Bomag BW 216 D-3 BW 216 DH-3 BW 216 PDH-3 BW 129 DH-3 BW 219 PDH-3 BW 225 D-3 BW 225 PD-3 Single Drum Roller Service Repair Manual Instant Download

1
Training Manual
Single Drum Rollers BW 216 D-3, BW 216
DH-3/PDH-3 BW 219 DH-3/PDH-3, BW 225 D-3/PD-3
4/2000
Part-No. 008 098 29
2
Service Training
Table of contents
Foreword A 1
Documentation A 2
General A 4
List of components B 1
Technical data B 2
Maintenance C1
Maintenance table C2
DEUTZ Diesel engine D 1
Service side D 2
Starter side D 3
Lubrication oil circuit D 4
Coolant circuit D 5
Checking and adjusting the valve clearance D 6
Plug-in injection pump D 8
Travel system E 1
Travel pump E 4
Servo control E 15
Multi-function valves E 17
Charge pressure relief valve E 20
Axle drive motor E 21
Drum drive motor with reduction gear E 23
Flushing valve E 26
Trouble shooting travel system ETr 1
BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3,
BW 225 D-3/PD-3
3
Service Training
Vibration Vibration pump Control High pressure
protection Charge pump Vibration motor Trouble
shooting vibration
F 1 F 4 F 8 F 8 F 8 F 9 FTr 1
Steering Steering pump Steering valve
Articulated joint Trouble shooting steering
G 1 G 3 G 5 G 7 GTr 1
Electrical system Power supply Ignition and
starter circuit Fault monitoring board
Brakes Speed range selector Anti Spin Control
(ASC) Vibration
H 1 H 2 H 4 H 7 H 11 H 14 H 18 H 20
BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3,
BW 225 D-3/PD-3
4
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com
5
Service Training
Foreword This training manual was specifically
written for the new single drum rollers BW 216
D-3, BW 216 DH- 3/PDH-3, BW 219 DH-3/PDH3 and BW
225 D-3/PD-3 of generation 3. This range of
single drum rollers is the consequent further
development of the machine range of heavy single
drum rollers of generation 2 and is also an
adaptation to the presently most modern status of
technology. Single drum rollers of this product
ranges are today needed on construction sites all
over the world. Rol- lers of this size are
mainly used in earth construction and for the
preparation and sealing of sanitary landfill
sites. During the development of this new
generation of single drum rollers the
requirements and demands of our customers,
operators and maintenance personnel were the main
aspects which were taken into consideration. Sin
ce we would like to increase the benefit for our
customers also in the future, we ask you kindly
to inform us about your ideas and
suggestions. The introduction of new or improved
products on the market is not possible without
thorough training of all persons responsible for
the efficient after sales service for all these
products. This is the reason why this document
was prepared on the basis of the training
material for the new ran- ge of single drum
rollers of generation 3. This material will help
the trainer to transfer the necessary knowledge
to the participants in the training session in an
easy to understand way. This manual is by no
means complete. Technical data and details, which
were not available at the date of release of
this manual, or which have changed since the
release of this manual, require special at-
tention of the respective trainer during the
training course. These training documents are
not subjected to a regular updating service. All
important changes to the machine will, however,
be worked in during the revision of this training
manual. The chapter "Documentation contains
information about other documents for this
machine. The latest operating and maintenance
instructions and the up-to-date electric and
hydraulic diagrams are part of this training
manual.
BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3,
BW 225 D-3/PD-3
6
Service Training
Documentation For the single drum rollers BW 216
D-3, BW 216 DH-3/PDH-3, BW 219 DH-3/PDH3 and BW
225 D-3/ PD-3 the following documents are
additionally available 1. Operating and
maintenance instructions
Machine type Catalogue No. from serial no. to serial no.
BW 216 D-3 008 140 61 101 580 40 0101
BW 216 DH-3 008 140 61 101 580 42 0101
BW 216 PDH-3 008 140 61 101 580 43 0101
BW 219 DH-3 008 140 61 101 580 50 0101
BW 219 PDH-3 008 140 61 101 580 51 0101
BW 225 D-3 008 140 61 101 580 60 0101
BW 225 PD-3 008 140 61 101 580 61 0101
2. Spare parts catalogue
Machine type BW 216 D-3 BW 216 DH-3 BW 216
PDH-3 BW 219 DH-3 BW 219 PDH-3 BW 225 D-3 BW 225
PD-3
Catalogue No. 008 153 40 008 153 42 008 153
43 008 153 50 008 153 51 008 153 60 008 153 61
from serial no. 101 580 40 0101 101 580 42
0101 101 580 43 0101 101 580 50 0101 101 580 51
0101 101 580 60 0101 101 580 61 0101
to serial no.

