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
Part-No. 008 098 29
4/2000
Service Training Table of contents Foreword
A1
Documentation
A2
General
A4
List of components
B1
Technical data
B2
Maintenance
C1
Maintenance table
C2
DEUTZ Diesel engine
D1
Service side
D2
Starter side
D3
Lubrication oil circuit
D4
Coolant circuit
D5
Checking and adjusting the valve clearance
D6
Plug-in injection pump
D8
Travel system
E1
Travel pump
E4
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
BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3, BW 225 D-3/PD-3
ETr 1
Service Training Vibration
F1
Vibration pump
F4
Control
F8
High pressure protection
F8
Charge pump
F8
Vibration motor
F9
Trouble shooting vibration
FTr 1
Steering
G1
Steering pump
G3
Steering valve
G5
Articulated joint
G7
Trouble shooting steering
GTr 1
Electrical system
H1
Power supply
H2
Ignition and starter circuit
H4
Fault monitoring board
H7
Brakes
H 11
Speed range selector
H 14
Anti Spin Control (ASC)
H 18
Vibration
H 20
BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3, BW 225 D-3/PD-3
Service Training Foreword This training manual was specifically written for the new single drum rollers BW 216 D-3, BW 216 DH3/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. Rollers 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 range 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 attention 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
-A1-
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.
BW BW BW BW BW BW BW
008 008 008 008 008 008 008
101 101 101 101 101 101 101
216 D-3 216 DH-3 216 PDH-3 219 DH-3 219 PDH-3 225 D-3 225 PD-3
140 140 140 140 140 140 140
61 61 61 61 61 61 61
580 580 580 580 580 580 580
40 42 43 50 51 60 61
to serial no.
0101 0101 0101 0101 0101 0101 0101
2. Spare parts catalogue Machine type
Catalogue No.:
from serial no.
BW BW BW BW BW BW BW
008 008 008 008 008 008 008
101 101 101 101 101 101 101
216 D-3 216 DH-3 216 PDH-3 219 DH-3 219 PDH-3 225 D-3 225 PD-3
153 153 153 153 153 153 153
40 42 43 50 51 60 61
580 580 580 580 580 580 580
40 42 43 50 51 60 61
to serial no.
0101 0101 0101 0101 0101 0101 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
BW BW BW BW BW BW BW
581 581 581 581 581 581 581
101 101 101 101 101 101 101
216 D-3 216 DH-3 216 PDH-3 219 DH-3 219 PDH-3 225 D-3 225 PD-3
201 201 201 201 201 201 201
26 26 26 27 27 28 28
BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3, BW 225 D-3/PD-3
580 580 580 580 580 580 580
40 42 43 50 51 61 61
to serial number
0101 0101 0101 0101 0101 0101 0101
-A2-
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
-A3-
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 D3/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, especially in earth work and for the construction of sanitary landfill sites. High compaction performance and extremely good traction are properties, which are of utmost importance 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 condition 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
BW 216 D-3, BW 216 DH-3/PDH-3 BW 219 DH-3/PDH-3, BW 225 D-3/PD-3
-A4-
Service Training •
automatic engine shut down at too high coolant temperature, too low hydraulic oil level (when reaching 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/PD3 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
-A5-
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
-B1-
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values Status: 2001-07-09
Product type:
BW 216 D-3
Type No.: Serial numbers from: Serial numbers up to:
580 40 101 580 40 0101 101 580 40 0181
Engine: Manufacturer: Type: Combustion principle: Cooling: Number of cylinders: Power acc. to ISO 9249: Power data at nominal speed of: Low idle speed: High idle speed: Spec. fuel consumption: Valve clearance, inlet: Valve clearance, outlet: Opening pressure, injection valves: Starter voltage: Starter power:
Deutz BF6M1013E 4-stroke-Diesel Water 6 137 kW 2200 U/min 850+/-150 U/min 2350+/-100 U/min 228 g/kWh 0,3 mm 0,5 mm 250 bar 12 V 3,1 kW
Travel pump: Manufacturer: Type: System: Max. displacement: Max. flow ratio: High pressure limiation: Charge pressure, high idle:
