Bomag bw 225 pd 3 single drum roller service repair manual

Training Manual
Single Drum Rollers
BW 216 D-3, BW 216 DH-3/PDH-3
4/2000Part-No. 008 098 29
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3

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

Service Training
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3
Vibration F 1
Vibration pump F 4
Control F 8
High pressure protection F 8
Charge pump F 8
Vibration motor F 9
Trouble shooting vibration FTr 1
Steering G 1
Steering pump G 3
Steering valve G 5
Articulated joint G 7
Trouble shooting steering GTr 1
Electrical system H 1
Power supply H 2
Ignition and starter circuit H 4
Fault monitoring board H 7
Brakes H 11
Speed range selector H 14
Anti Spin Control (ASC) H 18
Vibration H 20

Service Training
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - A 1 -
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.
Since 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.

Service Training
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - A 2 -
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 Catalogue No.: from serial no. to serial no.
BW 216 D-3 008 153 40 101 580 40 0101
BW 216 DH-3 008 153 42 101 580 42 0101
BW 216 PDH-3 008 153 43 101 580 43 0101
BW 219 DH-3 008 153 50 101 580 50 0101
BW 219 PDH-3 008 153 51 101 580 51 0101
BW 225 D-3 008 153 60 101 580 60 0101
BW 225 PD-3 008 153 61 101 580 61 0101
3. Wiring diagram*
Drawing No.: from serial number to serial number
582 700 38 for single drum rollers with new monitoring board
4. Hydraulic diagram*
Machine type Drawing No.: from serial number to serial number
BW 216 D-3 581 201 26 101 580 40 0101
BW 216 DH-3 581 201 26 101 580 42 0101
BW 216 PDH-3 581 201 26 101 580 43 0101
BW 219 DH-3 581 201 27 101 580 50 0101
BW 219 PDH-3 581 201 27 101 580 51 0101
BW 225 D-3 581 201 28 101 580 61 0101
BW 225 PD-3 581 201 28 101 580 61 0101

Service Training
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - A 3 -
5. Repair instructions
Catalogue No.: Component Part-No.
6. Service Information
Comment:
* These documents are part of the training manual

Service Training
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - A 4 -
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.
A monitoring board with light emitting diodes and easy to understand pictograms informs the operator
about any faults occurring during operation. The operator is therefore always informed about the condi-
tion of the machine.
The generously dimensioned windows in the cabin with windscreen wiper and washer systems for front
and rear windscreens allow excellent view to all directions.
• strong ROPS/FOPS according to SAE standard
• wear free service brake due to the closed hydraulic travel circuits
• multi-disc brakes in the planetary drives working as parking and emergency brakes
• high stability due to the low centre of gravity and the use of an articulated joint
• operational safety due to the use of monitoring boards for all important system data

Service Training
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - A 5 -
• 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.

Service Training
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - B 1 -
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

BOMAG Central Service Seite 1 von 2
http://bo_web/ext_resource/tk_tech/english/search_components_result.asp 09.07.01
BOMAG Central Service - Technical data and adjustment values
Status: 2001-07-09
Product type: BW 216 D-3
Type No.: 580 40
Serial numbers from: 101 580 40 0101
Serial numbers up to: 101 580 40 0181
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
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:
Type: CR 31
Transmission ratio: 45,6
Travel motor, rear:
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:
Type: 51C 110

Displacement stage 1: 110 cm3/U
Displacement stage 2: 40,3 cm3/U
Vibration pump:
Type: 42R 041
Starting pressure: 350+/-50 bar
Operating pressure, soil dependent: ca.100 bar
Vibration motor:
Type: MMF 044
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
Max. steering pressure: 225+/-15 bar
Steering valve:
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)

Status: 2001-07-09
Type No.: 580 40
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 075
Type: CR 31
Travel motor, rear:
Type: 51D110
Drum drive:
Type: 51C 110

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Vibration pump:
Type: 42R 041
Vibration motor:
Manufacturer: Hydromatik
Type: A2FM 45
System: Axial piston-bent axe
Frequency: 30/36 Hz
Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Filling capacities:
Ethane-diol-basis)

Status: 2001-07-09
Product type: BW 216 DH-3
Type No.: 580 42
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 075
Type: CR 31
Travel motor, rear:
Type: 51D110
Min. displacement (stage 2): 31,4 cm3/U
Drum drive:
Type: 51C 110

Vibration pump:
Type: 42R 041
Vibration motor:
Type: MMF 044
Frequency: 30/36 Hz
Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Filling capacities:
Ethane-diol-basis)

Bomag bw 225 pd 3 single drum roller service repair manual

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Bomag bw 225 pd 3 single drum roller service repair manual