Bomag repair manual 008 912 46 tears down six BW-3 series single drum rollers on paper, the BW 216 DH-3 through the 225 D-3 Vario, in 422 pages of factory repair procedure. Flushing schematics in the PDF trace the drum drive, axle drive and vibration circuits so contaminated oil never reaches a fresh pump, and a troubleshooting diagram works the travel circuit fault by fault. Supplier sections take the Series 90R travel pump, Series 51 travel drive, CR gearbox and brake assembly down to the last Belleville washer. Set the charge pressure relief valve at 25 bar, prove the multi-function valves at 425 bar, and confirm the 216 series' low-range vibration at 31 Hz before you hand the machine back. A roller dead on a half-finished lift keeps the whole crew standing. Bookmarked, with a real text layer you can search, this download tells you the exact piece to name at the parts counter, first call.
What's Inside This Bomag BW 216 DH-3, 219 DH-3, 219 PDH-3, 225 D-3, 225 PD-3, 225 D-3 Vario Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 5-14 | Foreword, Safety Regulations, General Repair Instructions |
| Tests and Adjustments | 15-42 | Technical Data, Special Tools, Checking the Rotation Speeds, Checking / Adjusting the Mechanical Neutral Position of the Travel Pump, Pressure Tests in the Travel Circuit |
| Flushing | 43-68 | Special Tools for Flushing, Flushing Schematic for Drum Drive, Flushing Schematic for Axle Drive, Flashing the Travel Circuit, Flushing Schematic for Vibration Drive |
| Trouble Shooting | 69-94 | Trouble Shooting Diagram |
| Drum | 95-144 | Special Tools, Repair Overview for Drum, Removing and Installing the Drum, Repairing the Drum, Repair Overview Drum Vario |
| Oscillating Articulated Joint | 145-158 | Special Tools, Repair Overview Oscillating Articulated Joint, Removing and Installing the Oscillating Articulated Joint, Dismantling the Oscillating Articulated Joint |
| Travel Pump Series 90R | 161-250 | Variable Displacement Pumps, Fixed Displacement Motor, Charge Pump, Multi-Function Valves, Displacement Limiters, Pressure Override Valve |
| Vibration Pump 42R 041 | 251-288 | Pump Neutral Adjustment, Control Neutral Adjustment, Mdc Control Module, Edc Control Module, Charge Relief Valve, Loop Flushing Valve |
| Travel Drive Series 51 | 289-370 | Hydraulic Proportional Control, Electric 2-Position Control, Pressure Compensator Regulator, Loop Flushing Shuttle Valve, Displacement Limiters, Speed Sensor |
| Transmission CR | 371-396 | Roller Drive Gearbox, Brake Assembly, Planet Gear Carriers, Spindle Group, Cartridge Motor |
| Brake System, Axle | 397-422 | Annular Unit, Disk Push Device, Annular Piston Unit, Safety Brake, Brake Disks, Belleville Washers |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for M4 screw (8.8) | 3 Nm (2 ft-lb) | p. 11 |
| Tightening torque for M30 screw (12.9) | 2400 Nm (1770 ft-lb) | p. 11 |
| Multi-function valve pressure | 425 bar | p. 13 |
| Charge pressure relief valve pressure | 25 bar | p. 13 |
| BW 216 DH/PDH-3 low frequency | 31 Hz (1860 rpm) | p. 36 |
| BW 216 DH/PDH-3 high frequency | 36 Hz (2160 rpm) | p. 36 |
| Charge pressure gauge (idle speed) | 24 ... 29 bar | p. 34 |
| Charge pressure gauge (maximum speed) | 28 ... 30 bar | p. 35 |
| Roller drum filling | 40 l water + 40 l Glysantine | p. 143 |
| Torque wrench setting for screws (11) | 15–20 Nm | p. 407 |
| High pressure limitation (Travel Pump) | 435 bar | p. 17 |
| Charge pressure limitation (Travel Pump) | 29 bar | p. 17 |
Bomag BW 216 DH-3, 219 DH-3, 219 PDH-3, 225 D-3, 225 PD-3, 225 D-3 Vario Common Problems This Manual Covers
Bomag BW 216 DH-3 will not drive forward or reverse, travel lever has no effect
Warm the hydraulic oil to 40 to 50 °C, then tee a gauge into the charge circuit and follow the chart on page 73. You need 25 bar charge pressure and 425 bar high pressure with the travel lever stroked. Confirm the brake releases at 25 bar before condemning the drum drive motor.
