, replacing the refrigerant compressor V-belt 89
5.25 Service the air conditioning 90
5.26 Checking, adjusting the valve clearance 93
5.27 Checking / replacing the ribbed V-belt 95
5.28 Check the engine mounts 96
5.29 Change the oil in the drive axle 96
5.30 Change the oil in the wheel hubs 97
5.31 Changing the oil in the axle reduction gear 98
5.32 Change the oil in the drum reduction gear 99
5.33 Change the oil in the vibration bearings 100
5.34 Tightening the fastening of the axle to the frame 101
5.35 Tighten the wheel nuts 101
5.36 Check the ROPS 102
5.37 Cleaning the oil bath air filter 102
5.38 Changing hydraulic oil and breather filter 103
5.39 Changing the hydraulic oil filter 104
5.40 Changing the coolant 105
5.41 Checking the injection valves 107
5.42 Service the combustion air filter 109
5.43 Adjust the scrapers 112
5.44 Adjust the parking brake 113
5.45 Changing the tires 114
5.46 Change the fresh air filter in the cabin 115
5.47 Tightening torques 115
5.48 Engine conservation 116
Trouble shooting 117

Table of Contents
6.2 Engine 119

Cab assembly before initial start-up 123
7.1 Preparations 125
7.2 Cabin assembly 126
7.3 Final function tests and checks 132

Table of Contents

1 Technical Data

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
*
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 ... 6,5 0 ... 6,5
Travel speed 4 km/h 0 ... 10,5 0 ... 10,5
Max. gradability (depend- % 50 50
ing on soil)
10 BOMAG BW 219 D-4/BW 219 PD-4

Technical Data
* BW 219 D-4 BW 219 PD-4

Engine
Engine manufacturer Deutz Deutz
Type BF6M 2012 C BF6M 2012 C
Cooling Water Water
Number of cylinders 6 6
Rated power ISO 3046 kW 147 147
Rated speed rpm 2300 2300
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 2,02 2,02
Tires
Tire size 23.1-26/12 TL R3 23.1-26/12 TL R1
Air pressure bar 1,6 1,5
Filling capacities
Engine Litres 12,5 12,5
Fuel Litres 340 340
Hydraulic oil Litres 60 60
* The right for technical modifications remains reserved
BW 219 D-4/BW 219 PD-4 BOMAG 11

Technical Data
12 BOMAG BW 219 D-4/BW 219 PD-4

2 Safety regulations
BW 219 D-4/BW 219 PD-4 BOMAG 13

Safety regulations
General Unintended use

This BOMAG machine is built in accordance Dangers may, however, arise from the machine if
with the latest technical standard and the valid it is used by untrained personnel in an unprofes-
technical rules and regulations. There is, how- sional way or if it is used for purposes other than
ever, a risk of danger for persons and property those mentioned in these instructions.
if: Do not work with vibration on hard concrete, on a
cured concrete layer or heavily frozen ground.
l the machine is used for purposes other than
those it is intended for Starting and operation of the machine in an explo-
sive environment is prohibited.
l the machine is operated by untrained person-
nel
Who is allowed to work with the ma-
l the machine is modified or converted in an un-
professional way
chine?
The machine must only be operated by trained
l the applicable safety regulations are not ob-
and authorized persons which are at least 18
served.
years of age. The responsibilities for the operation
Each person involved in operation, mainte- of the machine must be clearly specified and com-
nance and repair of the machine must there- plied with.
fore read and apply these safety regulations. Persons under the influence of alcohol, medica-
This should be confirmed by obtaining the sig- tion or drugs must not operate, service or repair
natures of the customer, if necessary. the machine.
Furthermore the following regulations and instruc- Maintenance and repair tasks require specific
tions are obviously also valid: knowledge and must therefore only be carried out
l applicable accident prevention instructions by trained and qualified personnel.
l generally acknowledged safety and road traffic

regulations Conversions and alterations to the ma-
chine
l country specific safety regulations. It is the
duty of the operator to know and observe Unauthorized conversions to the machine are pro-
these regulations. This applies also for local hibited for safety reasons.
regulations and the regulations for various Original parts and accessories have been special-
types of manual work. If the recommendations ly designed for this machine. We wish to make ex-
in this manual differ from the regulations valid pressly clear that we have not tested or authorized
in your country, you must strictly observe the any original parts or special equipment not sup-
regulations in your country. plied by us. The installation and/or use of such
products can impair the active and/or passive driv-
Intended use ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
This machine must only be used for:
non-original parts or accessories.
l compaction of bituminous materials, e.g. road
surface layers. (AC and AD machines only) Safety notes in the operating and main-
l medium and heavy compaction tasks in earth tenance instructions:
work (road sub-bases)
l This machine must only be operated with fully Danger
!
functional safety equipment.
Sections marked like this point out possible
l The machine should be checked by an expert dangers for persons.
once every year.
14 BOMAG BW 219 D-4/BW 219 PD-4

Safety regulations
Caution
! Towing the machine
Sections marked like this point out possible You should generally use a tow bar.
dangers for the machine or for parts of the ma- Max. towing speed 1 km/h (1.6 mph), max. towing
chine. distance 500 m (1640 ft.).
Before releasing the multi-disc brakes secure the
i Note machine properly against unintended rolling.
Sections marked like this provide technical infor-
mation concerning the optimal economical use of Checking the Roll Over Protection
the machine. Structure (ROPS)
Environment i Note
Sections marked like this highlight activities On machines with cabin the ROPS is an integral
for the safe and environmental disposal of fu- part of the cabin.
els and lubricants as well as replaced parts.
The machine frame must not be distorted, bent or
Observe all environment protection regula- cracked in the area of the ROPS fastening points.
tions.
The ROPS must not show any signs of corrosion,
damage, hairline cracks or open fractures.
Information and safety stickers/decals
The ROPS must not rattle about during driving.
on the machine This would mean that it is not properly fastened.
Keep stickers/decals complete (see spare parts All bolted connections must be in accordance with
catalogue) and fully legible and observe their the prescribed specifications and correctly tight-
meaning. ened (observe the tightening torque values).
Replace damaged or illegible stickers/decals im- Screws and nuts must not be damaged, bent or
mediately. deformed.
With the cabin installed check also the condition of
Loading the machine the cabin mounts (rubber elements and screws).
Use only strong and stable loading ramps. The Neither must any additional parts be welded or
ramp inclination must be lower than the gradability bolted on, nor must any holes be drilled without the
of the machine. permission of the manufacturer, since this may im-
pair the strength of the structure.
Secure the machine against turning over or slip-
ping off.
Starting the machine
Secure the machine on the transport vehicle
against rolling off, slipping and turning over. Before starting
Persons are highly endangered if Operation of the machine is only permitted when
l they step or stand under loads being lifted sitting in the operator's seat.
l they remain in the drive range of the machine Use only machines which have been properly
during a demonstration or during loading. serviced at regular intervals.
Become acquainted with the equipment, the con-
The machine must not swing about when lifted off
trol elements, the working mode of the machine
the ground.
and the area you will be working in.
Use only safe lifting gear of sufficient load bearing
Use your personal protective outfit (hard hat, safe-
capacity.
ty boots etc.).
Attach the lifting gear only to the specified lifting
Check before mounting the machine if:
points.
l there are persons or obstructions beside or
under the machine
BW 219 D-4/BW 219 PD-4 BOMAG 15

Safety regulations
l the machine is free of any oily and combustible Driving the machine
material
Persons in the endangered area
l all handrails, steps and platforms are free of
grease, oils, fuels, dirt, snow and ice If the machine has turned over and the cabin door
is jammed, use the right hand cabin window as an
l the engine compartment hood is closed and emergency exit.
locked
Before starting or resuming work and especially
To climb onto the machine use steps and hand- when driving backwards, check that there are no
rails. persons or obstructions in the endangered area.
Check before starting, whether: If necessary give warning signals. Stop work im-
l the machine shows any obvious defects mediately if persons remain in the danger area de-
spite the warning.
l all protective devices are properly secured in
their place Do not step or stand into the articulation area of
the machine while the engine is running. Danger of
l steering, brakes, control elements, lighting squashing!
and warning horn are in order
Driving
l the seat is correctly adjusted
In events of emergency actuate the emergency
l the mirrors (if available) are clean and correct-
stop switch immediately. Do not use the emergen-
ly adjusted.
cy stop push button as service brake.
Do not start the machine if any gauges, control
Restart the machine only after the danger, that has
lights or controls are defective.
caused the actuation of the emergency stop, has
Do not take any loose objects with you or fasten been eliminated.
them to the machine.
If the machine has come in contact with high-volt-
On machines with ROPS you should always wear age power lines:
your seat belt!
l do not leave the operator's stand
Starting l warn others from coming too close to the ma-
Start and operate the machine only from the oper- chine or touching it
ator's seat l if possible drive the machine out of the danger
For starting set all control levers to "neutral posi- zone
tion".
l have the power shut off.
Do not use any starting aids such as Start Pilot or
Operate the machine only from the operator's
ether.
seat.
After starting check all gauges.
Keep the cabin doors closed.
Starting with jump leads Do not adjust the seat while driving.
Connect plus with plus and minus with minus Do not climb onto or off the machine while driving.
(ground cable) - always connect the ground cable
Change the travel direction only while the machine
last and disconnect it first! Wrong connections
is standing.
may cause severe damage in the electric system.
Do not use the machine to transport persons.
Never start the engine by bridging the electrical
connections on the starter, because the machine Stop the machine if you notice unusual noises or
would probably start to move immediately. the development of smoke. Investigate the cause
and have the fault corrected.
Starting in closed rooms
Keep a sufficient distance to excavations and em-
Exhaust gases are toxic! Always ensure an ade- bankments and make sure that you work does not
quate supply of fresh air when starting in closed impair the stability of the machine.
rooms!
16 BOMAG BW 219 D-4/BW 219 PD-4

