BW216DH 3 BW225D 3 Service Training

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-3BW 219 DH-3/PDH-3, BW 225 D-3/PD-3

Table of contentsForeword A 1Documentation A 2General A 4

List of components B 1Technical data B 2

Maintenance C1Maintenance table C2

DEUTZ Diesel engine D 1Service side D 2Starter side D 3Lubrication oil circuit D 4Coolant circuit D 5Checking and adjusting the valve clearance D 6Plug-in injection pump D 8

Travel system E 1Travel pump E 4Servo control E 15Multi-function valves E 17Charge pressure relief valve E 20Axle drive motor E 21Drum drive motor with reduction gear E 23Flushing valve E 26Trouble shooting travel system ETr 1

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

Vibration F 1Vibration pump F 4Control F 8High pressure protection F 8Charge pump F 8Vibration motor F 9Trouble shooting vibration FTr 1

Steering G 1Steering pump G 3Steering valve G 5Articulated joint G 7Trouble shooting steering GTr 1

Electrical system H 1Power supply H 2Ignition and starter circuit H 4Fault monitoring board H 7Brakes H 11Speed range selector H 14Anti Spin Control (ASC) H 18Vibration H 20

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BW 216 D-3, BW 216 DH-3/PDH-3BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - A 1 -

ForewordThis 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.

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DocumentationFor 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 instructionsMachine type Catalogue No.: from serial no. to serial no.BW 216 D-3 008 140 61 101 580 40 0101BW 216 DH-3 008 140 61 101 580 42 0101BW 216 PDH-3 008 140 61 101 580 43 0101BW 219 DH-3 008 140 61 101 580 50 0101BW 219 PDH-3 008 140 61 101 580 51 0101BW 225 D-3 008 140 61 101 580 60 0101BW 225 PD-3 008 140 61 101 580 61 0101

2. Spare parts catalogueMachine type Catalogue No.: from serial no. to serial no.BW 216 D-3 008 153 40 101 580 40 0101BW 216 DH-3 008 153 42 101 580 42 0101BW 216 PDH-3 008 153 43 101 580 43 0101BW 219 DH-3 008 153 50 101 580 50 0101BW 219 PDH-3 008 153 51 101 580 51 0101BW 225 D-3 008 153 60 101 580 60 0101BW 225 PD-3 008 153 61 101 580 61 0101

3. Wiring diagram*Drawing No.: from serial number to serial number582 700 38 for single drum rollers with new monitoring board

4. Hydraulic diagram*Machine type Drawing No.: from serial number to serial numberBW 216 D-3 581 201 26 101 580 40 0101BW 216 DH-3 581 201 26 101 580 42 0101BW 216 PDH-3 581 201 26 101 580 43 0101BW 219 DH-3 581 201 27 101 580 50 0101BW 219 PDH-3 581 201 27 101 580 51 0101BW 225 D-3 581 201 28 101 580 61 0101BW 225 PD-3 581 201 28 101 580 61 0101

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5. Repair instructionsCatalogue No.: Component Part-No.

6. Service Information

Comment:

* These documents are part of the training manual

Service Training


GeneralThe 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


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-3BW 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 pump2 Reduction gear 14 Travel pump3 Vibration motor 15 Hand pump for hood4 Articulated joint 16 Hydraulic oil filter5 Hydraulic oil cooler 17 Starter 6 Radiator 18 Wheels (with axle and axle drive motor)7 Fuel filter 19 Generator8 Pressure accumulator to compensate 20 Radiator blower

vibrations in the steering system 21 Operator's seat9 Engine oil filter 22 Steering wheel with steering valve10 Steering/charge pump 23 Drum11 Fuel pre-filter12 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-3Type No.: 580 40Serial numbers from: 101 580 40 0101Serial numbers up to: 101 580 40 0181

Engine:Manufacturer: DeutzType: BF6M1013ECombustion principle: 4-stroke-DieselCooling: WaterNumber of cylinders: 6Power acc. to ISO 9249: 137 kWPower data at nominal speed of: 2200 U/minLow idle speed: 850+/-150 U/minHigh idle speed: 2350+/-100 U/minSpec. fuel consumption: 228 g/kWhValve clearance, inlet: 0,3 mmValve clearance, outlet: 0,5 mmOpening pressure, injection valves: 250 barStarter voltage: 12 VStarter power: 3,1 kW