• Wiring diagram
• Drawing No. from serial number to serial number
• 582 700 38 for single drum rollers with new
  monitoring board
• Hydraulic diagram

Machine type BW 216 D-3 BW 216 DH-3 BW 216
PDH-3 BW 219 DH-3 BW 219 PDH-3 BW 225 D-3 BW 225
PD-3
Drawing No. 581 201 26 581 201 26 581 201 26 581
201 27 581 201 27 581 201 28 581 201 28
from serial number 101 580 40 0101 101 580 42
0101 101 580 43 0101 101 580 50 0101 101 580 51
0101 101 580 61 0101 101 580 61 0101
to serial number
BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3,
BW 225 D-3/PD-3
7
Service Training
5. Repair instructions Catalogue No. Component
Part-No.
6. Service Information
Comment These documents are part of the
training manual
BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3,
BW 225 D-3/PD-3
8
Service Training

• General
• The new single drum rollers BW 216 D-3, BW 216
  DH-3/PDH-3, BW 219 DH-3/PDH3 and BW 225 D-
  3/PD-3 from BOMAG are mainly further developments
  of the preceding models BW 219 D-2 and BW 219
  DH-2.
• These machines have been successfully used over
  years on construction sites all over the world,
  espe- cially in earth work and for the
  construction of sanitary landfill sites.
• High compaction performance and extremely good
  traction are properties, which are of utmost im-
  portance for machines of this type.
• All components used in these machines are series
  production products and are permanently subjected
  to stringent quality checks. This ensures a high
  level of reliability and safety.
• As on many other BOMAG products and here
  particularly on the large single drum rollers of
  the new generation, we have also with these
  machines made a decision in favour of the
  approved drive system with diesel engine (water
  cooled) and hydrostatic drive. Hydrostatic drives
  transfer the output power of the diesel engine
  directly to the drum, the drive wheels and the
  steering cylinder.
• Drum and drive wheels are driven by fast rotating
  hydraulic motors and reduction gear (drum) or
  axle (drive wheels).
• On construction equipment the work place of the
  operator is of utmost importance. Under such
  operating conditions the health and safety of
  the operator must be treated with top priority.
• The cabin is very spacious and clearly layed out.
  The operator's seat is very comfortable and can
  be individually adjusted for every operator,
  even to the weight.
• All controls and gauges are within the reach and
  the field of vison of the operator.

BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3,
BW 225 D-3/PD-3
9
Service Training

• automatic engine shut down at too high coolant
  temperature, too low hydraulic oil level (when
  rea- ching the lowest level the engine will be
  shut down after 20 seconds) and too low engine
  oil pressure.
• The single drum rollers BW 216 D-3, BW 216
  DH-3/PDH-3, BW 219 DH-3/PDH3 and BW 225 D-3/PD-
  3 are very well designed down to the smallest
  detail, suitable for the tough requirements on
  large scale construction sites all over the
  world.

BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3,
BW 225 D-3/PD-3
10
Service Training
List of components
Fig. 1 Position of important service points
1 Drum drive motor 13 Vibration pump
2 Reduction gear 14 Travel pump
3 Vibration motor 15 Hand pump for hood
4 Articulated joint 16 Hydraulic oil filter
5 Hydraulic oil cooler 17 Starter
6 Radiator 18 Wheels (with axle and axle drive motor)
7 Fuel filter 19 Generator
8 Pressure accumulator to compensate 20 Radiator blower
vibrations in the steering system 21 Operator's seat
9 Engine oil filter 22 Steering wheel with steering valve
10 Steering/charge pump 23 Drum
11 Fuel pre-filter
12 Deutz engine BF6M 1013 E
BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3,
