Factory publication 008 911 37 serves as the official 840-page Bomag BW 219 D-4, BW 219 PD-4 service manual for keeping these single drum rollers moving on the fill. Detailed hydraulic schematics and wiring diagrams map out the closed-loop travel circuits, letting you trace pilot pressures straight to the multi-function valve. Teardown procedures guide you through dismantling the oscillating articulated joint and rebuilding the drum change-over weights without guesswork. You work with verified factory tolerances, confirming the travel system multi-function valve relieves at exactly 400 bar and servicing the fuel pre-filter cartridge right at the 500-hour mark. When a dead roller means the crew cannot hit target density on the lift, waiting for answers is not an option. Download this bookmarked, searchable PDF to your tablet and carry the exact repair data wherever the machine is parked.
What's Inside This Bomag BW 219 D-4, BW 219 PD-4 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 7-28 | Introduction, Safety Regulations, General Repair Instructions |
| Maintenance | 29-38 | Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Chart |
| Technical Data | 39-44 | Weights, Travel Characteristics, Engine, Steering, Vibration, Filling Capacities |
| Connection Overview | 45-48 | Control Solenoid, Multi-Function Valve, Pilot Pressure Test Port, High Pressure Port, Charge Pump, Leak Oil Connection |
| Tests and Adjustments | 49-64 | Special Tools, Checking the Rotation Speeds, Checking / Adjusting the Neutral Positions of the Travel Pump, Pressure Tests in the Travel Circuit |
| Flushing and Bleeding | 65-100 | Special Tools for Flushing, Flushing - General, Flushing Schematic Travel Circuit, Flushing the Travel Circuit, Flushing Schematic for Vibration Drive |
| Fundamental Electrics | 101-154 | Understanding Circuit Diagrams, Terminal Designations, Current and Voltage, Resistance, Series / Parallel Connection, Ohm's Law, Electrical Energy, Formula Diagram |
| Special Tools, Electrics | 155-164 | Vibration Reed Frequency Meter, Sirometer, Hydraulic Test Case, Multimeter, Crimping Pliers, Magnetic Coil Tester |
| Machine Related Electrics | 165-232 | Electrics Bem, Seat Contact Module |
| Speedometer Module | 233-236 | Programmable Module, Speedometer Function, Self-Teaching Mode, Speed Sensor, Path Pulses |
| Service Training | 237-344 | Service Training Machine |
| Air Conditioning System | 345-394 | Physical Basics, Refrigerant R134a, Compressor Oil / Refrigeration Oil, Working Principle of the Air Conditioning System, Monitoring Devices, Components |
| Replacing the Cab Window Panes | 395-404 | Assembly of Window Panes, Special Tools, Auxiliary Materials, Removing and Installing the Window Pane |
| Drum | 405-460 | Special Tools, Single Drum Rollers, Repair Overview for Drum, Removing and Installing the Drum, Repairing the Drum, Dismantling, Assembling the Change-Over Weights |
| Oscillating Articulated Joint | 461-476 | Special Tools, Repair Overview Oscillating Articulated Joint, Removing and Installing the Oscillating Articulated Joint, Dismantling the Oscillating Articulated Joint |
| Suppliers Documentation | 477-766 | Travel Pump Vibration Pump Series 90R, Travel Drive Series 51, Transmission CR, Axle Dana 193 |
| Circuit Diagrams | 767-840 | Wiring Diagram, Hydraulic Diagram |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for M4 screw (8.8) | 3 Nm | p. 24 |
| Tightening torque for M4 screw (10.9) | 5 Nm | p. 24 |
| Fuel pre-filter cartridge replacement interval | every 500 operating hours | p. 36 |
| Fuel filter cartridge replacement interval | every 500 operating hours | p. 36 |
| Multi-function valve (boost check and pressure relief valve) - travel system | 400 bar | p. 47 |
| Charge pressure relief valve | 26 bar | p. 47 |
| Max. displacement - travel pump | 75 cm3/rev. | p. 41 |
| Max. flow capacity - travel pump | 163.65 l/min | p. 41 |
| Displacement (stage 1) - drum drive motor | 110 cm3/rev. | p. 41 |
| Displacement (stage 2) - drum drive motor | 55 cm3/rev. | p. 41 |
| Final discharging voltage | 10.5 Volt | p. 125 |
| Open circuit voltage for recharge | 12.25 Volt | p. 125 |
Bomag BW 219 D-4, BW 219 PD-4 Common Problems This Manual Covers
Bomag BW 219 D-4 engine cranks but will not start or turns over slowly in cold weather.
Test the starter battery voltage. Verify open circuit voltage for recharge is at least 12.25 Volt as noted on page 125. If voltage drops below 10.5 Volt during cranking, replace the battery and check terminal connections before returning the roller to the pass.
Manual Section: Fundamental Electrics p. 125Hydrostatic travel system loses performance and machine drives in one direction only when pushing material.
Check the travel system troubleshooting procedures. Inspect the multi-function valves and confirm the boost check and pressure relief valve holds 400 bar as listed on page 47. If the valve is faulty, replace it and torque the new multi-function valves to 89 Nm per page 299 before the mat cools.
Manual Section: Service Training p. 47Drum vibration fails to engage or exciter shaft speed remains too low during compaction passes.
Inspect the vibration system solenoids. Measure the low amplitude solenoid voltage and current to confirm it receives 12V / 3.33A as shown on page 338. If the electrical supply is correct but the drum will not vibrate, verify the charge pressure relief valve is adjusted to 26 bar.
Manual Section: Service Training p. 338Engine loses power during heavy rolling and fuel system loses prime under load.
Replace the fuel filter cartridge every 500 operating hours according to the maintenance schedule on page 36. Bleed the lines and check the main fuel filter pre-pressure. If the pressure falls below the 10 bar specification on page 257, inspect the fuel delivery pump for wear.
Manual Section: Maintenance p. 36Frequently Asked Questions
What are the torque specifications for the wheel nuts on the BOMAG BW 219 D-4?
Tightening torque for wheel nuts (fine thread) on the BW 219 D-4 is 500 - 600 Nm for M22x1.5 thread diameter. p. 25
What is the engine oil capacity for the BW 219 D-4?
Engine oil capacity for the BW 219 D-4 runs approximately 12.5 litres without the oil filter. p. 34
What is the correct valve clearance on the Bomag BW 219 D-4, BW 219 PD-4 single drum roller?
Valve clearance for the engine must be checked and adjusted when the engine is cold. The intake valve clearance is 0.3 mm and the exhaust valve clearance is 0.5 mm. p. 258
How often should the hydraulic oil filter element be replaced?
Replace the hydraulic oil filter element every 500 operating hours. p. 33
What is the tightening torque for the multi-function valves on the travel pump of a Bomag BW 219 D-4, BW 219 PD-4?
Multi-function valves on the travel pump must be tightened with a torque of 89 Nm. p. 299
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