Sauer-Danfoss 90R 075 Axial piston-swash plate 75 cm3/U 172,9 l/min 435 +/-15 bar 25+/-1 bar
Reduction gear, drum: Manufacturer: Type: Transmission ratio:
Sauer-Danfoss CR 31 45,6
Travel motor, rear: Manufacturer: Type: System: Max. displacement (stage 1):
Sauer-Danfoss 51D110 Axial piston-bent axle
Min. displacement (stage 2):
50 cm3/U 2 l/min
Perm. leak oil quantity:
110 cm3/U
Drum drive: Manufacturer: Type: System:
Sauer-Danfoss 51C 110 Axial piston-swash plate
http://bo_web/ext_resource/tk_tech/english/search_components_result.asp
09.07.01
BOMAG Central Service
Seite 2 von 2
Displacement stage 1:
110 cm3/U
Displacement stage 2:
40,3 cm3/U 2 l/min
Perm. leak oil quantity:
Vibration pump: Manufacturer: Type: System: Max. displacement:
Sauer-Danfoss 42R 041 Axial piston-swash plate
41 cm3/U Starting pressure: 350+/-50 bar Operating pressure, soil dependent: ca.100 bar
Vibration motor: Manufacturer: Type: System: Displacement: Frequency: Amplitude:
Sauer-Danfoss MMF 044 Axial piston-swash plate 44 cm3/U 30/36 Hz 1,8/0,9 mm
Steering and charge pump: Manufacturer: Type: System: Displacement: Max. steering pressure:
Bosch HY/ZFS11/16 Gear pump 16 cm3/U 225+/-15 bar
Steering valve: Manufacturer: Type: System:
Sauer-Danfoss OSPC 500 ON Rotary valve
Rear axle: Manufacturer: Type: Differential: Degree of locking: Reduction ratio:
Dana CHC 193/51 No-Spin 100 % 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 Ă–l)
http://bo_web/ext_resource/tk_tech/english/search_components_result.asp
09.07.01
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values Status: 2001-07-09
Product type:
BW 216 D-3
Type No.: Serial numbers from: Serial numbers up to:
580 40 101 580 40 0182 101 580 82 1019
Engine: Manufacturer: Type: Combustion principle: Cooling: Number of cylinders: Power acc. to ISO 9249: Power data at nominal speed of: Low idle speed: High idle speed: Spec. fuel consumption: Valve clearance, inlet: Valve clearance, outlet: Opening pressure, injection valves: Starter voltage: Starter power:
Deutz BF6M1013E 4-stroke-Diesel Water 6 145 kW 2300 U/min 850+/-150 U/min 2375+/-125 U/min 228 g/kWh 0,3 mm 0,5 mm 250 bar 12 V 3,1 kW
Travel pump: Manufacturer: Type: System: Max. displacement: Max. flow ratio: High pressure limiation: Charge pressure, high idle:
Sauer-Danfoss 90R 075 Axial piston-swash plate 75 cm3/U 178,1 l/min 435 +/-15 bar 25+/-1 bar
Reduction gear, drum: Manufacturer: Type: Transmission ratio:
Sauer-Danfoss CR 31 45,6
Travel motor, rear: Manufacturer: Type: System: Max. displacement (stage 1):
Sauer-Danfoss 51D110 Axial piston-bent axle
Min. displacement (stage 2):
50 cm3/U 2 l/min
Perm. leak oil quantity:
110 cm3/U
Drum drive: Manufacturer: Type: System:
Sauer-Danfoss 51C 110 Axial piston-swash plate
http://bo_web/ext_resource/tk_tech/english/search_components_result.asp
09.07.01
BOMAG Central Service
Seite 2 von 2
Displacement stage 1:
110 cm3/U
Displacement stage 2:
40,3 cm3/U 2 l/min
Perm. leak oil quantity:
Vibration pump: Manufacturer: Type: System: Max. displacement:
Sauer-Danfoss 42R 041 Axial piston-swash plate
41 cm3/U Starting pressure: 350+/-50 bar Operating pressure, soil dependent: ca.100 bar
Vibration motor: Manufacturer: Type: System: Displacement: Frequency: Amplitude:
Sauer-Danfoss MMF 044 Axial piston-swash plate 44 cm3/U 30/36 Hz 1,8/0,9 mm
Steering and charge pump: Manufacturer: Type: System: Displacement: Max. steering pressure:
Bosch HY/ZFS11/16 Gear pump 16 cm3/U 225+/-15 bar
Steering valve: Manufacturer: Type: System:
Sauer-Danfoss OSPC 500 ON Rotary valve
Rear axle: Manufacturer: Type: Differential: Degree of locking: Reduction ratio:
Dana CHC 193/51 No-Spin 100 % 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 Ă–l)
http://bo_web/ext_resource/tk_tech/english/search_components_result.asp
09.07.01
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values Status: 2001-07-09
Product type:
BW 216 D-3
Type No.: Serial numbers from:
580 40 101 580 40 1020
Engine: Manufacturer: Type: Combustion principle: Cooling: Number of cylinders: Power acc. to ISO 9249: Power data at nominal speed of: Low idle speed: High idle speed: Spec. fuel consumption: Valve clearance, inlet: Valve clearance, outlet: Opening pressure, injection valves: Starter voltage: Starter power:
Deutz BF6M1013E 4-stroke-Diesel Water 6 137 kW 2200 U/min 850+/-150 U/min 2350+/-100 U/min 228 g/kWh 0,3 mm 0,5 mm 250 bar 12 V 3,1 kW
Travel pump: Manufacturer: Type: System: Max. displacement: Max. flow ratio: High pressure limiation: Charge pressure, high idle:
Sauer-Danfoss 90R 075 Axial piston-swash plate 75 cm3/U 178,1 l/min 435 +/-15 bar 25+/-1 bar
Reduction gear, drum: Manufacturer: Type: Transmission ratio:
Sauer-Danfoss CR 31 45,6
Travel motor, rear: Manufacturer: Type: System: Max. displacement (stage 1):
Sauer-Danfoss 51D110 Axial piston-bent axle
Min. displacement (stage 2):
50 cm3/U 2 l/min
Perm. leak oil quantity:
110 cm3/U
Drum drive: Manufacturer: Type: System: Displacement stage 1:
Sauer-Danfoss 51C 110 Axial piston-swash plate 110 cm3/U
http://bo_web/ext_resource/tk_tech/english/search_components_result.asp
09.07.01
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING
NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
BOMAG Central Service
Displacement stage 2: Perm. leak oil quantity:
Seite 2 von 2
40,3 cm3/U 2 l/min
Vibration pump: Manufacturer: Type: System: Max. displacement:
Sauer-Danfoss 42R 041 Axial piston-swash plate
41 cm3/U Starting pressure: 350+/-50 bar Operating pressure, soil dependent: ca.100 bar
Vibration motor: Manufacturer: Type: System: Displacement: Frequency: Amplitude:
Hydromatik A2FM 45 Axial piston-bent axe 45 cm3/U 30/36 Hz 1,8/0,9 mm
Steering and charge pump: Manufacturer: Type: System: Displacement: Max. steering pressure:
Bosch HY/ZFS11/16 Gear pump 16 cm3/U 225+/-15 bar
Steering valve: Manufacturer: Type: System:
Sauer-Danfoss OSPC 500 ON Rotary valve
Rear axle: Manufacturer: Type: Differential: Degree of locking: Reduction ratio:
Dana CHC 193/51 No-Spin 100 % 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 Ă–l)
http://bo_web/ext_resource/tk_tech/english/search_components_result.asp
09.07.01
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values Status: 2001-07-09
Product type:
BW 216 DH-3
Type No.: Serial numbers from: Serial numbers up to:
580 42 101 580 42 0101 101 580 42 0132
Engine: Manufacturer: Type: Combustion principle: Cooling: Number of cylinders: Power acc. to ISO 9249: Power data at nominal speed of: Low idle speed: High idle speed: Spec. fuel consumption: Valve clearance, inlet: Valve clearance, outlet: Opening pressure, injection valves: Starter voltage: Starter power:
Deutz BF6M1013E 4-stroke-Diesel Water 6 137 kW 2200 U/min 850+/-150 U/min 2350+/-100 U/min 228 g/kWh 0,3 mm 0,5 mm 250 bar 12 V 3,1 kW
Travel pump: Manufacturer: Type: System: Max. displacement: Max. flow ratio: High pressure limiation: Charge pressure, high idle:
Sauer-Danfoss 90R 075 Axial piston-swash plate 75 cm3/U 172,9 l/min 435 +/-15 bar 25+/-1 bar
Reduction gear, drum: Manufacturer: Type: Transmission ratio:
Sauer-Danfoss CR 31 45,6
Travel motor, rear: Manufacturer: Type: System: Max. displacement (stage 1):
Sauer-Danfoss 51D110 Axial piston-bent axle
Min. displacement (stage 2):
31,4 cm3/U 2 l/min
Perm. leak oil quantity:
110 cm3/U
Drum drive: Manufacturer: Type: System:
Sauer-Danfoss 51C 110 Axial piston-swash plate
http://bo_web/ext_resource/tk_tech/english/search_components_result.asp
09.07.01
BOMAG Central Service
Seite 2 von 2
Displacement stage 1:
110 cm3/U
Displacement stage 2:
27,5 cm3/U 2 l/min
Perm. leak oil quantity:
Vibration pump: Manufacturer: Type: System: Max. displacement:
Sauer-Danfoss 42R 041 Axial piston-swash plate
41 cm3/U Starting pressure: 350+/-50 bar Operating pressure, soil dependent: ca.100 bar
Vibration motor: Manufacturer: Type: System: Displacement: Frequency: Amplitude:
Sauer-Danfoss MMF 044 Axial piston-swash plate 44 cm3/U 30/36 Hz 1,8/0,9 mm
Steering and charge pump: Manufacturer: Type: System: Displacement: Max. steering pressure:
Bosch HY/ZFS11/16 Gear pump 16 cm3/U 225+/-15 bar
Steering valve: Manufacturer: Type: System:
Sauer-Danfoss OSPC 500 ON Rotary valve
Rear axle: Manufacturer: Type: Differential: Degree of locking: Reduction ratio:
Dana CHC 193/51 No-Spin 100 % 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 Ă–l)
http://bo_web/ext_resource/tk_tech/english/search_components_result.asp
09.07.01