Travel pump:Manufacturer: Sauer-DanfossType: 90R 075System: Axial piston-swash plateMax. displacement: 75 cm3/UMax. flow ratio: 172,9 l/minHigh pressure limiation: 435 +/-15 barCharge pressure, high idle: 25+/-1 bar

Reduction gear, drum:Manufacturer: Sauer-DanfossType: CR 31Transmission ratio: 45,6

Travel motor, rear:Manufacturer: Sauer-DanfossType: 51D110System: Axial piston-bent axleMax. displacement (stage 1): 110 cm3/UMin. displacement (stage 2): 50 cm3/UPerm. leak oil quantity: 2 l/min

Drum drive:Manufacturer: Sauer-DanfossType: 51C 110System: Axial piston-swash plate



Displacement stage 1: 110 cm3/UDisplacement stage 2: 40,3 cm3/UPerm. leak oil quantity: 2 l/min

Vibration pump:Manufacturer: Sauer-DanfossType: 42R 041System: Axial piston-swash plateMax. displacement: 41 cm3/UStarting pressure: 350+/-50 barOperating pressure, soil dependent: ca.100 bar

Vibration motor:Manufacturer: Sauer-DanfossType: MMF 044System: Axial piston-swash plateDisplacement: 44 cm3/UFrequency: 30/36 HzAmplitude: 1,8/0,9 mm

Steering and charge pump:Manufacturer: BoschType: HY/ZFS11/16System: Gear pumpDisplacement: 16 cm3/UMax. steering pressure: 225+/-15 bar

Steering valve:Manufacturer: Sauer-DanfossType: OSPC 500 ONSystem: Rotary valve

Rear axle:Manufacturer: DanaType: CHC 193/51Differential: No-SpinDegree 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 l)




Status: 2001-07-09










Status: 2001-07-09

Product type: BW 216 D-3Type No.: 580 40Serial numbers from: 101 580 40 1020





Drum drive:Manufacturer: Sauer-DanfossType: 51C 110System: Axial piston-swash plateDisplacement stage 1: 110 cm3/U



Displacement stage 2: 40,3 cm3/UPerm. leak oil quantity: 2 l/min


Vibration motor:Manufacturer: HydromatikType: A2FM 45System: Axial piston-bent axeDisplacement: 45 cm3/UFrequency: 30/36 HzAmplitude: 1,8/0,9 mm









Status: 2001-07-09

Product type: BW 216 DH-3Type No.: 580 42Serial numbers from: 101 580 42 0101Serial numbers up to: 101 580 42 0132




Travel motor, rear:Manufacturer: Sauer-DanfossType: 51D110System: Axial piston-bent axleMax. displacement (stage 1): 110 cm3/UMin. displacement (stage 2): 31,4 cm3/UPerm. leak oil quantity: 2 l/min





Status: 2001-07-09

Product type: BW 216 PDH-3Type No.: 580 43Serial numbers from: 101 580 43 0110Serial numbers up to: 101 580 43 1003









Status: 2001-07-09

Product type: BW 216 DH-3Type No.: 580 42Serial numbers from: 101 580 42 1003










Vibration motor:Manufacturer: HydromatikType: A2FM 45System: Axial piston-bent axeDisplacement: 45 cm3/UFrequency: 30/36 HzAmplitude: 1,8/0,9 mm









Status: 2001-07-09










Status: 2001-07-09

Product type: BW 216 PDH-3Type No.: 580 43Serial numbers from: 101 580 43 1004










Vibration motor:Manufacturer: HydromatikType: A2FM 45System: Axial piston-bent axleDisplacement: 45 cm3/UFrequency: 30/36 HzAmplitude: 1,64/0,82 mm









Status: 2001-07-09



Travel pump:Manufacturer: Sauer-DanfossType: 90R 100System: Axial piston-swash plateMax. displacement: 100 cm3/UMax. flow ratio: 235 l/minHigh pressure limiation: 435 +/-15 barCharge pressure, high idle: 29+/-1 bar








Vibration motor:Manufacturer: Sauer-DanfossType: 90M 055System: Axial piston-swash plateDisplacement: 55 cm3/UFrequency: 28/35 HzAmplitude: 2,14/1,21 mm