Safety regulations
Do not work with vibration on hard concrete, on a Parking on slopes and gradients
cured concrete layer or heavily frozen ground. Secure the machine against rolling, place metal
When passing under flyovers, bridges, tunnels, chocks in front of and behind the drums.
electric power lines etc. keep a sufficient distance.
Driving on slopes and gradients Filling the fuel tank

Do not drive up and down gradients, which exceed Do not inhale fuel fumes.
the max. gradability of the machine. Refuel only after shutting the engine and the aux-
On lopes always drive directly up or down. Change iliary heater down.
to the lower speed range before approaching the Do not refuel in closed rooms.
slope. No open fire, do not smoke.
Wet and loose soils reduce the ground adhesion of Do not spill any fuel. Catch running out fuel, do not
the machine and inclinations and slopes consider- let it seep into the ground.
ably. Higher risk of accident!
Wipe off spilled fuel. Keep fuel free of dirt and wa-
Behaviour in traffic ter.
Match the speed of the machine to the working Leaking fuel tanks can cause explosions. Ensure
conditions. tight fit of the fuel tank filling cover, replace it if nec-
Always allow loaded transport vehicles to pass. essary.
Switch the lights on when the visibility is poor. Fire protection measures
Keep clear of edges and embankments. Make yourself acquainted with the location and the
operation of fire extinguishers. Observe fire warn-
Check the effect of vibration ing and fire fighting installations.
When compacting with vibration check the effect
of the vibration on nearby buildings and under- Maintenance
ground supply lines (gas, water, sewage, electric
power supply), stop vibratory compaction if neces- Observe the maintenance tasks described in the
sary. operating and maintenance instructions, including
the exchange of parts.
Do not work with vibration on hard (frozen, con-
crete) ground. Risk of bearing damage! For service and repair work in the engine compart-
ment support the engine compartment hood.
Parking the machine Maintenance work must only be carried out by
qualified and authorized personnel.
Park the machine on level and firm ground.
When performing maintenance work above body
Before leaving the machine: height use the access steps on the machine or any
l straighten the articulated joint to allow easy other safe ladders and working platforms. Do not
access to and from the machine. use machine parts as access steps.
l return the travel lever to neutral position Keep unauthorized persons away from the ma-
chine.
l apply the parking brake
Do not perform maintenance work with the ma-
l shut the engine down and pull the ignition key chine driving or the engine running.
out.
Park the machine on horizontal, level and stable
l lock the cabin ground.
l secure the machine against unauthorized use. Pull the key out of the ignition switch.
Do not jump off the machine, use access steps Lock the articulated joint with the articulation lock.
and hand rails.
Always secure parked machines, which could be
in the way, with appropriate measures.
BW 219 D-4/BW 219 PD-4 BOMAG 17

Safety regulations
Working on hydraulic lines l Do not mix up hoses by mistake.

Always relieve the pressure in the hydraulic circuit l damage or deformation of the fitting, which im-
before working on hydraulic lines. Hydraulic oil es- pairs the function and strength of the hose/
caping under pressure may penetrate through the hose connection.
skin and cause severe injury. In case of being in-
Only genuine BOMAG hydraulic hoses ensure
jured by hydraulic oil you should immediately seek
that the correct type of hose (pressure range) is
medical advice, as otherwise this may lead to se-
used at the right place.
rious infections.
When adjusting the hydraulic system do not stand Working on the engine
behind or in front of the drum/wheels. Shut the engine down before opening the engine
Do not change the setting of high pressure relief compartment hood.
valves. Drain the engine oil at operating temperature -
Drain hydraulic oil at operating temperature - dan- danger of scalding!
ger of scalding! Wipe off spilled oil, catch running out oil and dis-
Catch running out hydraulic oil and dispose of en- pose of environmentally.
vironmentally. Store used filters and other oily materials in a sep-
Always catch and dispose of biological hydraulic arate, specially marked container and dispose of
oils separately. environmentally.
Do not start the engine after draining off the hy- Do not leave any tools or other objects, which
draulic oil. could cause damage, in the engine compartment.
Once all work is completed (with the system de- Idle speed and full load speed must not be
pressurized!) check all connections and fittings for changed, since this would have a negative effect
tight and leak-free fit. on the exhaust gas values and cause damage to
engine and drive.
Changing hydraulic hoses
Turbo chargers work with high speeds and high
All hydraulic hoses must be inspected visually at temperatures. Keep hands, tools and materials
regular intervals. away from the intake and outlet openings of the
Hydraulic hoses must be changed immediately if: turbo charger and do not touch any hot surfaces.
l the outer layer is worn down to the metal lining Check and replace the coolant only when the en-
(e.g. chafing, cuts, cracks) gine is cold.
l embrittlement of the outer layer (development Catch running out coolant and dispose of environ-
of cracks in the hose material) mentally.
l deformation under pressurized and depressu- Working on electrical equipment

rized condition, which are not in accordance Before working on electrical equipment disconnect
with the normal shape of the hydraulic hose the battery and cover it with insulating material.
l deformation in bends, e.g, squeezes, kinks, Do not use any fuses with higher ampere ratings
layer separation, formation of blisters or repair a fuse with a piece of wire. Fire hazard!
l leakages. Always disconnect the battery before starting to
l non-observance of the installation require- wled on the machine.
ments Working on the battery
l separation of the hydraulic hose from the fit- When working on the battery do not smoke, do not
ting use open fire.
l corrosion of the fitting, which impairs the func- Do not let acid come in contact with skin and
tion and the strength. clothes. If being injured by acid flush off with clear
water and seek for medical advice.
18 BOMAG BW 219 D-4/BW 219 PD-4

Safety regulations
Metal objects (e.g. tools, rings, wrist watches) terials to the direct water jet, but cover them be-
must not contact the battery poles - danger of forehand.
short circuit and burns!
l Do not guide the water jet into the exhaust or
When recharging maintenance free batteries re- into the air filter.
move the plugs to avoid the accumulation of explo-
sive gases. After maintenance work
When using an external battery to start the ma- Reinstall all protective devices after completing
chine follow the respective instructions. the maintenance work.
Dispose of old batteries environmentally.
Repair
Switch the charging current off before removing
the charge clamps. Attach a warning tag to the steering wheel if the
machine is defective.
Ensure good ventilation, especially when charging
the battery in a closed room. Repairs must only be performed by qualified per-
sons who have been instructed for this purpose.
Working on the fuel system Use our repair instructions.
Do not inhale fuel fumes. Exhaust gases are highly dangerous! Always en-
No open fire, do not smoke, do not spill any fuel. sure an adequate supply of fresh air when starting
in closed rooms!
Catch running out fuel, do not let it seep into the
ground and dispose of environmentally. Test
Working on wheels and tires Depending on the type of application and the op-
erating conditions vibratory equipment has to be
Explosion like bursting of tires and parts of rims examined by a specialist whenever required, but
and tires can cause severe or even deadly injuries. at least once every year.
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/BW 219 PD-4 BOMAG 19

Safety regulations
20 BOMAG BW 219 D-4/BW 219 PD-4

3 Indicators and Controls
BW 219 D-4/BW 219 PD-4 BOMAG 21

Indicators and Controls
Fig. 5
22 BOMAG BW 219 D-4/BW 219 PD-4

1 Ignition switch 10 Push button for warning horn

2 Instrument cluster 11 Rotary momentary contact switch for engine
3 Vent for heating and ventilation, driver speed
4 Vent for heating and ventilation, footwell 12 Rotary switch for direction indicators left/right*
5 Push button vibration 13 Rotary switch for hazard light system*
6 Travel lever 14 Rotary switch for lighting (StVZO)*
7 Rotary switch vibration, high/low frequency 15 Rotary switch for working head lights*
8 Rotary switch for speed range selection 16 Steering wheel adjustment lever
9 Emergency stop push button
* Optional equipment
BW 219 D-4/BW 219 PD-4 BOMAG 23

3.1 General notes 3.2 Description of indicators

and control elements
Please read this section thoroughly before operat-
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/BW 219 PD-4

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.
Fig. 7 k yellow = not used
No. 2 = Instrument cluster l red = Hazard light, flashes when the haz-
ard light is activated
i Note m = Operating hour meter, counts the op-
With the ignition switch in position I all gauges and erating hours while the engine is run-
instruments are switched on for 3 seconds. ning. All maintenance work must be
performed according to the indicated
a red = flashes if the engine temperature ex- operating hours.
ceeds 135 °C, the warning buzzer
sounds, the engine is shut down after n = Fuel tank filling level
2 minutes. When falling below the lowest filling
Switch off vibration, run engine with level the last green LED will light and
idle speed or shut down engine if the red LED will additionally come on.
necessary, clean engine oil cooler When the fuel tank is empty only the
and radiator, if necessary repair en- red LED will flash.
gine. No. 3 = Vents for air conditioning, heating
and ventilation, driver
b red = flashes if engine oil pressure too low,
engine is shut down after 10 sec- No. 4 = Vents for air conditioning, heating
onds. Check engine oil level, repair and ventilation, footwell*
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/BW 219 PD-4 BOMAG 25

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
drive to the work location
i Note
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/BW 219 PD-4

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/BW 219 PD-4 BOMAG 27

Fig. 15 Fig. 17
No. 12 = Rotary switch for direction indicators No. 14 = Rotary switch for light system (StV-
left / right* ZO)***
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
No. 15 = Rotary switch for working lights****
Fig. 16
No. 13 = Rotary switch for hazard light system Position "left" = Light off
**
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.
* Optional equipment *** Optional equipment

