Bomag BW 219 D-4, PD-4 2007 Service Manual

If you are turning wrenches on a Bomag BW 219 D-4, PD-4 2007 Service Manual you need the real factory book, not some third-party rewrite that leaves out the charge pressure relief valve setting. I have seen too many rollers come into my shop with stripped ports and wrong hydraulic pressures because somebody grabbed a generic manual. This 840-page document is the OEM publication from Bomag, catalogue number 008 911 37, dated 05/2007. It covers both the BW 219 D-4 and PD-4 models from serial number 101 582 72 onward.

Engine and Fuel System Coverage

The manual dedicates specific sections to the Engine and Fuel system. Section 2.2 covers fuels and lubricants with exact specs for engine oil, hydraulic oil, and coolant. The notes on the fuel system (page 30) warn about contamination and proper bleeding procedures. Page 24 gives you the tightening torques for every fastener – use them or risk pulling threads in the block.

Tightening Torques – Page 24

You want the torque for the cylinder head bolts? Page 24. The manual lists tightening torques in the general repair instructions section (Chapter 1.4). Bomag uses a clock system for nuts (Fig. 9) and identification markings for screws (Fig. 7). Do not guess. Use a calibrated torque wrench – I have had to helicoil more than one head because a tech thought “good enough” meant 10 ft-lbs low.

7 Systems Covered in Detail

This manual is not a thin booklet. It covers connection overviews (Chapter 4), travel pump and vibration pump port maps with 37 labeled connections. Chapter 5 runs through pressure tests in the travel circuit (page 58), checking exciter shaft speeds, and adjusting neutral positions of the travel pump. Chapter 7 gives you fundamental electrics from Ohm’s law to Deutsch plug pinouts. Chapter 12 goes into the air conditioning system – refrigerant R134a, compressor oil level checks, and magnetic clutch inspection.

Does This Manual Include Flushing and Bleeding?

Yes, and that is where most roller failures start. Chapter 6 covers flushing the travel circuit (distribution travel pump on page 73), flushing schematic for vibration drive (page 91), and bleeding both circuits (page 96). If you skip bleeding air from the vibration circuit, you will burn out the motor. The manual gives you step-by-step flushing procedures with special tool lists – no shortcuts.

Source Validity – OEM vs. Aftermarket Reprints

This is an original factory printed service manual from Bomag, not a copy of a copy. The PDF we sell is a scan of the 2007 publication – every page, every torque value, every wiring diagram is as Bomag intended. I have seen aftermarket manuals that combine three different models into one book and omit the vibration pump charge pressure relief valve setting. That gets your customer a dead roller and you an earful. Stick with OEM. Check out related manuals like the BOMAG BMP 8500 Service Training Manual or the BOMAG BW 62 H / BW 65 H Service and Maintenance Instructions if you work on smaller compactors. Also available: BOMAG BMP 8500 Service Manual Multi-purpose compactor.

For a deeper understanding of driveline theory, read up on Manual Transmission operation – but this manual already has all the electrical theory you need in Chapter 7. The three-phase generator and starter sections (7.12–7.13) alone are worth the price if you chase charging system faults.

FAQ

Does this manual cover the PD-4 model with the vibration pump?

Yes. The title includes both BW 219 D-4 and PD-4. The connection overview (Chapter 4) labels every port on the vibration pump, including the multi-function valves at 345 bar and the charge pressure relief valve.

Is the wiring diagram accurate for 2007 machines?

It is the exact diagram Bomag used at the factory in 2007. No aftermarket “interpretations.” Chapter 9 covers BEM electrics and seat contact module. If your machine has a Deutsch plug, see page 144 for pin assignments.

Stop chasing ghosts in the hydraulic system. Download the Factory Manual and get the real torque specs, test pressures, and wiring diagrams. Your rollers will thank you.