BW 225 D-3/PD-3
- B 1 -
11
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and
adjustment values Status 2001-07-09
Product type Type No. Serial numbers from Serial numbers up to BW 216 D-3 580 40 101 580 40 0101 101 580 40 0181
Engine Engine
Manufacturer Deutz
Type BF6M1013E
Combustion principle 4-stroke-Diesel
Cooling Water
Number of cylinders 6
Power acc. to ISO 9249 137 kW
Power data at nominal speed of 2200 U/min
Low idle speed 850/-150 U/min
High idle speed 2350/-100 U/min
Spec. fuel consumption 228 g/kWh
Valve clearance, inlet 0,3 mm
Valve clearance, outlet 0,5 mm
Opening pressure, injection valves 250 bar Opening pressure, injection valves 250 bar
Starter voltage 12 V
Starter power 3,1 kW
Travel pump
Manufacturer Sauer-Danfoss
Type 90R 075
System Axial piston-swash plate
Max. displacement 75 cm3/U
Max. flow ratio 172,9 l/min
High pressure limiation 435 /-15 bar
Charge pressure, high idle 25/-1 bar
Reduction gear, drum
Manufacturer Sauer-Danfoss
Type CR 31
Transmission ratio 45,6
Travel motor, rear
Manufacturer Sauer-Danfoss
Type 51D110
System Axial piston-bent axle
Max. displacement (stage 1) 110 cm3/U
Min. displacement (stage 2) 50 cm3/U
Perm. leak oil quantity 2 l/min
Drum drive
Manufacturer Sauer-Danfoss
Type 51C 110
System Axial piston-swash plate
http//bo_web/ext_resource/tk_tech/english/search_
components_result.asp
09.07.01
12
BOMAG Central Service
Seite 2 von 2
Displacement stage 1 Displacement stage 2 Perm. leak oil quantity 110 cm3/U 40,3 cm3/U 2 l/min
Vibration pump Vibration pump
Manufacturer Sauer-Danfoss
Type 42R 041
System Axial piston-swash plate
Max. displacement 41 cm3/U
Starting pressure 350/-50 bar
Operating pressure, soil dependent ca.100 bar Operating pressure, soil dependent ca.100 bar
Vibration motor
Manufacturer Sauer-Danfoss
Type MMF 044
System Axial piston-swash plate
Displacement 44 cm3/U
Frequency 30/36 Hz
Amplitude 1,8/0,9 mm
Steering and charge pump
Manufacturer Bosch
Type HY/ZFS11/16
System Gear pump
Displacement 16 cm3/U
Max. steering pressure 225/-15 bar
Steering valve
Manufacturer Sauer-Danfoss
Type OSPC 500 ON
System Rotary valve
Rear axle
Manufacturer Dana
Type CHC 193/51
Differential No-Spin
Degree of locking 100
Reduction ratio 65,08
Filling capacities
Engine coolant 20 l (50 Water, 50 Anti-freeze agent on
Ethane-diol-basis)
Engine oil 20 l (SAE 15W-40, API SJ/CF)
Hydraulic oil 60 l (HVLP 46 VI 150)
Vibration bearing housing 2x 1,8 l (SAE 15W-40, API SJ/CF)
Rear axle 11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs 2,9 l (SAE 90 EP, API GL 5)
Rear axle, transmission 1,9 l (SAE 90 EP, API GL 5)
Reduction gear, drum 2,8 l (SAE 90 EP, API GL 5)
AC refrigerant 1100 g (R 134a)
Compressor oil (filling the system) 100 ml (PAG Öl)
http//bo_web/ext_resource/tk_tech/english/search_
components_result.asp
09.07.01
13
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and
adjustment values Status 2001-07-09
Product type Type No. Serial numbers from Serial numbers up to BW 216 D-3 580 40 101 580 40 0182 101 580 82 1019
Engine Engine
Manufacturer Deutz
Type BF6M1013E
Combustion principle 4-stroke-Diesel
Cooling Water
Number of cylinders 6
Power acc. to ISO 9249 145 kW
Power data at nominal speed of 2300 U/min
Low idle speed 850/-150 U/min
High idle speed 2375/-125 U/min
Spec. fuel consumption 228 g/kWh
Valve clearance, inlet 0,3 mm
Valve clearance, outlet 0,5 mm
Opening pressure, injection valves 250 bar Opening pressure, injection valves 250 bar
Starter voltage 12 V
Starter power 3,1 kW
Travel pump
Manufacturer Sauer-Danfoss
Type 90R 075
System Axial piston-swash plate
Max. displacement 75 cm3/U
Max. flow ratio 178,1 l/min
High pressure limiation 435 /-15 bar
Charge pressure, high idle 25/-1 bar
Reduction gear, drum
Manufacturer Sauer-Danfoss
Type CR 31
Transmission ratio 45,6