** Optional equipment **** Optional equipment
28 BOMAG BW 219 D-4/BW 219 PD-4

i Note
Swivelling angle max. 20° to either side.
Fig. 19
No. 16 = Lever, steering wheel adjustment
Fig. 21
!Danger
Danger of accident! No. 18 = 2-pole socket
Current only with the ignition switch in position "I"
Do not adjust the steering wheel while driving.
or when the engine is running.
pull up = adjust height of steering wheel
press down = adjust inclination of steering
wheel
Fig. 22
No. 19 = Fuses in electric installation box
F03, 15A = Vibration
Fig. 20
F05, 15A = Socket
No. 17 = Lever, swivelling of driver’s seat
F07, 15A = Hazard light *
F09, 10A = Parking tail light, left*
!Danger
Danger of accident! F10, 10A = Parking tail light, right*
F11, 15A = Head lights, StVZO*
Always lock the driver’s seat in one of the lock-
ing positions while driving. F13, 30A = Starting
Do not swivel the driver’s seat while driving. F14, 15A = Engine solenoid
swivel = Stop the machine and apply F18, 10A = Working head lights, relay*
the parking brake. Pull the le- F19, 15A = Working head lights, front, left*
ver up and swivel the driver’s
seat to the desired position.
BW 219 D-4/BW 219 PD-4 BOMAG 29

F22, 15A = Working head lights, rear* d = toggle switch for rear windscreen heating
F23, 10A = Warning horn
F24, 10A = Monitoring, gauges
F25, 10A = Solenoid valve brake/travel
F39, 15A = Cab*
F70, 15A = Indicator*
F105, 20A = Engine speed control
! Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
Fig. 24
No. 20 = Fuse box, cabin
! Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
(1), 15A = (F43) wiper/washer, rear
(2), 15A = (F44) wiper/washer, front
(3), 10A = (F130) relay for rear windscreen
heating, reading light
(4), 25A = (F31) cabin fan
Fig. 23
(5), 10A = (F41) flashing beacon
a = toggle switch for flashing beacon
(6), 15A = (F144) cab socket
b = toggle switch for front windscreen wiper/ (7), 15A = (F143) rear windscreen heating
washer
(8), 5A = (F42) potential 30, cab light
up = windscreen wiper moves to
end position and stops.
down = Switches on wiping of front
windscreen.
Push button = Front windscreen is sprayed
during wiping.
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 Fig. 25
during wiping. No. 21 = Control panel for ventilator, air condi-
tioning, heating
30 BOMAG BW 219 D-4/BW 219 PD-4

e = Rotary switch for cabin ventilator i = reading and dashboard light

Position ’’Off“ = cabin ventilator switched off. j = toggle switch for reading and dashboard
Position 1, 2 and light
3 = ventilator stages of different
strengths k = toggle switch for cabin light
f = Push button for air conditioning* l = cabin light
press = air conditioning switched on.
i Note
The lights above the push buttons light up.
With rotary switch (g) the air conditioning unit can
be regulated within the blue range.
press again = air conditioning switched off.
i Note
The light goes out.
g = Rotary switch for cabin heater (tempera-

Fig. 27
ture selector switch)
No. 23 = Main fuse for battery
Position ’’Off“ = cabin heater switched off.
125A = (F00)
Position blue
range = temperature selection for air
conditioning. i Note
Position red Battery with main fuse is located in the engine
range = Temperature selection for cab- compartment
in heater.
Fig. 28
Fig. 26 No. 24 = EVIBdisplay**
No. 22 = Cabin light 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
* Optional equipment ** Optional equipment
BW 219 D-4/BW 219 PD-4 BOMAG 31

Constant = end of compaction
i Note
Modular upgrading to BTM plus / BTM prof and/or
BCM 05 possible.
32 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 33

3.3 Display and control ele-

ments
BTM*
34 BOMAG BW 219 D-4/BW 219 PD-4

Fig. 29
BW 219 D-4/BW 219 PD-4 BOMAG 35

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
36 BOMAG BW 219 D-4/BW 219 PD-4

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 Print* * only with BTM prof
BW 219 D-4/BW 219 PD-4 BOMAG 37

The selected value is shown on the screen in field

„P3“
No. 11 = Button F11 is not used
No. 14 = Rotary switch P1 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.
38 BOMAG BW 219 D-4/BW 219 PD-4

3.5 Line diagram* (EVIB)
* only BTM prof
Fig. 30
BW 219 D-4/BW 219 PD-4 BOMAG 39

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 E VIB value 18 Measuring value raster line
19 Diagram line
10 Mean EVIB-value
20 Marking (thin line) jumping of the drum
40 BOMAG BW 219 D-4/BW 219 PD-4

Graduation of the measuring track (track length in

*
3.6 Description of line diagram printout) into fixed sections.
(EVIB) No. 16 = Marking of jump information
Indicates excessive jumping/tumbling of the drum
on the marked track section (thick line).
No. 1 = Pass
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
assignment of the EVIB-value and the location of a
This gauge shows the vertical amplitude the ma-
fault (over or under compaction).
chine has worked with on this track.
No. 20 = Marking of jump information
No. 8 = Maxiumum EVIB value
Indicates jumping of the drum on the marked track
No. 9 = Miniumum E VIB value
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.
* only BTM prof
BW 219 D-4/BW 219 PD-4 BOMAG 41

3.7 Bar diagram* (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.
* only BTM prof
42 BOMAG BW 219 D-4/BW 219 PD-4

4 Operation
BW 219 D-4/BW 219 PD-4 BOMAG 43

Operation
4.1 General notes 4.2 Tests before starting to op-

erate
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
The following tests must be performed before
you are not yet fully familiar with the indicators and
each work day or before a longer work period.
control elements of the machine.
All indicators and control elements are described
in detail in this chapter. ! 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.
44 BOMAG BW 219 D-4/BW 219 PD-4

Operation
l Check water separator in the fuel system,

drain if necessary. 4.3 Starting the engine
l Adjust the scrapers if necessary
l Tire pressure. Pressure see technical data. ! Danger
Danger of accident!
Caution
!
Always wear your seat belt.
Ensure equal pressure in both tires.
Fig. 31
l Check, whether the travel lever (Fig. 31) is en-

gaged to the right in brake position.
Fig. 32
l Turn the rotary vibration selector switch (Fig.

32) to position "0", vibration off.
BW 219 D-4/BW 219 PD-4 BOMAG 45

Operation
Fig. 33 Fig. 36
l Check, whether the emergency stop switch All control and warning lights (Fig. 36) in the fault
(Fig. 33) 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. 34
l Turn rotary switch (Fig. 34) to position "Min"

(idle speed).
Fig. 37
l Turn the ignition key to position "II" (Fig. 37),

the starter will crank the engine.
l As soon as the engine ignites return the igni-
tion key to position "I".
Fig. 35
l Turn the ignition key (Fig. 35) to position "I". Caution

!
Do not allow the engine to run longer than 10

minutes with idle speed.
46 BOMAG BW 219 D-4/BW 219 PD-4

Operation
4.4 Starting with jump wires 4.5 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.
Fig. 38
Always give way to loaded transport vehicles!
Before starting to drive make sure that the
!Caution drive range is absolutely safe.
A wrong connection will cause severe damage
in the electric system.
! Caution
l Bridge the machine only with a 12 Volt auxilia- Always keep the cabin door closed while driv-
ry battery. ing with the machine. With the door opened
l When jump starting with an external battery and the machine fully articulated extreme os-
connect both plus poles first. cillations of the machine may damage the
door.
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 i Note
far away from the battery as possible (Fig. 38). "Start engine", see previous sections.
l Start as described under 'Starting the engine'. The machine is equipped with a seat contact
l Once the engine is running switch on a power- switch (safety feature).
ful consumer (working light, etc.). If the travel lever is actuated with the engine run-
ning, but the driver's seat is not occupied, the sig-
! Caution nal horn is triggered and the engine shut down.
If no powerful consumer is switched on volt- If the driver gets up from his seat while driving, the
age peaks may occur when separating the con- signal horn is activated and the engine shut down
necting cables between the batteries, which after four seconds.
could damage electrical components. If the driver occupies the seat again within this pe-
l After starting disconnect the negative poles riod of four seconds, the machine will continue
(ground cable) first and the positive poles af- travelling.
ter.
l Switch off the consumer.
BW 219 D-4/BW 219 PD-4 BOMAG 47

Operation
Fig. 39 Fig. 42
l Close the cabin door (Fig. 39). l Select the desired travel speed range (Fig.
42).
Fig. 40
Fig. 43
l Sit down on the seat (Fig. 40).
l Turn the rotary switch (Fig. 43) to "Max" posi-
tion (full throttle).
Fig. 41
l Fasten your seat belt (Fig. 41).

Fig. 44
l Push the travel lever (Fig. 44) to the left out of

braking position and move it slowly to the de-
sired travel direction.
48 BOMAG BW 219 D-4/BW 219 PD-4

Operation
i Note
4.6 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.
! Danger
Returning the travel lever towards neutral will
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. 45
If the engine speed drops when driving up ex-
l Switch to working speed (Fig. 45) (turtle).
treme inclinations move the ravel lever slightly
back, if necessary change to the lower speed
range. Pre-selecting the vibration
Fig. 46
l Pre-select amplitude/frequency with the rotary

switch (Fig. 46).
BW 219 D-4/BW 219 PD-4 BOMAG 49

Operation
Switch the vibration on

4.7 Operating the parking
brake, stopping the ma-
chine
Fig. 47
l Turn the rotary switch (Fig. 47) to position

"Max" (full throttle).
Fig. 49
Caution
!
l Return the travel lever (Fig. 49) slowly to "neu-
Switch the vibration on only at max. engine
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. 48
l Press the push button (Fig. 48) 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".
50 BOMAG BW 219 D-4/BW 219 PD-4

Operation
4.8 Shutting the engine down
! Caution
Straighten the articulated joint to provide easi-
er access to the machine.
Fig. 52
l Turn the ignition switch (Fig. 52) to position "0"

or "P" and pull the ignition key out.
i Note
The parking brake closes automatically when
shutting the engine down.
Fig. 50
l Return the travel lever (Fig. 50) 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. 51
l Turn rotary switch (Fig. 51) 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.
BW 219 D-4/BW 219 PD-4 BOMAG 51

Operation
4.9 Emergency exit 4.10 Adjusting the steering

wheel
If the machine should turn over and the cabin door
is closed, the right hand side cabin window can be
used as an emergency exit.
Fig. 53
l Adjustment of steering wheel in height, pull le-

ver (Fig. 53) 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.
52 BOMAG BW 219 D-4/BW 219 PD-4

