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Bomag BW219D-4 service manual

Bomag BW219D-4 and BW219PD-4 service manual.
serial number ranges:
Bomag BW219D-4 S/N 101 582 72 ....>
Bomag BW219PD-4 S/N 101 582 73 ....>

INDEX:
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 24
Maintenance 29
2.1 General notes on maintenance 30
2.2 Fuels and lubricants 31
2.3 Table of fuels and lubricants 34
2.4 Running-in instructions 35
2.5 Maintenance chart 36
Technical data 39
3.1 Technical data 40
Connection overview 45
4.1 Connection overview 46
Tests and adjustments 49
5.1 Special tools, tests and adjustments 50
5.2 Checking the rotation speeds 54
5.3 Checking / adjusting the neutral positions of the travel pump 56
5.4 Pressure tests in the travel circuit 58
5.5 Checking / adjusting the vibrator shaft speeds 60
5.6 Pressure measurements in the vibration circuit 61
5.7 Check the leakage rate of the vibration motor 62
5.8 Pressure test in steering circuit 63
Flushing and bleeding 65
6.1 Special tools for flushing 66
6.2 Flushing - general 71
6.3 Flushing schematic travel circuit (distribution travel pump) 73
6.4 Flushing the travel circuit (travel pump distribution) 75
6.5 Flushing schematic travel circuit (distribution axle motor) 81
6.6 Flushing the travel circuit (axle motor distribution) 86
6.7 Flushing schematic for vibration drive 91
6.8 Flushing the vibration circuit 92
6.9 Bleeding the travel circuit 96
6.10 Bleeding the vibration circuit 98
Fundamental electrics 101
7.1 Understanding circuit diagrams 102
7.2 Terminal designations 106
7.3 Current and voltage 110
7.4 Resistance 114
7.5 Series / parallel connection 116
7.6 Ohm's law 118
7.7 Electrical energy 118
7.8 Formula diagram 119
7.9 Metrology 120
7.10 Diodes, relays, fuses 122
7.11 Batteries 125
7.12 Three-phase generator 128
7.13 Electric starter 135
7.14 Telemecanique switch 138
7.15 Inductive proximity switches 141
7.16 Angle sensor with current output 142
7.17 Plug connectors 143
7.18 Deutsch plug, series DT and DTM 144
7.19 Plugs and terminals in spring clamping technology 150 Special tools, electrics 155
8.1 Special tools, electrics 156 Machine related electrics 165
9.1 Electrics BEM (BOMAG Evib-meter) 167
9.2 Seat contact module 225 Speedometer Module 233
10.1 Speedometer module 234 Service Training 237
11.1 Service Training Machine 239 Air conditioning system 345
12.1 Physical basics 346
12.2 Refrigerant R134a 349
12.3 Compressor oil / refrigeration oil 350
12.4 Working principle of the air conditioning system 351
12.5 Monitoring devices 351
12.6 Description of components 352
12.7 Checking the compressor oil level 358
12.8 Checking the magnetic clutch 359
12.9 Inspection and maintenance work 360
12.10 Checking, replacing the refrigerant compressor V-belt 360
12.11 Service the air conditioning 361
12.12 Drying and evacuation 364
12.13 Emptying in case of repair 364
12.14 Leak test 365
12.15 Filling instructions 366
12.16 Trouble shooting in refrigerant circuit, basic principles 369
12.17 Trouble shooting, refrigerant circuit diagram 373
12.18 Trouble shooting procedure 374
12.19 Steam table for R134a 384
12.20 Heating control / air conditioning control 389 Replacing the cab window panes 395
13.1 Assembly of window panes 396
13.2 Special tools 397
13.3 Auxiliary materials 398
13.4 Removing and installing the window pane 400 Drum 405
14.1 Special tools, drum, single drum rollers 406
14.2 Repair overview for drum 408
14.3 Removing and installing the drum 417
14.4 Repairing the drum 423
14.5 Dismantling, assembling the change-over weights 455
14.6 Changing the rubber buffers and adjusting the pretension 458 Oscillating articulated joint 461
15.1 Special tools 462
15.2 Repair overview oscillating articulated joint 464
15.3 Removing and installing the oscillating articulated joint 468
15.4 Dismantling the oscillating articulated joint 470
15.5 Assembling the oscillating articulated joint 473 Suppliers documentation 477
16.1 Travel pump / vibration pump series 90R 479
16.2 Travel drive series 51 569
16.3 Transmission CR 651
16.4 Axle DANA 193 677 Circuit diagrams 767
17.1 Wiring diagram 769
17.2 Wiring diagram 799
17.3 Hydraulic diagram 835
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