Status: 2001-07-09










Status: 2001-07-09

Product type: BW 219 DH-3Type No.: 580 50Serial numbers from: 101 580 50 1001









Status: 2001-07-09









Displacement stage 1: 110 cm3/UDisplacement stage 2: 44 cm3/UPerm. leak oil quantity: 2 l/min











Status: 2001-07-09

Product type: BW 219 PDH-3Type No.: 580 51Serial numbers from: 101 580 51 1001








Displacement stage 2: 44 cm3/UPerm. leak oil quantity: 2 l/min











Status: 2001-07-09










Status: 2001-07-09

Product type: BW 225 D-3Type No.: 580 60Serial numbers from: 101 580 60 1001









Status: 2001-07-09

Product type: BW 225 PD-3Type No.: 580 61Serial numbers from: 101 580 61 0101Serial numbers up to: 101 580 61 0101









Status: 2001-07-09

Product type: BW 225 PD-3Type No.: 580 61Serial numbers from: 101 580 61 1001






Service Training

BW 216 D-3, BW 216 DH-3/PDH-3BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - C 1 -

MaintenanceSingle drum rollers are heavy-duty machines for extremely difficult applications in earthwork. To be able to meet these demands the machine must always be ready to be loaded up to its limits. Apart from this all safety installations must always be fully functional.

Thorough maintenance of the machine is therefore mandatory. It not only guarantees a remarkably higher functional safety, but also prolongs the lifetime of the machine and of important components.

The time required for thorough maintenance is only minor when being compared with the malfunctions and faults that may occur if these instructions are not observed.

The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance interval all the work for shorter preceding intervals must also be performed. During the 2000 hour interval you must also perform the maintenance work for the 250, 500 and 1000 hour intervals.

It should also be clear, that with the 2500 hours interval only the work for the 10, 250 and 500 hour intervals must be performed.

For maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and lubricants (oils, fuels, grease etc.).

Please refer to the operating and maintenance instructions for the individual maintenance intervals and the description of the individual maintenance tasks.

Service Training


Maintenance table

Maintenance work Comment

Ru

nn

ing-

in in

spe

ct.

(50 o

p. ho

urs

)10

o

per.

ho

urs

50 o

per.

ho

urs

250

op.

ho

urs

500

op.

ho

urs

1000

o

p. ho

urs

2000

o

p. ho

urs

as

re

quire

d

Change the engine oil filter X

Change the engine oil X

Check, adjust the valve clearance XTighten all screw connections on intake and exhaust manifold, oil sump and engine mounts

X

Tighten the screw connections on the machine

X

Tighten the fastening screws for the wheels X

Change the oil in the drive axle X

Change the oil in the planetary drives X

Change the oil in the axle reduction gear X

Change the oil in the drum drive reduction gear

X

Change the oil in the vibration housings see note X X X

Check the engine oil level Dipstick mark X X X X X X

Check the water separator X X X X X X

Check the fuel level approx. 340 l X X X X X X

Check the hydraulic oil level Inspection glass X X X X X X

Check the coolant level X X X X X X

Grease the articulated joint High press. grease X X X X XCheck the tire pressure 1.1 bar X X X X X

Adjust the scrapers X X X X XRetighten the screws on the articulated joint

X X X X

Service Training



Ru

nn

ing-

in in

spe

ct.

(50 o

p. ho

urs

)10

o

pera

t. ho

urs

50 o

pera

t. ho

urs

250

op.

ho

urs

500

op.

ho

urs

1000

o

p. ho

urs

2000

o

p. ho

urs

as

re

quire

d

Check condition, tension of V-belts, change the V-belts

X X X X

Check, clean cooling fins on radiator and hydraulic oil cooler

X X X X

Check the oil level in the drive axle X X X X

Check the oil level in the axle reduction gear

X X X X

Check the oil level in the planetary drive X X X X

Check the oil level in the vibration bearings X X X X

Check the oil level in the drum drive reduc-tion gear

X X X X

Change the engine oil min. 1 x year X X X

Change the engine oil filter cartridge X X X

Drain the fuel tank sludge X X X

Service the battery Pole grease X X X

Check and adjust the valve clearance(when engine is cold)

Intake = 0.3 mmExhaust = 0.5 mm

X X

Change the fuel prefilter cartridge X X

Change the fuel filter element X X

Change the oil in the drive axle min. 1 x year X X

Change the oil in the planetary drives min. 1 x year X X

Change the oil in the axle reduction gear min. 1 x year X X

Change the oil in the vibration bearings min. 1 x year X X

Check the fastening elements on the engine

X X

Check the fastening on axle and frame X X

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Note:

When changing filters use only the original filters specified in the spare parts catalogue for this machine. The use of incorrect filters (e.g. insufficient pressure resistance) can lead to severe damage on engine or hydraulic components.