Manual Section: Troubleshooting Diagram: Machine does not drive p. 73No vibration in either amplitude setting, drum still drives and steers normally on grade
Check the magnetic coil on the vibration valve first: it should read 12 V and 2.5 A, with roughly 20 bar pilot pressure at the valve, per the chart on page 86. If coil and pilot check good, gauge the vibration pump and look for approximately 370 bar high pressure at startup. Vibrator shaft bearings come last.
Manual Section: Troubleshooting Diagram: No vibration p. 86Drum vibration frequency too low at full throttle, passes not reaching density
Measure engine speed first; the chart on page 88 calls for 2200 rpm nominal before you blame the vibration pump. Then check the vibration motor leak oil rate: anything over 1.5 litres per minute, per page 39, means the motor is worn out. Compare measured frequency against the values for your specific model on page 36.
Manual Section: Troubleshooting Diagram: Vibrator shaft speed too low p. 88Hydraulic oil temperature climbing past normal during long passes, overheat warning on
Verify actual oil temperature; anything over 90 °C counts as overheating per page 85. Check the thermostat valve: it must open above 60 °C to route oil through the cooler. Inspect the multi-function valves in the travel pump for internal leakage, and clean the cooler core before pulling the machine off the fill.
Manual Section: Troubleshooting Diagram: Hydraulic oil overheating p. 85Steering slow or hard to turn in both directions with engine at full speed
Gauge steering pressure at the steering valve; the chart on page 75 sets 200 bar nominal. A low reading points to the steering/charge pump; correct pressure with sluggish response means worn steering cylinder seals. Check the oscillating articulated joint for binding before replacing cylinders, and keep oil at 40 to 50 °C while testing.
Manual Section: Troubleshooting Diagram: Steering function issues p. 75Frequently Asked Questions
Torque for M10 8.8 screws on Bomag BW 216 DH-3, BW 219 DH-3, BW 219 PDH-3, BW 225 D-3, BW 225 PD-3, BW 225 D-3 Vario?
For screws with a metric unified thread and a strength class of 8.8, the tightening torque for an M10 screw is 50 Nm (37 ft-lb). p. 11
What is the nominal charge pressure for the travel circuit on a BW 216 DH-3?
The nominal charge pressure for the travel circuit on a BW 216 DH-3, when measured at idle speed, is 24 to 29 bar. When measured at maximum engine speed, the nominal charge pressure is 28 to 30 bar. p. 34
What is the maximum permissible leak oil rate for the vibration motor on a Bomag BW 216 DH-3, BW 219 DH-3, BW 219 PDH-3, BW 225 D-3, BW 225 PD-3, BW 225 D-3 Vario?
The maximum permissible leak oil rate for the vibration motor is approximately 1.5 litre/min. If this rate is exceeded during testing, the vibration motor should be replaced. p. 39
How much engine oil should be filled into the flanged housing of the drum for a BW 216 DH/PDH-3?
For the BW 216 DH/PDH-3, you should fill approximately 1.0 litre of engine oil SAE-15W/40 into the flanged housing. p. 119
Vibration start pressure on Bomag BW 216 DH-3, BW 219 DH-3, BW 219 PDH-3, BW 225 D-3, BW 225 PD-3, BW 225 D-3 Vario?
The nominal starting pressure for the vibration circuit test is 390 to 430 bar for both high and low frequencies, per the test chart on page 38. p. 38
How will I receive this Bomag BW 216 DH-3 Repair Manual?
Instant PDF download. You get the full 422-page searchable Repair Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Am I able to print pages from this Bomag BW 216 DH-3 manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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