Operation
4.11 Adjusting the seat 4.12 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. 54
l To adjust the seat in longitudinal direction dis-

engage lever e (Fig. 54) 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. 56
back.
l Unlock the lock (Fig. 56).
l To swivel the seat pull lever (b) up and turn the
seat to the desired direction. l To open the hood press in the button and turn
the handle.
Fig. 55
Fig. 57
l To adjust the height of the seat lift the seat up
(Fig. 55) until it engages at the desired level. l Pull the support out of the bracket and support
the hood (Fig. 57).
When lifting the seat completely it will sink down to
lowest position.
Top position
l Push the hood to top position.
BW 219 D-4/BW 219 PD-4 BOMAG 53

Operation
4.13 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. 58
When towing downhill you must use a rigid
towing device.
l Pull the spring pin (Fig. 58) out of the bracket.
The machine cannot be steered.
l Secure the hood i´n the protection tube with
spring plug.
Fig. 59
l Attach chains (Fig. 59) or towing ropes secure-

ly to the lifting eyes.
Caution
!
Towing speed 1 km/h, max. towing distance

500 m.
l Open the tailgate.
54 BOMAG BW 219 D-4/BW 219 PD-4

Operation
Fig. 60 Fig. 62
l Slacken the middle hexagon on both valves l Turn both screws (Fig. 62) for releasing the
(Fig. 60) for approx. 2 to 3 turns. drum brake evenly in clockwise direction, until
the drum can turn freely.
Caution
!
Do not turn the valves out completely.

After towing
!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. 62) anti-clockwise against the stop.
l Turn all brake releasing screws of the axle
evenly back out, until they are light moving
again.
Fig. 61
l To release the brake turn counter nuts 1 (Fig.

61) 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. 63
l Repeat this measure on the opposite wheel l Turn the brake releasing screws (Fig. 63) back
side. in again, until they abut against the brake pis-
ton.
BW 219 D-4/BW 219 PD-4 BOMAG 55

Operation
4.14 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.
Fig. 64 Do not stand or step under loads being lifted.
l Unscrew the brake releasing screws (Fig. 64) Always use shackles on the lifting points for
for two turns and tighten the counter nuts. loading, tying or lifting the machine.
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.
Fig. 65
l Pull the spring pin (Fig. 65) out.

l Engage the articulation lock and secure it with
the spring pin.
Fig. 66
l Engage the articulation lock and secure it with

the spring pin (Fig. 66).
56 BOMAG BW 219 D-4/BW 219 PD-4

Operation
Fig. 67 Fig. 69
l Lash the machine on the transport vehicle l Position of centre of gravity (Fig. 69).
(Fig. 67), use the four lashing eyes on front
and rear frame for this purpose. Machine L H
l Support the front frame to avoid overstressing
of the rubber buffers. BW 219-4 1020±80 900±40
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. 68
l For lifting use also the four lifting eyes (Fig. 68)
and appropriate lifting gear.
BW 219 D-4/BW 219 PD-4 BOMAG 57

Operation
4.15 Measuring pass with BTM*
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. 71
Measuring values must only be compared for l Control field F5 (Fig. 71) 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. 72
l Turn the ignition key (Fig. 72) to position „II en-

gine start.
Fig. 70
l Turn the ignition key (Fig. 70) to position "I"

The BTM plus/prof performs a self-test.
58 BOMAG BW 219 D-4/BW 219 PD-4

Operation
Fig. 74
l Choose the maximum forward speed (Fig. 74).

The adjusted travel speed is indicated by a green
ring segment in the tachometer on the LCD display
*
unit.
Fig. 73
l Mark the track to be compacted (Fig. 73).
! 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.
i Note
Maximum track length 150 m.
Fig. 75
Forward: l In the starting distance set the rotary switch for
Mark 1 = Start of track engine speed (Fig. 75) to "ECO" or "MAX".
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.
* only DH-4 machines
BW 219 D-4/BW 219 PD-4 BOMAG 59

Operation
Fig. 76 Fig. 78
l Shift the travel lever (Fig. 76) fully to position l When mark 1 is reached, press button F5
„I“. “START” (Fig. 78).
The machine accelerates up to the preadjusted Control field to the left of F5 lights green.
travel speed. The EVIB- display shows the present value.
! Caution
Differences in the travel speeds falsify the
measuring result!
Fig. 79
l When the end of the track, mark 2, is reached,

press the button F6 “STOP” (Fig. 79).
l Stop the machine.
Fig. 77
l Switch the vibration on (Fig. 77).

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.
60 BOMAG BW 219 D-4/BW 219 PD-4

Operation
4.16 Finishing compaction of a

track
Fig. 80
l Drive forward and reverse passes on a track Fig. 81

until the green control field to the left of F5 (Fig.
l Repeat the complete compaction process on
80) goes out and the red control field F6 below
the next track (Fig. 81) 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/BW 219 PD-4 BOMAG 61

Operation
4.17 Printing measuring data af-

ter completing compaction*
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. 83
l If no further printouts of this track are needed,

press the button F8 “DELETE” (Fig. 83) 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. 82
l At the end of the measurement press push

button F7 "PRINT" (Fig. 82).
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).
* only BTM prof
62 BOMAG BW 219 D-4/BW 219 PD-4

Operation
4.18 Changing the paper roll in

the measuring value printer*
i Note
Use a new paper roll if a red stripe appears on the
paper.
Fig. 86
l Insert a new paper roll (Fig. 86).

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. 84
l Unscrew the star handles (Fig. 84) and re-

move the cover.
Fig. 85
l Remove shaft 1 (Fig. 85) with the rest of the

paper roll (2).
* only BTM prof
BW 219 D-4/BW 219 PD-4 BOMAG 63

Operation
4.19 Changing the printer ribbon

in the measuring value
printer*
i Note
In case of faint or poorly legible diagrams the print-
er ribbon needs to be replaced.
Fig. 87
l Unscrew the star handles (Fig. 87) and re-

move the cover.
Fig. 88
l Lift the tongue at point 1 (Fig. 88) 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.
* only BTM prof
64 BOMAG BW 219 D-4/BW 219 PD-4

5 Maintenance
BW 219 D-4/BW 219 PD-4 BOMAG 65

Maintenance
l Do not let the suction hose disturb the sludge

5.1 General notes on mainte- on the bottom of the drum.
nance l Do not draw off fuel from near the bottom of
the fuel drum.
When servicing the machine pay careful attention l Fuel left in the fuel drum is not suitable for the
to all applicable safety instructions. engine and should only be used for cleaning
Thorough maintenance of the machine ensures purposes.
maximum reliability and prolongs the lifetime of im-
portant components. The necessary effort can by Notes on the engine performance
no means be compared with the problems and
malfunctions that could occur if this is not ob- Combustion air and fuel injection rates of the die-
served. sel engine have been carefully adjusted and deter-
mine the engine's performance and temperature
The terms left/right are always related to travel di- level as well as the quality of the exhaust gas.
rection forward.
If your machine has to operate permanently in
l Clean machine and engine thoroughly before "thin air" (at high altitudes) and with full power, you
starting maintenance work. should consult the after sales service of BOMAG
l For maintenance work park the machine on or the service department of the engine manufac-
level ground. turer.
l Maintenance work must generally be carried
out with the engine shut down. Notes on the hydraulic system
l Depressurize hydraulic lines before working During maintenance work in the hydraulic system
on them. cleanliness is of utmost importance. Make sure
that no dirt or other impurities can enter into the
l Disconnect the battery and cover it with insu- system. Small particles can flute valves, cause
lation material before starting to work on elec- pumps to seize and block restrictors and pilot
trical components. bores, thereby causing costly repairs.
l Always attach the articulation lock (transport l If during the daily oil level check the oil level is
lock) before starting to work in the articulation found to have dropped, check all lines, hoses
area of the machine. and components for leakages.
l Seal external leaks immediately. If necessary
Environment inform the responsible service department.
Catch running out oils, coolant and fuel and do l Do not store drums with hydraulic oil outside,
not let them seep into the ground or into the or at least keep them under a cover. During
sewage system. Dispose of oils, coolant and weather changes water may penetrate
fuels environmentally. through the bunghole.
l Always fill the hydraulic system using the filling
Notes on the fuel system and filtering unit (BOMAG part-no.
The lifetime of the diesel engine is decisively de- 007 610 01). This unit is equipped with a fine
pending on the cleanliness of the fuel. filter, which filters the hydraulic oil and pro-
l Keep the engine free of dirt and water as this longs the lifetime of the system filter.
could damage the injection elements of the en- l Clean fittings, filler caps and their immediate
gine. surrounding area before removing them, so
l Zinc lined drums are not suitable for storing fu- that no dirt can fall in.
el. l Do not leave the tank opening unnecessarily
l The fuel drum should rest for a longer period open, cover it so that no dirt can fall in.
of time before drawing off fuel.
66 BOMAG BW 219 D-4/BW 219 PD-4

Maintenance
Notes on the cooling system

5.2 Fuels and lubricants
On water cooled engines the preparation and
monitoring of the coolant is of utmost importance,
as otherwise engine failures caused by corrosion, Engine oil
caviation and freezing may occur.
The coolant is a mixture of water and a cooling Quality
system protection agent. Lubrication oils are classified according to their
The cooling system must be permanently moni- performance and quality class. Oils according to
tored. Apart from the coolant level inspection this other comparable specifications may be used.
includes also the inspection of the concentration of
cooling system protection agent. Approved engine oils
The concentration of the cooling system protection Deutz DQC II DQC III
agent can be checked with commercially available ACAE E3/96/E5-02 E4-99
test instruments (glycomat). API CH-4/CG-4 -
DHD DHD-1 -
! Danger The exact assignment of the approved oil qualities
Health hazard! and oil change intervals can be taken from the fol-
lowing section "Lubrication oil change intervals".
The mixing of nitride based cooling system
protection agents with amine based agents will Consult your local service station if in doubt.
cause the generation of highly toxic nitro-
Oil viscosity
samines.
Multi-purpose oils should be generally used.
Environment Since lubrication oil changes its viscosity with the

temperature, the ambient temperature at the oper-
Cooling system protection agents must be dis- ating location of the engine is of utmost impor-
posed of environmentally. tance when choosing the viscosity class (SAE-
class) .
Optimal operating conditions can be achieved by
using the opposite oil viscosity chart (Fig. 89) 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, occassional ex-
ceeding of the limits should not happen over a
longer period of time.
BW 219 D-4/BW 219 PD-4 BOMAG 67