Travel motor, rear
Manufacturer Sauer-Danfoss
Type 51D110
System Axial piston-bent axle
Max. displacement (stage 1) 110 cm3/U
Min. displacement (stage 2) 50 cm3/U
Perm. leak oil quantity 2 l/min
Drum drive
Manufacturer Sauer-Danfoss
Type 51C 110
System Axial piston-swash plate
http//bo_web/ext_resource/tk_tech/english/search_
components_result.asp
09.07.01
14
BOMAG Central Service
Seite 2 von 2
Displacement stage 1 Displacement stage 2 Perm. leak oil quantity 110 cm3/U 40,3 cm3/U 2 l/min
Vibration pump Vibration pump
Manufacturer Sauer-Danfoss
Type 42R 041
System Axial piston-swash plate
Max. displacement 41 cm3/U
Starting pressure 350/-50 bar
Operating pressure, soil dependent ca.100 bar Operating pressure, soil dependent ca.100 bar
Vibration motor
Manufacturer Sauer-Danfoss
Type MMF 044
System Axial piston-swash plate
Displacement 44 cm3/U
Frequency 30/36 Hz
Amplitude 1,8/0,9 mm
Steering and charge pump
Manufacturer Bosch
Type HY/ZFS11/16
System Gear pump
Displacement 16 cm3/U
Max. steering pressure 225/-15 bar
Steering valve
Manufacturer Sauer-Danfoss
Type OSPC 500 ON
System Rotary valve
Rear axle
Manufacturer Dana
Type CHC 193/51
Differential No-Spin
Degree of locking 100
Reduction ratio 65,08
Filling capacities
Engine coolant 20 l (50 Water, 50 Anti-freeze agent on
Ethane-diol-basis)
Engine oil 20 l (SAE 15W-40, API SJ/CF)
Hydraulic oil 60 l (HVLP 46 VI 150)
Vibration bearing housing 2x 1,8 l (SAE 15W-40, API SJ/CF)
Rear axle 11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs 2,9 l (SAE 90 EP, API GL 5)
Rear axle, transmission 1,9 l (SAE 90 EP, API GL 5)
Reduction gear, drum 2,8 l (SAE 90 EP, API GL 5)
AC refrigerant 1100 g (R 134a)
Compressor oil (filling the system) 100 ml (PAG Öl)
http//bo_web/ext_resource/tk_tech/english/search_
components_result.asp
09.07.01
15
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and
adjustment values Status 2001-07-09
Product type Type No. Serial numbers from BW 216 D-3 580 40 101 580 40 1020
Engine Engine
Manufacturer Deutz
Type BF6M1013E
Combustion principle 4-stroke-Diesel
Cooling Water
Number of cylinders 6
Power acc. to ISO 9249 137 kW
Power data at nominal speed of 2200 U/min
Low idle speed 850/-150 U/min
High idle speed 2350/-100 U/min
Spec. fuel consumption 228 g/kWh
Valve clearance, inlet 0,3 mm
Valve clearance, outlet 0,5 mm
Opening pressure, injection valves 250 bar Opening pressure, injection valves 250 bar
Starter voltage 12 V
Starter power 3,1 kW
Travel pump
Manufacturer Sauer-Danfoss
Type 90R 075
System Axial piston-swash plate
Max. displacement 75 cm3/U
Max. flow ratio 178,1 l/min
High pressure limiation 435 /-15 bar
Charge pressure, high idle 25/-1 bar
Reduction gear, drum
Manufacturer Sauer-Danfoss
Type CR 31
Transmission ratio 45,6
Travel motor, rear
Manufacturer Sauer-Danfoss
Type 51D110
System Axial piston-bent axle
Max. displacement (stage 1) 110 cm3/U
Min. displacement (stage 2) 50 cm3/U
Perm. leak oil quantity 2 l/min
Drum drive
Manufacturer Sauer-Danfoss
Type 51C 110
System Axial piston-swash plate
Displacement stage 1 110 cm3/U
http//bo_web/ext_resource/tk_tech/english/search_
components_result.asp
09.07.01
16
BOMAG Central Service
Seite 2 von 2
Displacement stage 2 Perm. leak oil quantity 40,3 cm3/U 2 l/min
Vibration pump Vibration pump
Manufacturer Sauer-Danfoss
Type 42R 041
System Axial piston-swash plate
Max. displacement 41 cm3/U
Starting pressure 350/-50 bar
Operating pressure, soil dependent ca.100 bar Operating pressure, soil dependent ca.100 bar
Vibration motor
Manufacturer Hydromatik
Type A2FM 45
System Axial piston-bent axe
Displacement 45 cm3/U
Frequency 30/36 Hz
Amplitude 1,8/0,9 mm
Steering and charge pump
Manufacturer Bosch
Type HY/ZFS11/16
System Gear pump
Displacement 16 cm3/U
Max. steering pressure 225/-15 bar
Steering valve