The coolant for the water cooled engine must always be mixed with 40 to 50% of anti-freeze additive (even under hot environmental conditions) as a preventive measure against corrosion and cavitation. However, the additive proportion must not exceed 60%, since this would have an adverse effect on the cooling ability of the coolant.

Oil change intervals in the vibration housings: after 50 h, after 500 h, after 1000 h and then every 1000 h.


Ru

nn

ing-

in in

spe

ct.

(50 o

p. ho

urs

)10

o

pera

t. ho

urs

50 o

pera

t. ho

urs

250

op.

ho

urs

500

op.

ho

urs

1000

o

p. ho

urs

2000

o

p. ho

urs

as

re

quire

d

Tighten the wheel nuts X X

Check the ROPS X X X

Change hydraulic oil and breather filter min. every 2 years X X

Change the hydraulic oil filter min. every 2 years and after repairs in the hydraulic system

X X

Change the coolant min. every 2 years X X

Clean, change the dry air filter element min, 1 x year, safety cartridge min. every 2 years

X

Adjust the parking brake XChange the tires X

Change the fresh air filter for the cabin X

Retighten the screw connections Observe the tighte-ning torques

X

Engine conservation Before shutting the engine down for a longer period of time

X

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

Deutz Diesel engine All 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 powered by water cooled Deutz diesel engines of the latest product range BF6M1013E.

This engine is characterized by the following positive features:

short and compact design,

low noise level,

almost vibration-free running,

low fuel consumption,

high power reserves and

good access to all service points.

Crankcase and cylinders of this engine are made of alloyed cast iron. This provides rigidness and ensures high wear resistance.

The engines are fitted with wet cylinder liners, which allows simple replacement in case of repairs.

The forged steel conrod is fitted with a compensation weight near the conrod bearing seat. This weight compensates manufacturing tolerances with respect to weight and centre of gravity.

The pistons are made of an aluminium alloy. The combustion trough has side walls which slant 10 inwards and is slightly offset with respect to the centre of the piston. All pistons are fitted with three piston rings and a cast iron ring carrier for the first ring. The pistons are cooled by an oil spray.

The forged crankshaft is fitted with integrated counter-weights.

The block-type cylinder head is made of cast iron. Each of the cylinders has one intake and one exhaust valve. The valve guides are shrunk into the cylinder. The valve seat rings are made of high quality steel and shrunk fitted.

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Service side

Fig. 1: Service side BF6M1013E

1 Oil filler plug 8 Fuel pump2 Valve, boost fuel 9 Engine mounts3 Engine solenoid 10 Fuel filter4 Oil pressure switch 11 Lubrication oil filter5 Radiator blower 12 Oil sump6 Coolant pump 13 Dipstick7 V-belt pulley 14 Steering/charge pump

1

23 4

5

6

7

8910111213

14

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Starter side

Fig. 2: Starter side

1 Flywheel2 Earth cable3 Starter4 Turbo charger5 Generator6 Coolant temperature switch

1

2

3

4

5

6

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Lubrication oil circuit

Fig. 3: Lubrication oil circuit

1 Oil pan 12 Spray nozzle for piston cooling2 Turbocharger return to crankcase 13 Camshaft bearing3 Turbo charger 14 Main oil gallery4 Oil line to turbo charger 15 Lubrication oil cooler5 Line to mass balancing gear (2 x) 16 Lubrication oil pump6 Oil pressure sensor 17 Pressure relief valve7 Tappet with pulse lubrication 18 Back leak fuel valve8 Push rod, oil supply to rocker arms 19 Lubrication oil filter9 Line to spray nozzle 20 Suction line10 Rocker arm 21 Crankshaft bearing11 Return line to oil sump 22 Conrod bearing

12

3 4 5 6 7 8 9 10 11 12 13 14 15

16171819202122

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Coolant circuit

Fig. 4: Coolant circuit

1 Radiator2 To radiator3 From radiator4 Coolant oil pump5 Lubrication oil cooler6 Cylinder cooling7 Cylinder head cooling8 Vent connection from cylinder head to heat exchanger

1

2

3

45

6

7

8

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Checking and adjusting the valve clearance

Too big or too small valve clearance can cause failure of the engine as a result of mechanical and ther-mal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the inter-vals specified in the operating and maintenance instructions.