Maintenance
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.
Fig. 89
The following fuel specifications are permitted:
With their better temperature and oxidation stabil- DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75;
ity synthetic lubrication oils offer quite a few bene- BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-
fits. D.
Oil change intervals l DIN/EN 590
The longest permissible time a lubrication oil l BS 2869
should remain in an engine is 1 year. If the follow-
ing oil change intervals are not reached over a pe- l ASTM D 975-78: 1-D and 2-D.
riod of 1 year, the oil change should be performed l Nato Codes: F-54, F-34, F44 und XF63
at least once per year, irrespective of the operating
hours reached. Winter fuel
ACEA*
Danger
!
E3-96/E5-02
Fire hazard!
E4-99 = 500 operating hours
Diesel fuels must never be mixed with gaso-
API** line.
CG-4/CH-4 = 500 operating hours For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At
Caution
! very low temperatures disturbing paraffin separa-
tion can also be expected when using winter diesel
These intervals apply only when using a diesel
fuel.
fuel with maximum 0.5 % sulphur by weight
* European Engine Oil Sequences
** American Petroleum Institute
68 BOMAG BW 219 D-4/BW 219 PD-4

Maintenance
In most cases a sufficient cold resistance can also Environment

be achieved by adding flow enhancing fuel addi-
tives. Consult the engine manufacturer. Cooling system protection agents must be dis-
posed of environmentally.
Operation with rape seed oil methyl ester (RME
„Bio Diesel“) Hydraulic oil
Due to the extreme quality differences of RMEW- The hydraulic system is operated with hydraulic oil
fuels available on the market, which are caused by HV 46 (ISO) with a kinematic viscosity of
the non-existence of a standardization, BOMAG 46 mm 2/s at 40°C. For topping up or for oil chang-
does generally not approve any RME-fuels. If this es use only high-quality hydraulic oil, type HVLP
is neglected the warranty will become null and according to DIN 51524, part 3, or hydraulic oils
void! type HV according to ISO 6743/3. The viscosity in-
However, if you still intend to operate the machine dex (VI) should be at least 150 (observe informa-
with RME-fuels you should observe the following tion of manufacturer).
information:
Bio-degradable hydraulic oil
l Reduced engine power (approx. 7%), higher
On request the hydraulic system can also be filled
fuel consumption.
with ester based biodegradable hydraulic oil (Pan-
l The quality of RME-fuel should be in compli- olin HLP Synth. 46). The biologically quickly de-
ance with DIN draft 51606. gradable hydraulic oil meets all demands of a
l Avoid longer periods of standstill (formation of mineral oil based hydraulic oil according to DIN
resin, corrosion in injection system) 51524.
l RME-fuel can damage the paint finish of the In hydraulic systems filled with Panolin HLP Synth.
machine. 46 always use the same oil to top up. When
changing from mineral oil based hydraulic oil to an
l Fuel dilution of engine oil, therefore shortening ester based biologically degradable oil, you should
of oil change intervals to half. consult the lubrication oil service of the oil manu-
l Rubber parts, such as leak fuel return lines, facturer for details.
seats will be damaged in the long run and Check the filter more frequently after this change.
need to be replaced on a regular basis or
should be replaced by parts made of fluorinat-
ed rubber. However, fluorinated rubber is not !Caution
resistant against normal diesel fuel. Oil change bio-degradable hydraulic oil:
l If the fuel filter is clogged the filter change in- Perform regular oil analyses for content of wa-
tervals must be shortened accordingly. ter and mineral oil.
Replace the hydraulic oil filter element every
Coolant, anti-freeze agent 500 operating hours.
Use only soft tap water (drinking water) to prepare
the coolant mix. Oil for drive axle
As a protection against frost, corrosion and boiling For the drive axle use only multi-purpose transmis-
point anti-freeze agents must be used under any sion oil of API-class GL5 with viscosity class SAE
climatic conditions. 90.
The proportion of cooling system protection agent The additives in this oil ensure low wear lubrication
must be between min. 35% and max. 45% to the under all operating conditions.
water.
Lubrication grease
! Caution For lubrication use only EP-high pressure grease,
Do not mix different coolants and additives of lithium saponified (penetration 2).
any other kind.
BW 219 D-4/BW 219 PD-4 BOMAG 69

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/E5-02 or approx. 12.5 litres without

oil filter
API: CG-4/CH-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. 12.5 litres
Wheel hubs Gear oil SAE 90, API GL5 approx3.5 l 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
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)
70 BOMAG BW 219 D-4/BW 219 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 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/BW 219 PD-4 BOMAG 71

Maintenance
5.5 Maintenance chart
every 10 operating hours, daily
every 1000 operating hours


after 250 operating hours
Running-in instructions
No. Maintenance work Remark
as required
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 Check the tire pressure X
5.13 Clean the cooling fins on engine and X
hydraulic oil cooler
5.14 Check the oil level in the drive axle X
5.15 Check the oil level in the wheel hubs X
5.16 Check the oil level in the axle reduc- X
tion gear
5.17 Check the oil level in the drum reduc- X
tion gear
5.18 Check the oil level in the vibration X
bearings
5.19 Change engine oil and oil filter car- min. 1x per year X
tridge*
5.20 Change the fuel filter cartridge X
5.21 Drain the sludge from the fuel tank X
5.22 Service the battery Pole grease X
5.23 Change the fuel pre-filter cartridge X
72 BOMAG BW 219 D-4/BW 219 PD-4

Maintenance


as required
5.24 Check, replace the refrigerant com- X
pressor V-belt
5.25 Service the air conditioning X
5.26 Check, adjust the valve clearance Intake = 0,3 mm X
Exhaust = 0,5 mm
5.27 Check, replace the ribbed V-belt X
5.28 Check the engine mounts X X
5.29 Oil change in drive axle min. 1x per year X X
5.30 Oil change in wheel hubs min. 1x per year X X
5.31 Oil change, axle reduction gear min. 1x per year X X
5.32 Oil change in drum drive reduction min. 1x per year X X
gear**
5.33 Oil change vibration bearings** see foot note, min. 1 X X
x per year
5.34 Retighten the fastening of the axle on X
the frame
5.35 Tighten the wheel nuts X X
5.36 Check the ROPS X
5.37 Clean the oil bath air filter min. 1x per year X
5.38 Change hydraulic oil and breather fil- at least every 2 X
ter*** years
5.39 Change the hydraulic oil filter**** at least every 2 X
years
5.40 Change the coolant at least every 2 X
years
5.41 Check the injection valves X
BW 219 D-4/BW 219 PD-4 BOMAG 73

Maintenance


as required
5.42 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2 years
5.43 Adjusting the scrapers X
5.44 Adjust the parking brake X
5.45 Change the tires X
5.46 Change the fresh air filter in the cabin X
5.47 Tightening torques X
5.48 Engine conservation X
* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h.
*** Also in case of repair in the hydraulic system.
**** Also in case of repair in the hydraulic system.
74 BOMAG BW 219 D-4/BW 219 PD-4

Every 10 operating hours
Every 10 operating hou rs
5.6 Check the engine oil level 5.7 Check, clean the water sep-
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. 90
l Pull the dipstick (Fig. 90) 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. 91
For quality and quantity of oil refer to the table l Slacken the drain plug (Fig. 91) for a few turns
of fuels and lubricants. 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/BW 219 PD-4 BOMAG 75

Caution
!
5.8 Check the fuel level
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. 92
l Check the fuel level on the fuel level gauge

(Fig. 92) 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. 93
l Open the fuel tank cover (Fig. 93).
76 BOMAG BW 219 D-4/BW 219 PD-4

5.9 Checking the hydraulic oil 5.10 Check the coolant level
level
! Danger
! Caution Danger of scalding!
In mit Panolin HLP Synth. 46, the same oil must Fill up coolant only when the engine is cold.
be used for filling up. In case of any other ester
based oil consult the lubrication service de-
partment of the respective oil manufacturer.
Fig. 95
l Check the coolant level (Fig. 95).

Fig. 94
l Check the oil level in the inspection glass (Fig. ! Caution

94) on the hydraulic oil tank. If, during the daily inspection the coolant level
is found to have dropped, check all lines, hos-
Normal level es and engine for leaks.
approx. 3 cm below the upper edge of the inspec- l To top up unscrew the filler cap and fill in cool-
tion glass. ant up to the MAX-mark.
Minimum level For quality of coolant refer to the chapter 5.2,
middle of inspection glass. fuels and lubricants.
!Caution
If during the daily oil check the oil level is
found to have dropped, check all lines, hoses
and components for leakages.
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/BW 219 PD-4 BOMAG 77

5.11 Checking the dust separa-

tor on the oil bath air filter*
Fig. 96
l If the dust reaches the mark loosen the clamp

(Fig. 96), take the cover off and clean the bowl.
* Option
78 BOMAG BW 219 D-4/BW 219 PD-4

Every 250 oper ating hours
5.12 Checking the tire pressure 5.13 Clean the cooling fins on
engine and hydraulic oil
! Caution
cooler
Since the tires are filled with water, you should
always turn the inflation valve to top position
to check the tire pressure! Danger
!
Danger of injury!
Always close the valves with the dust cap.
Perform cleaning work only after the engine
has cooled down and with the engine stopped.
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
Fig. 97 cooler and clean the cooling surfaces after.
l Check the tire pressure with a pressure gauge
and the tire inflation valve 1 (Fig. 97) in top po- Cleaning with compressed air
sition.
Nominal value see "technical data".
i Note
Ensure even pressure in all tires.
l Screw the valve caps back on.
Fig. 98
i Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 98) out with compressed
air.
BW 219 D-4/BW 219 PD-4 BOMAG 79

