BOMAG BW219 D-4 & PD-4 Single Drum Roller Service Manual – 008 924 53 PDF

Description

BOMAG BW219 D-4 & PD-4 Single Drum Roller Service Manual – Document 008 924 53

This BOMAG BW219 D-4 & PD-4 Single Drum Roller Service Manual is the full workshop reference for the BW219 D-4 and BW219 PD-4 single drum rollers, issued by BOMAG under document number 008 924 53. Across 932 pages the manual takes a technician through disassembly, inspection, repair, adjustment and reassembly of every major assembly on the machine – from the Deutz diesel engine and its EMR II electronic engine management, through the closed-loop hydrostatic travel and vibration circuits, to the drum, oscillating articulated joint, cabin and air conditioning system. The BOMAG BW219 D-4 & PD-4 Service Manual is written for the professionally qualified personnel or after-sales service of BOMAG and assumes the reader is using the appropriate workshop equipment.

File Details

• Manual type: Service Manual (Workshop Manual)
• Brand / Manufacturer: BOMAG
• Models covered: BW219 D-4, BW219 PD-4
• Document number: 008 924 53
• Serial number range: S/N 861 582 758 259 > / S/N 861 582 768 054 >
• Language: English
• Page count: 932 pages
• File format: PDF

Chapters Covered

The BW219 D-4 & PD-4 service manual is organised into the following main chapters, each with its own sub-sections:

• General – Introduction, safety regulations, general repair instructions, tightening torques
• Technical data – machine dimensions, weights, travel, engine, steering, vibration, tires, filling capacities
• Maintenance – general notes, fuels and lubricants, table of fuels and lubricants, running-in instructions, maintenance table
• Electrics – acceleration transducer, proximity switches, diesel tank level sensor R03, hydraulic oil filter differential pressure switch B21, fuel pre-heating, air filter vacuum switch, coolant float switch, charge control light, engine RPM-meter, battery service, main battery fuse, jump starting, electric component overview, indicators and control elements, fuses
• Electronic modules – BEM (BOMAG Evib-meter), electrics module A68, electric module K04, electric module A108, speedometer module
• Engine – Deutz diesel engine, EMR II electronic engine control, troubleshooting, SERDIA diagnostics, valve clearance, plug-in injection pump, engine components
• Hydraulics – hydraulic circuit (open and closed), travel/vibration pump connection overview, travel pump 90R075, vibration pump 90R 041, axial piston swash plate principle, travel motor 51C/D 110, vibration motor 90M 055, external gear pumps, travel circuit, parking brake adjustment and check, towing, vibration circuit, steering circuit, hydraulic oil level and changes
• Tests and adjustments – special tools, service mode, driving against closed brake, pressure tests in travel and vibration circuits, neutral position adjustment, leakage rate checks, steering pressure tests
• Flushing and bleeding – flushing and bleeding the travel circuit and the vibration circuit
• Dust protection / gasket – assembly of dust protection
• Air conditioning system – physical basics, refrigerant R134a, compressor oil, working principle, monitoring devices, components, inspection, evacuation, leak test, filling instructions, troubleshooting, steam table
• Cabin assembly – preparations, cabin assembly, final function tests and checks
• Replacing the cab window panes – assembly of window panes, special tools, auxiliary materials
• Drum – special tools, repair overview, removal and installation, repairing the drum, change-over weights, rubber buffers and pretension
• Oscillating articulated joint – dismantling and assembly
• Suppliers documentation – travel and vibration pump, travel motor, drum reduction gear, steering valve, axle, vibration motor
• Circuit diagrams – hydraulic diagram 581 202 01, wiring diagram 62

IMAGES PREVIEW

Altogether, the BOMAG BW219 D-4 & PD-4 Service Manual gives a technician a single reference that ties the mechanical, hydraulic and electronic systems of the machine together. Procedures reference specific tightening torques, pressure values, adjustment limits and measurement values, and the suppliers’ documentation chapter reproduces the Sauer-Danfoss pump and motor manuals used on these rollers, along with the drum reduction gear, steering valve and Dana axle documentation.

Systems and Procedures Covered in Depth

The engine chapter covers the Deutz diesel engine used on the BW219 D-4 and BW219 PD-4 range, including the EMR II electronic engine control, its individual sensors and actuator, diagnostic fault codes and how to use SERDIA. Valve clearance checking and adjustment and the assembly of the plug-in injection pump are covered step by step, with the calculation of the compensation shim and the tightening sequence after installation.

The hydraulic chapters walk through both the travel circuit and the vibration circuit as closed loops, including the travel pump 90R075 and vibration pump 90R 041, their multi-function valves, charge pressure relief valves, bypass function and the axial piston swash plate principle. Travel and vibration motors (51C/D 110 and 90M 055) are described with their flushing valves and displacement controls. Adjustment of the parking brake, checking it, and towing the machine are documented with nominal values.

The drum chapter includes a full repair overview, removal and installation of the drum, disassembly and assembly of the exciter units on both the travel motor side and the vibration motor side, changing the change-over weights, and setting the rubber buffer pretension. The oscillating articulated joint chapter covers dismantling and reassembly with the Belleville springs and rocker bearings.

On the electrical side, the BW219 D-4 & PD-4 manual covers the acceleration transducer used on BVC and Evib-meter machines, proximity switches with their PNP/NPN circuitry, the diesel tank level sensor, hydraulic oil filter differential pressure switch, fuel pre-heating, air filter vacuum switch, coolant float switch, charge control light and RPM meter, battery service and jump starting, plus the electric modules A68, K04, A108, the BEM and the speedometer module. Fuse layouts and descriptions of indicators and control elements are included.

What This Service Manual Enables You to Do

With the BOMAG BW219 D-4 & PD-4 Single Drum Roller Service Manual on hand, a workshop can diagnose EMR II fault codes, adjust travel and vibration pump neutral positions, test pressures in the travel, vibration and steering circuits, flush and bleed both circuits after a component change, remove and rebuild the drum, service the articulated joint, replace cab window panes, and service the air conditioning system. The tightening torque tables, adjustment limits and service data inside the manual are the values the machine was designed to, so repairs follow the manufacturer’s method rather than a generic procedure.

Because the manual reproduces the Sauer-Danfoss suppliers’ documentation for the travel and vibration pumps and motors, the drum reduction gear, the steering valve and the Dana axle, this single PDF covers the machine-specific service content and the supplier-side overhaul detail in one place.

Instant PDF Delivery

The manual is delivered as an instant PDF download after payment – no shipping, no waiting. It can be viewed on any device, searched and printed, and the pages you need can be kept next to the machine in the workshop.