Note:

The valve clearance must be checked and adjusted when the engine is cold.

Inlet valve = 0.3 mm

Exhaust valve = 0.5 mm

Turn the crankshaft until both valves on cylinder 1 are overlapping (exhaust valve not yet closed, inlet valve starts to open).

Check and adjust the valve clearance by following the adjustment schematic, black marking. For con-trol purposes mark the respective rocker arm with chalk.

Fig. 5: Crankshaft position 1

Flywheelside

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Turn the crankshaft one full rotation (360) further.

Fig. 6: Crankshaft position 2

Check and adjust the valve clearance by following the adjustment schematic, black marking.

Flywheelside

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Plug-in injection pump

Deutz diesel engines of series 1013 are equipped with Bosch single injection pumps of series PF 33.

With the single injection pump concept it is possible to realize high injection pressures in conjunction with extremely short injection lines, a prerequisite for a high hydraulic stiffness of the injection system. This in turn establishes the basis for achieving low exhaust emission levels (soot) together with a low fuel consumption.

The single injection pumps come with the following dimensions:

Stroke 12 mm

Diameter 9 mm

A snubber valve ( 0.7 mm) after the pressure valve prevents cavitation in the injection lines under high pressure and during the secondary injection of the injectors. The constant-volume relief volume is 50 mm.

Assembly of single injection pumps

The setting of the commencement of injection pump delivery (COD) has an effect on the

fuel consumption,

the power output and

the exhaust emission

of the engine.

On engines of series 1012 the commencement of delivery is set without any tolerance. The commence-ment of delivery is indicated in degree of crank angle before top dead centre (TDC) of the piston and depends on the application, power and speed of the engine.

The injection pump starts to deliver when the plunger is just about to close off the inlet port in the plunger barrel.

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On engines with in-line injection pumps the flywheel is turned to commencement of delivery (COD) po-sition and the closing of the fuel inlet port in the injection pump plunger is determined with a high-pres-sure pump. Any tolerances are compensated at the coupling of the injection pump drive, with the injection pump camshaft being turned to commencement of delivery position, relatively to the stationary flywheel.

Since the injection pump cams on engines of series 1012 are located on the engine camshaft, the pre-vious method for setting the commencement of delivery is no longer applicable.

The commencement of injection pump delivery must therefore be set using a different method.

The conventional setting method consists of length measurememnts for individual components and arithmetic steps.

The permissible manufacturing tolerances of the components

crankcase with integrated cylinder liners,

camshaft,

roller tappet and

single injection pump

are determined and eliminated by setting the commencement of delivery.

In all cases, which are of interest for BOMAG mechanics, the engines are not completely overhauled, but individual injection pumps are replaced.

Crankcase, camshaft and roller tappets remain unchanged.

This results in a certain installation measurement for the for the engine drive, which is mentioned on the engine type plate.

This measurement can be found in the column EP as CODE for each cylinder.

Note:When replacing an injection nozzle you must also replace the corresponding high pressure line to the injection nozzle.

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Determining the shim thickness for replacement of single injection pump

For the replacement of single injection pumps without any alterations to the crankshaft assembly of the engine, a simplified method can be applied to determine the thickness of the required shim. The column EP on the engine type plate contains a code for the injection pump of each cylinder.

Fig. 7: Injection pump code BFM 1013

With the help of the EP-code the correct installation dimension Ek can be taken from table 1.

397

Each line represents 1 cylindere.g. 1st cell = cylinder 1 2nd cell = cylinder 2 etc.