Cleaning with cold cleansing agent

5.14 Check the oil level in the
! Caution
drive axle
Protect electrical equipment such as genera-
tor, regulator and starter against the direct wa-
ter jet.
l Spray the engine with a suitable cleansing
agent, e.g. cold cleanser, let it soak in for a
while and spray it off with a strong water jet.
l Run the engine warm for a while to avoid cor-
rosion.
Fig. 99
l Unscrew the oil level inspection plug (Fig. 99)

and check the oil level.
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.
The oil level must reach the bottom edge of the
level bore.
l Top up oil, if necessary.
For quality of oil refer to the table of fuels and

lubricants.
l Turn the level inspection plug tightly back in.
80 BOMAG BW 219 D-4/BW 219 PD-4

5.15 Check the oil level in the 5.16 Check the oil level in the
wheel hubs axle reduction gear
Fig. 100 Fig. 101
l Move the drive wheel so that the oil level mark l Unscrew the filler and oil level inspection plug
on the plug (Fig. 100) is in horizontal position. (Fig. 101) and check the oil level.
l Unscrew the plugs The oil level must reach the bottom edge of the
bore, top up oil if necessary.
level bore. For quality of oil refer to the table of fuels and
l Top up oil, if necessary. lubricants.
l Retighten the filler and level inspection plug.
lubricants.
l Turn the plug tightly back in.
l Repeat this inspection on the other side.
BW 219 D-4/BW 219 PD-4 BOMAG 81

Caution
!
5.17 Check the oil level in the
Investigate the cause for the oil loss, if neces-
drum reduction gear sary seal the gearbox

Check lubricants.
l Retighten the filler and level inspection plug.
Fig. 102
l Unscrew the oil level inspection plug (Fig. 102)

and check the oil level.
bore, top up oil if necessary.
Filling up
l Move the drum until drain and filler plugs are
exactly vertically in line.
Fig. 103
l Unscrew the filler plug at the top (Fig. 103) and

fill in oil, until it reaches the bottom edge of the
inspection bore.
82 BOMAG BW 219 D-4/BW 219 PD-4

5.18 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.
Fig. 104
l Move the drum, until oil level inspection plug 1

(Fig. 104) 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.

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/BW 219 PD-4 BOMAG 83

Every 500 operating h ours
5.19 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. 106
l Thoroughly clean the outside of both filter car-

tridges (Fig. 106).
Danger
!
Danger of scalding! l Unscrew both filter cartridges using an appro-

priate filter wrench.
When draining off hot oil.
By hot oil when unscrewing the engine oil fil-
ter.
i Note
The filter cartridges are fitted with a valve that pre-
vents engine oil from running out during removal
Environment and installation.
Catch running out oil and dispose of environ- l Clean the sealing face on the filter carrier from
mentally together with the engine oil filter car- any dirt.
tridge.
l Slightly oil the rubber seal on the new filter car-
tridges.
Fig. 105
l Unscrew the drain plug (Fig. 105) and catch Fig. 107
running out oil.
l Turn the new filter cartridges (Fig. 107) on by
l Turn the drain plug tightly back in. hand, until the seal contacts.
l Tighten the filter cartridges for another half
turn.
84 BOMAG BW 219 D-4/BW 219 PD-4

5.20 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. 108
Do not inhale any fuel fumes.
l Fill in new engine oil (Fig. 108).

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. 109
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. 109) 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. 110
l Slightly oil the rubber seal (Fig. 110) on the

new filter cartridge.
BW 219 D-4/BW 219 PD-4 BOMAG 85

l Fill the filter cartridge with clean diesel fuel.

5.21 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!
open fire, do not smoke!
Do not spill any fuel.
the ground.
Fig. 111
l Unscrew the cap (Fig. 111) and drain off ap-

prox. 5 litres of fuel.
l Turn the cap tightly back in.
86 BOMAG BW 219 D-4/BW 219 PD-4

!Caution
5.22 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. 112
not need to be checked. Each battery suffers un- l Remove the battery (Fig. 112) 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. 113
BW 219 D-4/BW 219 PD-4 BOMAG 87

5.23 Change the fuel pre-filter

cartridge
! Danger
Fire hazard!
open fire, do not smoke and do not spill any fu-
el.
the ground.
Fig. 116
l Apply a thin coat of oil to the rubber seal of the
water separator 1 (Fig. 116).
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).
Fig. 114 l Check the filter cartridge for leaks after a short
l Unscrew the fuel filter cartridge (Fig. 114) us- test run.
ing an appropriate filter wrench.
l Clean the sealing face on the filter carrier from i Note
any dirt. Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the en-
gine and makes starting impossible.
Therefore bleed the fuel system after changing the
fuel prefilter.
Fig. 115
l Unscrew the water separator from the filter

cartridge (Fig. 115).
88 BOMAG BW 219 D-4/BW 219 PD-4

5.24 Checking, replacing the re-

frigerant compressor V-
belt*
Danger
!
Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.
Fig. 117 Check the V-belt

l Slacken the bleeding screw (Fig. 117) on the
fuel pre-filter for 2 to 3 turns.
l Operate the hand pump manually, until fuel
flows out of the slackened bleeding screw (Fig.
117) without air bubbles.
l Then tighten the bleeding screw while pump-
ing.
Fig. 118
l Inspect the entire circumference of the V-belt

(Fig. 118) 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.
BW 219 D-4/BW 219 PD-4 BOMAG 89

Tighten the V-belt.

5.25 Service the air conditioning*
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
Fig. 119
conditioning off and clean the condenser.
l Slightly slacken fastening screws 1, 2 and 3
In case of formation of foam have the air con-
(Fig. 119).
ditioning system inspected by the service de-
l Press the compressor in direction of arrow, un- partment.
til the correct V-belt tension is reached.
l Retighten all fastening screws. Danger
!
Danger of accident!
Changing the V-belt
Do not clean with a hot water jet. Heat will
l Slightly slacken the fastening screws 1, 2 and cause extreme overpressure, which could
3. cause damage or explosion of the system.
l Press the compressor against the direction of Use access steps and grips to mount and dis-
arrow completely against the engine. mount the machine.
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.
Fig. 120
l Unscrew the condenser fastening screws (Fig.

120) and fold the condenser forward.
l Clean the condenser fins on front and back
with compressed air or cold water.
90 BOMAG BW 219 D-4/BW 219 PD-4

Checking the refrigerant level

l Start the engine.
Fig. 123
l Check whether the white float (Fig. 123) inside

the inspection glass of the drier/collector unit
Fig. 121 floats right at the top.
l Switch the air conditioning (Fig. 121) on.
i Note
The refrigerant level is correct.
Fig. 122
l Choose a cooling temperature with the rotary

switch for cabin heater (Fig. 122) in the blue Fig. 124
section.
l If the white float (Fig. 124) inside the inspec-
l Open the air outlet nozzles. tion glass of the drier/collector unit floats at the
l Check, whether the outflowing air is noticeably bottom, inform the service department.
cooler.
i Note
i Note The refrigerant level is not correct.
The adjusted temperature must be below the actu- l Refrigerant must be filled up, if necessary
al temperature inside the cabin, so that the com- check the air conditioning system for leaks.
pressor will be switched on.
l Open the hood.
BW 219 D-4/BW 219 PD-4 BOMAG 91

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. 125
l Check the moisture indication pearl (Fig. 125)

inside the inspection glass of the drier/collec-
tor unit.
blue = drying agent o.k.
purple = moisture level of drying agent too
high. Fig. 126
l Inform the service department. Replace drier/ l Check the drier/collector unit (Fig. 126) 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
92 BOMAG BW 219 D-4/BW 219 PD-4

5.26 Checking, adjusting the

valve clearance
! Caution
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. 128
Valve adjustment schematic Crankshaft position 1 (Fig. 128) (6 cylinder en-
gine)
l Crank the engine with the starter or a spanner
by the V-belt pulley until both valves on cylin-
der 1 are “overlapping”.
Overlapping means: Exhaust valve not yet closed,
intake valve starts to open.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram "crankshaft posi-
tion 1", black mark.
l For control purposes mark the respective rock-
er arm with while chalk once the correspond-
ing valve is adjusted.
Fig. 127
Valve 1 (Fig. 127) white = not adjustable
Valve (2) black = adjustable
Fig. 129
Crankshaft position 2 (Fig. 129) (6 cylinder en-

gine)
l Turn the crankshaft one revolution (360 °) fur-
ther.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram "crankshaft posi-
tion 2", black mark.
BW 219 D-4/BW 219 PD-4 BOMAG 93

Check the valve clearance with little resistance after retightening the
counter nut.
l Loosen the crankcase ventilation valve and
swing it to the side. l Perform tests and adjustments on all other ad-
justable valves.
l Remove the valve cover (2).
l Check the gasket of the valve cover, replace it
l Crankshaft position as per "valve adjustment if necessary.
schematic".
l Reassemble the cylinder head cover.
l Swivel the ventilation valve back to correct po-
sition and fasten it.
l Fasten the air filter again and ensure correct fit
of combustion air hoses and clamps.
Fig. 130
l Check valve clearance 2 (Fig. 130) between

rocker arm (1) and valve (3) with a feeler
gauge.
Intake valve = 0.3 mm
Exhaust valve = 0.5 mm
The feeler gauge must fit with little resistance.
l If the gap is too narrow or too wide for the feel-
er gauge, the valve must be adjusted.
Adjusting the valve clearance
Fig. 131
l Slightly slacken the counter nut. Adjust set-

screw 7 (Fig. 131) with a screwdriver, until the
feeler gauge (6) can be inserted and pulled out
94 BOMAG BW 219 D-4/BW 219 PD-4

