Bomag BW 219 D-4 - User Manual

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Overview

This document is a service manual for the BOMAG BW 219 D-4/PD-4 single drum roller, covering serial numbers from 101 582 72 onwards. It provides comprehensive information for maintenance, repair, and adjustment of the machine, targeting service personnel and technicians.

The manual begins with general information, including an introduction to the machine, safety regulations, and general repair instructions. It emphasizes the importance of adhering to safety guidelines to prevent accidents and ensure proper operation. Tightening torques for various components are also provided, which are crucial for ensuring the structural integrity and reliability of the machine during assembly and repair.

Maintenance is a significant section, detailing general notes on maintenance, recommended fuels and lubricants, and a table outlining these specifications. It also includes running-in instructions for new or overhauled machines, which are essential for optimizing performance and longevity. A detailed maintenance chart guides users through scheduled inspections and service tasks, ensuring the machine remains in optimal working condition.

Technical data for the BW 219 D-4/PD-4 is presented, providing key specifications necessary for understanding the machine's capabilities and for troubleshooting. This section likely includes dimensions, weights, engine specifications, and performance parameters.

A connection overview is provided, which is fundamental for understanding the machine's various systems and their interconnections. This visual or descriptive overview helps in tracing circuits and identifying components during diagnostics.

The "Tests and adjustments" section is critical for diagnosing and resolving operational issues. It lists special tools required for specific tests and adjustments. Detailed procedures are outlined for checking engine speeds, adjusting the neutral positions of the travel pump, and performing pressure measurements in both the vibration and steering circuits. The manual also covers checking the leakage rate of the vibration motor, which is important for assessing the health of the hydraulic system.

Flushing procedures are extensively covered, starting with special tools required for flushing and general flushing guidelines. Specific flushing schematics and procedures are provided for various hydraulic circuits, including the travel circuit (both distribution travel pump and axle motor distribution) and the vibration drive. This ensures that hydraulic systems are kept clean and free from contaminants, which is vital for their performance and lifespan. The manual also includes instructions for bleeding both the travel and vibration circuits to remove air, which can impair hydraulic system efficiency.

Fundamental electrics are explained to provide a solid understanding of the machine's electrical systems. This section covers how to understand circuit diagrams, terminal designations, and basic electrical concepts such such as current, voltage, resistance, series/parallel connections, Ohm's law, and electrical energy. It also includes a formula diagram and information on metrology, diodes, relays, and fuses, which are essential for electrical troubleshooting and repair.

The manual delves into specific electrical components, starting with batteries, the three-phase generator, and the electric starter. It also describes the Telemecanique switch, inductive proximity switches, and angle sensors with current output. Various plug connectors, including Deutsch plugs (series DT and DTM) and plugs/terminals in spring clamping technology, are detailed, which is useful for electrical connections and repairs.

Special tools for electrical work are listed, followed by machine-related electrics. This includes a detailed description of the Electrics BEM (BOMAG Evib-meter) and the seat contact module, which are integral to the machine's control and safety systems. The speedometer module and its functions are also explained.

Service training information is provided, indicating that the manual supports training for machine maintenance and repair.

A comprehensive section on the air conditioning system covers its physical principles, refrigerants, and refrigeration oil. It explains the working principle of the air conditioning system, describes its components, and provides procedures for checking compressor oil levels and the magnetic clutch. Maintenance tasks, such as checking and replacing the refrigerant compressor V-belt, servicing the air conditioning, drying and evacuation, emptying in case of repair, leak testing, and filling instructions, are all detailed. Troubleshooting for the refrigerant circuit, including basic principles, circuit diagrams, and procedures, is also included, along with a steam table for R134a and information on heating control.

Replacing the cab window panes is addressed with instructions on assembly, special tools, auxiliary materials, and the removal/installation process.

The drum section covers special tools for the drum on single drum rollers and provides a repair overview. Detailed procedures for removing and installing the drum, repairing the drum, dismantling and assembling change-over weights, and changing rubber buffers and adjusting pretension are included.

The oscillating articulated joint section provides information on special tools, a repair overview, and procedures for removing, installing, dismantling, and assembling the joint.

Finally, the manual includes a suppliers' documentation section, which likely contains information from manufacturers of specific components used in the BOMAG BW 219 D-4/PD-4. This includes details on the travel pump/vibration pump (series 90R), travel drive (series 51), Transmission CR, and Axle DANA 193.

Circuit diagrams are provided for both wiring and hydraulic systems, which are indispensable for diagnosing and repairing electrical and hydraulic faults. These diagrams allow technicians to trace the flow of power and fluid, identify components, and understand system logic.

Overall, this service manual is a comprehensive guide for maintaining and repairing the BOMAG BW 219 D-4/PD-4 single drum roller, covering everything from basic safety and maintenance to complex electrical and hydraulic system diagnostics and repair.