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Ek (mm) = correct injection pump dimension determined with the EP-code from the engine type plate acocrding to table 1

EK(mm)

EPcode

EK(mm)

EPcode

EK(mm)

EPcode

EK(mm)

EPcode

EK(mm)

EPcode

144.5

144.525

144.55

144.575

145.1

145.125

145.15

145.175

145.7

145.725

145.75

145.775

349

350

351

352

146.3

146.325

146.35

146.375

373

374

375

376

146.9

146.925

146.95

146.975

397

398

399

400

144.6

144.625

144.65

144.675

145.2

145.225

145.25

145.275

145.8

145.825

145.85

145.875

353

354

355

356

146.4

146.425

146.45

146.475

377

378

379

380

147.0

147.025

147.05

147.075

401

144.7

144.725

144.75

144.775

145.3

145.325

145.35

145.375

335

336

145.9

145.925

145.95

145.975

357

358

359

360

146.5

146.525

146.55

146.575

381

382

383

384

147.1

147.125

147.15

147.175

144.8

144.825

144.85

144.875

145.4

145.425

145.45

145.475

337

338

339

340

146.0

146.025

146.05

146.075

361

362

363

364

146.6

146.625

146.65

146.675

385

386

387

388

147.2

147.225

147.25

147.275

144.9

144.925

144.95

144.975

145.5

145.525

145.55

145.575

341

342

343

344

146.1

146.125

146.15

146.175

365

366

367

368

146.7

146.725

146.75

146.775

389

390

391

392

147.3

147.325

147.35

147.375

145.0

145.025

145.05

145.075

145.6

145.625

145.65

145.675

345

346

347

348

146.2

146.225

146.25

146.275

369

370

371

372

146.8

146.825

146.85

146.875

393

394

395

396

147.4

147.425

147.45

147.475

Table 1: Injection pumpe code BFM 1013

Service Training


During the manufacturing process of the single injection pump, closing of the fuel inlet port is determined with the high pressure method. In this position - commencement of delivery position of the injection pump plunger - the distance is measured between pump contact surface and tappet foot contact sur-face.

The measurement A is written with an electric pen on the pump in 1/100 of a mm.

Fig. 8: Marking of plunger code

Service Training


Fig. 9: Plugin injection pump

Service Training


The dimension A indicates by how many 1/100 of a mm the distance between contact surface of crank-case and tappet foot exceeds the hydraulic standard dimension Lo..

Fig. 10: Representation of measurement A

Lo = 119 mm - BFM 1012

Lo = 143 mm - BFM 1013

A = XXX

Service Training


Fig. 11: Crankshaft assembly in commencement of delivery position after determination of Ts

The single injection pump is now frictionally and rigidly connected with the crankshaft assembly in com-mencement of delivery position by inserting a calibrated shim Z.

The illustration shows that there is a distance Ts between injection pump tappet foot and roller tappet, which can be calculated as follows:

Ek - (Lo + A/100)

This distance must be compensated by shim Z of calculated thickness.

Service Training


For the determination of the theoretical shim thickness Ts it is therefore necessary to determine the measurement Lo + A/100 of the new injection pump.

This measurement must be subtracted from the corrected injection pump measurement Ek.

Ts = Ek - (Lo + A/100) [mm]

The actual thickness of the compensation shim Ss is determined according to table 2.

Theor. thicknessTs

(mm)

Shimthickness

Ss(mm)

Theor.thickness

Ts

(mm)

Shimthickness

Ss(mm)

0.95 - 1.0491.05 - 1.1491.15 - 1.2491.25 - 1.3491.35 - 1.4491.45 - 1.5491.55 - 1.6491.65 - 1.7491.75 - 1.8491.85 - 1.9491.95 - 2.0492.05 - 2.1492.15 - 2.2492.25 - 2.3492.35 - 2.449

1.01.11.21.31.41.51.61.71.81.92.02.12.22.32.4

2.45 - 2.5492.55 - 2.6492.65 - 2.7492.75 - 2.8492.85 - 2.9492.95 - 3.0493.05 - 3.1493.15 - 3.2493.25 - 3.3493.35 - 3.4493.45 - 3.5493.55 - 3.6493.65 - 3.7493.75 - 3.850

2.52.62.72.82.93.03.13.23.33.43.53.63.73.8

Table 2:

Service Training


Calculation example for BFL 1013:

EP-Code on engine type plate: 397

see table 1

corrected injection pump measurement Ek: 146.9 mm

Lo = 143 mm (fixed measurement)

Value for A/100 on new injection pump A/100 = 133

Ts = Ek - (Lo + A/100)

Ts = 146.9 mm - (143 mm + 133/100 mm)

Ts = 2.57 mm

see table 2

Ss = 2.6 mm

Service Training


Installation of the plug-in injection pumps into the crankcase

Note:Because of the high pressures any injection line that has been disassembled must be replaced.