Changing the ribbed V-belt

5.27 Checking / replacing the
ribbed V-belt
! Danger
Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.
Checking the wear limit of the ribbed V-

belt
Fig. 133
l Unscrew the fastening screws (Fig. 133) and

slide the fan forward.
Fig. 132
l Check the distance between the tongue of the

moveable tensioner arm and the fixed tension-
er housing (Fig. 132).
l If measurement "a" is smaller than 3 mm, re- Fig. 134
place the ribbed V-belt. l Release the idler pulley (Fig. 134) in direction
of arrow until the ribbed V-belt is free.
l Pull the ribbed V-belt first to the smallest pul-
ley.
l Install the new ribbed V-belt.
l Release the idler pulley against the direction
of arrow until the V-belt is tensioned.
l Measure the V-belt tension, tighten if neces-
sary.
i Note
Retighten the new fan V-belt after a running time
of 20 minutes.
BW 219 D-4/BW 219 PD-4 BOMAG 95

5.28 Check the engine mounts 5.29 Change the oil in the drive
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. 135
l Tighten fastenings of intake and exhaust man- l Park the machine on level ground.
ifolds (Fig. 135) 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. 136
l Clean and unscrew all level inspection and

drain plugs (Fig. 136).
l Drain and catch all oil.
l Clean the drain plug and turn it back in with a
new seal ring.
96 BOMAG BW 219 D-4/BW 219 PD-4

5.30 Change the oil in the wheel

hubs
! Caution
Change the oil on both sides of the axle.
Environment
Fig. 137
l Fill in oil through the oil level inspection bores

(Fig. 137), 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.

l Retighten the filler and level inspection plug. Fig. 138
l Move the drive wheel, until the plug (Fig. 138)

is in bottom position.
l Clean and unscrew the plug.
l Drain and catch all oil.
Fig. 139
l Move the drive wheel, until the plug (Fig. 139)

is in horizontal position on the housing.
l Fill in oil, until it reaches the bottom edge of the
bore .
BW 219 D-4/BW 219 PD-4 BOMAG 97


of fuels and lubricants. 5.31 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. 140
l Unscrew the filler plug (Fig. 140).

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.

l Clean the filler plug and screw it back in tightly
with a new sealing ring.
98 BOMAG BW 219 D-4/BW 219 PD-4

5.32 Change the oil in the drum

reduction gear
! Caution
Environment
l Move the drum until drain and filler plugs are
exactly vertically in line. Fig. 143
l Fill in oil through the filler bore (Fig. 143), until

it reaches the bottom edge of the inspection
bore.

l Clean filler and level control plugs and screw
them tightly back in with new sealing rings.
Fig. 141
l Unscrew the filler plug at the top (Fig. 141).

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. 142
l Unscrew the level inspection plug (Fig. 142).
BW 219 D-4/BW 219 PD-4 BOMAG 99

5.33 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. 145
l Park the machine on level ground. l Unscrew oil level inspection plug 1 (Fig. 145)
on the drum and fill in oil through the filler
opening (2), until it starts to drip out from the
level inspection bore.

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. 144 ! Caution

l Move the drum, until the drain plug 1 (Fig. 144) 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.
100 BOMAG BW 219 D-4/BW 219 PD-4

5.34 Tightening the fastening of 5.35 Tighten the wheel nuts

the axle to the frame
Fig. 147
Fig. 146 l Tighten the wheel nuts (Fig. 147) cross-wise

l Check all fastening nuts for the axle retaining Tightening torques: 550 Nm (405 ft-lb)
bolts (Fig. 146) for tight fit. (M22x1.5)
BW 219 D-4/BW 219 PD-4 BOMAG 101

5.36 Check the ROPS 5.37 Cleaning the oil bath air fil-
ter *
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. 149
l Loosen the quick locks (Fig. 149), take the fil-

ter bowl off and empty it.
l Clean the filter mesh by repetitive dipping into
diesel fuel.
Fig. 148
l Clean the filter bowl with diesel fuel and fill in
l Inspect the cabin, especially the ROPS (Fig. engine oil up to the level mark.
148), 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.
* Option
102 BOMAG BW 219 D-4/BW 219 PD-4

5.38 Changing hydraulic oil and

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. 150
Perform the oil change when the hydraulic oil l Unscrew the plug (Fig. 150) and drain off all
is warm. hydraulic oil.
Clean the area round hydraulic oil tank, filler l Check seal ring (1), replace if necessary and
opening and breather filter. turn the plug tightly back in.
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
Catch running out oil and dispose of environ- Fig. 151
mentally. l Remove the filler cap (Fig. 151).
l Fill in new hydraulic oil through the screen.
i Note
Generally replace the hydraulic oil filter element
after the test run.
i Note
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/BW 219 PD-4 BOMAG 103


of fuels and lubricants. 5.39 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. 152
l Unscrew the cap nut 4 (Fig. 152) 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
104 BOMAG BW 219 D-4/BW 219 PD-4

possible malfunction of important parts. In

such a case you should perform trouble shoot- 5.40 Changing 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. 153
l Set the cock valve for the cabin heater to posi-

tion "warm".
Fig. 154
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/BW 219 PD-4 BOMAG 105

Fig. 155
l Unscrew the cap and fill in coolant up to the

MAX-mark.
For quality of coolant refer to the chapter 5.2,

fuels and lubricants.
l Start the diesel engine and run it warm to op-
erating temperature.
l Let the engine cool down and check the cool-
ant level again, top up if necessary.
106 BOMAG BW 219 D-4/BW 219 PD-4

5.41 Checking the injection

valves
i Note
This work must only be performed by authorized
service personnel.
The injection valves must be replaced every
12000 operating hours.
BW 219 D-4/BW 219 PD-4 BOMAG 107

108 BOMAG BW 219 D-4/BW 219 PD-4

As required
As r equired
5.42 Service the combustion air i Note

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.
Fig. 157
The main filter element must be replaced after
3 times cleaning, but at the latest after one l Open the engine hood (Fig. 157) 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.
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. 158
l Release the locking hook (Fig. 158) and take

the filter hood off.
l Clean filter hood and dust discharge valve.
Fig. 156
Maintenance of the dry air filter is due when con-
trol light “c” (Fig. 156) in the instrument cluster
lights permanently when the engine is running, but
at the latest after one year.
BW 219 D-4/BW 219 PD-4 BOMAG 109

As required
Fig. 159 Fig. 161
l Carefully loosen the main filter element (Fig. l Clean the sealing face on the outlet tube (Fig.
159). 161).
The main filter element is located directly on the air Dust on the outer diameter of the outlet tube can
intake tube, thereby providing a seal on the inside impair effective sealing.
of the filter cover. Carefully remove the main filter
l Check the old main filter element.
element, in order to reduce the released amount of
dust. To release the seal pull the main filter ele- The old main filter element can be of help to dis-
ment carefully up, down and sideways or turn it cover foreign particles on the sealing face, which
(Fig. 159). could lead to leaks. A line of dust on the clean air
side of the filter may be a sign for such a leak.
Eliminate this problem before installing a new
Caution
!
main filter element.
Avoid contact between main filter element and
l If the main filter element is damaged, the safe-
housing.
ty element must be replaced as well.
l Clean or replace the main filter element.
i Note
We generally recommend to change the filter. A
new filter element is far less expensive than a pos-
sible engine damage.
l Examine the main filter element thoroughly for
damage.
Before installing the new main filter element check
it for possible damage from transport, cleaning or
incorrect handling. Especially on the inside of the
open end (sealing area). Do not install damaged
Fig. 160
filter elements.
l Pull the main filter element (Fig. 160) carefully
l If necessary use safety elements.
out of the housing.
110 BOMAG BW 219 D-4/BW 219 PD-4

As required
Fig. 162 Fig. 163
l Insert the main filter element (Fig. 162).

The radial sealing area is located at the inside of i Note
the open filter edge. This critical sealing area must For cleaning purposes fit a tube to the compressed
be under slight tension after the filter has been in- air gun (Fig. 163), the end of which should be bent
stalled. In order to achieve a tight seal apply pres- for approx. 90°.
sure to the outer edge of the filter and not to the The length should reach down to the bottom of the
moveable centre. element.
l Reinstall the filter hood with the dust discharge l Blow the main filter element out with com-
valve. pressed air (max. 5 bar) from inside to outside
by moving the tube up and down inside the el-
Caution
! ement, until it if free of dust.
The dust discharge valve must point vertically l Examine the main filter element with a torch
downwards. for cracks and holes in the paper bellows.
Dry cleaning of the main filter element Caution

!
Do not continue to use a damaged main filter

! Danger element. If in doubt use a new main filter ele-
Eye injury! ment.
Wear protective clothing (goggles, gloves).

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.
The safety filter element must be replaced:
if the main filter element is defective,
after three times cleaning of the main filter ele-
ment,
at the latest after 2 years,
BW 219 D-4/BW 219 PD-4 BOMAG 111

As required
if the warning light comes on again after serv-

icing the main filter cartridge. 5.43 Adjust the scrapers
l Remove the housing cover and pull the main
filter element off.
Smooth drum
l Check adjustment and condition of front and
rear scrapers, if necessary adjust or replace
the scraper rubber.
Fig. 164
l Pull the safety element (Fig. 164) out by turn-

ing it lightly.
l Push in a new safety filter element. Fig. 165
l Reassemble main filter element and cover. l In order to adjust the scrapers 2 (Fig. 165),
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.
112 BOMAG BW 219 D-4/BW 219 PD-4

As required
5.44 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. 166
l Check adjustment and condition of scrapers

(Fig. 166), 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. 167
l Disengage the travel lever (Fig. 167) to the

left, but do not move to position "I" or "II".
The parking brake is released
Fig. 168
l Unscrew locking plate 2 (Fig. 168).

l Turn the square (1) in anti-clockwise direction
against the stop.
BW 219 D-4/BW 219 PD-4 BOMAG 113

As required
5.45 Changing the tires
! 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. 169
l In order to adjust the brake clearance turn the

square 1 (Fig. 169) 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. 170
l Attach the wheel (Fig. 170) and tighten the

wheel nuts crosswise with 550 Nm (405 ft. lb.).
l Check the tire pressure, see technical data.
114 BOMAG BW 219 D-4/BW 219 PD-4