Manufacturer Sauer-Danfoss
Type OSPC 500 ON
System Rotary valve
Rear axle
Manufacturer Dana
Type CHC 193/51
Differential No-Spin
Degree of locking 100
Reduction ratio 65,08
Filling capacities
Engine coolant 20 l (50 Water, 50 Anti-freeze agent on
Ethane-diol-basis)
Engine oil 20 l (SAE 15W-40, API SJ/CF)
Hydraulic oil 60 l (HVLP 46 VI 150)
Vibration bearing housing 2x 1,8 l (SAE 15W-40, API SJ/CF)
Rear axle 11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs 2,9 l (SAE 90 EP, API GL 5)
Rear axle, transmission 1,9 l (SAE 90 EP, API GL 5)
Reduction gear, drum 2,8 l (SAE 90 EP, API GL 5)
AC refrigerant 1100 g (R 134a)
Compressor oil (filling the system) 100 ml (PAG Öl)
http//bo_web/ext_resource/tk_tech/english/search_
components_result.asp
09.07.01
17
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and
adjustment values Status 2001-07-09
Product type Type No. Serial numbers from Serial numbers up to BW 216 DH-3 580 42 101 580 42 0101 101 580 42 0132
Engine Engine
Manufacturer Deutz
Type BF6M1013E
Combustion principle 4-stroke-Diesel
Cooling Water
Number of cylinders 6
Power acc. to ISO 9249 137 kW
Power data at nominal speed of 2200 U/min
Low idle speed 850/-150 U/min
High idle speed 2350/-100 U/min
Spec. fuel consumption 228 g/kWh
Valve clearance, inlet 0,3 mm
Valve clearance, outlet 0,5 mm
Opening pressure, injection valves 250 bar Opening pressure, injection valves 250 bar
Starter voltage 12 V
Starter power 3,1 kW
Travel pump
Manufacturer Sauer-Danfoss
Type 90R 075
System Axial piston-swash plate
Max. displacement 75 cm3/U
Max. flow ratio 172,9 l/min
High pressure limiation 435 /-15 bar
Charge pressure, high idle 25/-1 bar
Reduction gear, drum
Manufacturer Sauer-Danfoss
Type CR 31
Transmission ratio 45,6
Travel motor, rear
Manufacturer Sauer-Danfoss
Type 51D110
System Axial piston-bent axle
Max. displacement (stage 1) 110 cm3/U
Min. displacement (stage 2) 31,4 cm3/U
Perm. leak oil quantity 2 l/min
Drum drive
Manufacturer Sauer-Danfoss
Type 51C 110
System Axial piston-swash plate
http//bo_web/ext_resource/tk_tech/english/search_
components_result.asp
09.07.01
18
Suggest If the above button click is invalid.
Please download this document first, and then
click the above link to download the complete
manual. Thank you so much for reading
19
BOMAG Central Service
Seite 2 von 2
Displacement stage 1 Displacement stage 2 Perm. leak oil quantity 110 cm3/U 27,5 cm3/U 2 l/min
Vibration pump Vibration pump
Manufacturer Sauer-Danfoss
Type 42R 041
System Axial piston-swash plate
Max. displacement 41 cm3/U
Starting pressure 350/-50 bar
Operating pressure, soil dependent ca.100 bar Operating pressure, soil dependent ca.100 bar
Vibration motor
Manufacturer Sauer-Danfoss
Type MMF 044
System Axial piston-swash plate
Displacement 44 cm3/U
Frequency 30/36 Hz
Amplitude 1,8/0,9 mm
Steering and charge pump
Manufacturer Bosch
Type HY/ZFS11/16
System Gear pump
Displacement 16 cm3/U
Max. steering pressure 225/-15 bar
Steering valve
Manufacturer Sauer-Danfoss
Type OSPC 500 ON
System Rotary valve
Rear axle
Manufacturer Dana
Type CHC 193/51
Differential No-Spin
Degree of locking 100
Reduction ratio 65,08
Filling capacities
Engine coolant 20 l (50 Water, 50 Anti-freeze agent on
Ethane-diol-basis)
Engine oil 20 l (SAE 15W-40, API SJ/CF)
Hydraulic oil 60 l (HVLP 46 VI 150)
Vibration bearing housing 2x 1,8 l (SAE 15W-40, API SJ/CF)
Rear axle 11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs 2,9 l (SAE 90 EP, API GL 5)
Rear axle, transmission 1,9 l (SAE 90 EP, API GL 5)
Reduction gear, drum 2,8 l (SAE 90 EP, API GL 5)
AC refrigerant 1100 g (R 134a)
Compressor oil (filling the system) 100 ml (PAG Öl)
http//bo_web/ext_resource/tk_tech/english/search_
components_result.asp
09.07.01
20
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com