To obtain uniform delivery of the single injection pumps, all pumps must be installed in a specific position relative to each other.

with governor installed - in case of replacement

To set the injection pump control rod to stop position use a special tool (Deutz-no. 100 830). This tool must be inserted into the receiving bore of the shut-down solenoid.

The roller tappet of every single injection pump must be turned on the cam base circle. Turn the injection pump linkage lever to the middle of its travel and insert the single injection pump so that the linkage lever can be introduced into the notch of the control rod. Preload the flange screws of the single injection pump - chamfer pointing towards injection pump body - with 5 Nm. Thereafter the screws are slackened by 60. Use a torque wrench with drag indicator and special tool adapter to determine the friction torque Mr is determined by turning every injection pump anti-clockwise until stop. The injection pumps are tur-ned with the relevant Mr + 1 Nm anti-clockwise so that all of them rest against the control rod notch in the same position, i.e. the linkage levers of all injection pumps now rest equally against the control rod notches with 1 Nm. Then tighten all flange screws in steps with

7 Nm

10 Nm

30 Nm

Note:After installation of each single injection pump the control rod must be checked for free movement

Service Training


Fig. 12: Setting uniform fuel delivery of single injection pumps

1 Special tool (with governor removed)2 Timing chest cover3 Control rod guide4 Special tool adapter + torque wrench5 Linkage lever for injection pump6 Notch of control rod

Service Training


Control rod travel

With the governor removed, the control rod is always pressed out by the compression spring to boost fuel position.

With the single injection pumps removed the free travel of the control rod must be min. 17 + 0.5 mm.

With the single injection pumps installed, the travel of the control rod Y must be at least 16.8 mm.

The recess dimension X between control rod in stop position and contact face of the governor on the timing chest cover must be between 0.3 - 1.3 mm.

Note:It is absolutely necessary to indicate this recess dimension, thus determined when replacing or repairing the governor.

Fig. 13: Control rod travel

1 Full load + boost fuel X = 0.3 - 1.3 mm = recess dimension2 Stop position Y = 16.8 mm (fitted injection pump)3 Compression spring

Service Training

BW 216 D-3, BW 216 DH-3/PDH-3BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - E 1 -

Travel systemThe travel system of the single drum roller range BW 216 D-3, BW 216 DH-3/PDH-3, BW 219 DH-3/PDH-3 and BW 225 D-3/PD-3 is a closed hydrostatic circuit. The circuit consists mainly of

the travel pump with control and safety elements,

the drum drive motor,

the reduction gear for the drum drive with integrated multi-disc brake,

the axle drive motor

the charge pump (also for the vibration circuit),

the hydraulic oil filter in the charge circuit

the hydraulic oil cooler in the return flow to the hydraulic oil tank

the pressure resistant hydraulic hoses.

Service Training

BW 216 D

-3, BW 216 D

H-3/PDH-3

BW 219 D

H-3/PDH-3, BW

225 D-3/PD-3- E 2 -

Fig. 1 Hydraulic diagram travel system

1

22.1

2.2

34

5

6

Leckl zumThermostatventil

from brake valve

Charge pressre from hydraulic oil filterCharge pressure to vibration pump

1 Travel pump 3 Charge pressure relief valve2 Servo control BW 216 = 25 bar2.1 Orifice BW 219/225 = 29 bar

BW 216 = 0.81 mm 4 Multi-function valveBW 219/225 = 1.02 mm 5 Axle drive motor

2.2 Orifice 6 Drum drive motorBW 216 = 0.8 mmBW 219/225 = 1.0 mm

Service Training

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

Together with the vibration pump and the charge pump the travel pump is connected to a tandem pump unit. The charge pump, is integrated in the vibration pump.

The travel pump is the first pump section and is directly flanged to the flywheel side of the diesel engine.

The pump delivers the hydraulic oil to the paralle connected motors on drum and on axle. The pressure in the closed circuit generated by the resistance of the drum and the drive wheels is limited to maximum 425 bar by the high pressure relief valves in the pump.

When the machine is driving the flushing valves in the hydraulic motors for drum drive and axle drive will flush a certain amount of hydraulic oil out of the closed c

BW216DH 3 BW225D 3 Service Training

Documents

new single drum rollers

valve clearance d

coolant circuit d

vibration h

plugin injection pump

range of single drum

lubrication oil circuit

travel pump e