As required
5.46 Change the fresh air filter in 5.47 Tightening torques

the cabin
Fig. 172
* Strength classes for screws with untreated, non-
lubricated surface. Screw quality designations are
Fig. 171 stamped on the screw heads.
l Unscrew fastening screws for the ventilation 8.8 = 8G
grid (Fig. 171) and remove the filter. 10.9 = 10K
l Insert a new filter and reassemble the ventila- 12.9 = 12K
tion grid.
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 MOS2 the specified tighten-
ing torques do not apply.
i Note
Self-locking nuts must always be replaced once
they have been unscrewed.
BW 219 D-4/BW 219 PD-4 BOMAG 115

As required
5.48 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.
116 BOMAG BW 219 D-4/BW 219 PD-4

6 Trouble shooting
BW 219 D-4/BW 219 PD-4 BOMAG 117

Trouble shooting
6.1 General notes
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.
! Danger
Danger of injury!
Keep away from rotating parts of the engine.
118 BOMAG BW 219 D-4/BW 219 PD-4

Trouble shooting
6.2 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
BW 219 D-4/BW 219 PD-4 BOMAG 119

Trouble shooting
Faults Possible cause Remedy
Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance
Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Engine oil level too low Top up engine oil to the upper dipstick
mark
Filling capacity of the injection pump not Have adjusted by a specialist

correctly adjusted
Cooling air flow restricted Clean the cooling air duct
V-belt loos or broken Tension or replace the V-belt
Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark
Dry air filter dirty clean, change if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Charge air hose leaking Check fastening and connections
Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine oil pressure" lights, the warning
buzzer sounds)
Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective
120 BOMAG BW 219 D-4/BW 219 PD-4

Trouble shooting
BW 219 D-4/BW 219 PD-4 BOMAG 121

Trouble shooting
122 BOMAG BW 219 D-4/BW 219 PD-4

7 Cab assembly before initial start-up
BW 219 D-4/BW 219 PD-4 BOMAG 123

Cab assembly before initial start-up
General safety regulations for assem- The manufacturer explicitly excludes any liability
bly for damage caused by the use of non-original
parts or accessories.
When installing the cabin to your BOMAG ma-
chine you must strictly comply with the valid Notes on safety in the assembly in-
accident prevention instructions or the coun-
structions
try specific regulations. However, dangers for
persons and property may still arise, if:
l the lifting gear used has a too low bearing ca- ! Danger
pacity Paragraphs marked like this highlight possible
dangers for persons.
l damaged or worn lifting tackle is used
l unqualified personnel is entrusted with the in-
Caution
!
stallation
Paragraphs marked like this highlight possible
l the safety instructions are not observed dangers for machines or parts of the machine.
Each person involved in the installation of the
cabin must therefore read and comply with i Note
these safety regulations. If necessary, the cus-
Paragraphs marked like this contains technical in-
tomer must demand a written confirmation
formation and hints for optimal assembly.
with signature.
Moreover, the following instructions and regula-
tions must obviously also be complied with: Environment
Paragraphs marked like this point out practic-
l applicable accident prevention instructions
es for safe and environmental disposal of fuels
l generally accepted safety and road traffic reg- and lubricants as well as replacement parts.
ulations
Strictly observe the national regulations for
l country specific safety regulations. It is the the protection of the environment.
duty of the operator to be acquainted with
these instructions and to apply these accord- Information and safety stickers/decals
ingly. This applies also for local regulations
concerning different types of handling work.
on the cabin
Should the recommendations in these instruc- Keep stickers/decals in good and legible condition
tions be different from the regulations valid in (see spare parts catalogue) and comply with their
your country, you must comply with the safety meaning.
regulations valid in your country. Replace damaged stickers/decals
Changes and conversions to the cabin/ Work on heating lines

machine
Before starting work on heating pipes relieve any
Unauthorized changes to the cabin are prohibited pressure and let them cool down - danger of scald-
for safety reasons. ing!
Original parts and accessories have been special- After completing work on the heating system of the
ly designed for this machine. We wish to make ex- machine check all connections and fittings for
plicitly clear that we have not tested or approved leaks.
any parts or accessories not supplied by us. The
installation and/or use of such products may have Working on electric parts of the ma-
an adverse effect on the active and/or passive
driving safety.
chine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
124 BOMAG BW 219 D-4/BW 219 PD-4

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. 173
l Make sure that all fastening screws, washers,

spacers and nuts to fasten the cabin are avail-
able (Fig. 173).
l Check whether rear rack, foot mat, step plate
and fastening kit are available.
BW 219 D-4/BW 219 PD-4 BOMAG 125

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.
l Clean the operator's stand of dirt, oil and mois-
ture.
Fig. 174
l Fasten the lifting gear to the four lifting eyes 1

(Fig. 174).
l Loosen possible fastening on the transport
pallet.
l Slowly list the crane with a crane.
Danger
!
Danger of accident!
Fig. 175
l Stick the supplied sealing tape 1 (Fig. 175)

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!
126 BOMAG BW 219 D-4/BW 219 PD-4

Fig. 176 Fig. 178
l Stick the sealing tape 1 (Fig. 176) all around l Slowly lower the cabin vertically to the opera-
the operator's stand. tor's stand (Fig. 178).
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 cabine 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. 179
! Caution
Fig. 177
Take care that none of the hoses and electric
l Spray the sealing tape with soapsuds (Fig. cables become squashed (Fig. 179).
177), to be able to slide the cabin on the oper-
l Run cables and hoses from inside the cabin
ator's stand.
through the operator's stand to the outside.
BW 219 D-4/BW 219 PD-4 BOMAG 127

Fig. 180 Fig. 182
l Turn both fastening screws (Fig. 180) at the l Tighten the bottom fastening screw on the ac-
rear of the cabin in handtight. cess side (Fig. 182) with 578 Nm.
Fig. 181 Fig. 183
l Loosen both fastening screws (Fig. 183) 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. 181). i Note
The cabin will now slide into final assembly posi-
tion.
l Tighten both fastening screws (Fig. 183) at the
rear of the cabin with 578 Nm.
128 BOMAG BW 219 D-4/BW 219 PD-4

Fig. 184 Fig. 187
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. 184). tighten with 200 Nm (Fig. 187).
Fig. 185 Fig. 188
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. 185). right hand side with 578 Nm (Fig. 188).
Fig. 186 Fig. 189
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. 186). left hand side with 578 Nm (Fig. 189).
BW 219 D-4/BW 219 PD-4 BOMAG 129

Fig. 190 Fig. 193
l Cover all lateral fastening screws with plastic l Insert the dashboard and fasten it with four
caps (Fig. 190). fastening screws (Fig. 193).
Fig. 191 Fig. 194
l Insert the foot mat 1 (Fig. 191). l Insert the rear rack and knock both plastic fas-
teners carefully into the bores with a hammer
(Fig. 194).
Fig. 192
l Attach the step plate 1 (Fig. 192) and tighten

the three fastening screws (2).
130 BOMAG BW 219 D-4/BW 219 PD-4

Fig. 195 Fig. 197
l Connect the feed 1 (Fig. 195) and the return l Plug on the hoses for the washing water sup-
flow (2) for the air conditioning system with ply to front and rear windscreens 1 (Fig. 197).
quick release couplings.
l Connect the feed (4) and the return flow (3) of i Note
the heating. (Observe the marks on the hos- Check the function of the washing water system
es). 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. 198
l Insert the plug 1 (Fig. 198) 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. 196
l Plug on both connecting plugs for the washing

water pumps (Fig. 196).
BW 219 D-4/BW 219 PD-4 BOMAG 131

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. 199 are correctly connected.
l Connect the plug connection of the air condi- l Insert the ignition key and turn clockwise to po-
tioning system (Fig. 199). 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.
132 BOMAG BW 219 D-4/BW 219 PD-4

OMM BW219D-4 BF6M2012C 00812981.a05

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Operating instructions

BW 219 D-4 / PD-4

Single drum roller

No warranty claims can be lodged in case of dam-

BW 219 D-4/BW 219 PD-4 BOMAG 3

4 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 5

5.9 Checking the hydraulic oil level 77

6 BOMAG BW 219 D-4/BW 219 PD-4

6.2 Engine 119

BW 219 D-4/BW 219 PD-4 BOMAG 7

8 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 9

10 BOMAG BW 219 D-4/BW 219 PD-4

* BW 219 D-4 BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 11

12 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 13

General Unintended use

l generally acknowledged safety and road traffic

14 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 15

16 BOMAG BW 219 D-4/BW 219 PD-4

Driving on slopes and gradients Filling the fuel tank

BW 219 D-4/BW 219 PD-4 BOMAG 17

Working on hydraulic lines l Do not mix up hoses by mistake.

l deformation under pressurized and depressu- Working on electrical equipment

18 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 19

20 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 21

22 BOMAG BW 219 D-4/BW 219 PD-4

1 Ignition switch 10 Push button for warning horn

BW 219 D-4/BW 219 PD-4 BOMAG 23

3.1 General notes 3.2 Description of indicators

24 BOMAG BW 219 D-4/BW 219 PD-4

g red = Parking brake, with lever shifted to

BW 219 D-4/BW 219 PD-4 BOMAG 25

26 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 27

* Optional equipment *** Optional equipment

28 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 29

c = toggle switch for rear windscreen wiper/

30 BOMAG BW 219 D-4/BW 219 PD-4

e = Rotary switch for cabin ventilator i = reading and dashboard light

f = Push button for air conditioning* l = cabin light

press = air conditioning switched on.

g = Rotary switch for cabin heater (tempera-

BW 219 D-4/BW 219 PD-4 BOMAG 31

Constant = end of compaction

32 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 33

3.3 Display and control ele-

34 BOMAG BW 219 D-4/BW 219 PD-4

BW 219 D-4/BW 219 PD-4 BOMAG 35

1 EVIBdisplay 11 not used

36 BOMAG BW 219 D-4/BW 219 PD-4

To print out the measuring data saved during the