BOMAG BW 211 D-3 Roller Repair Manual – 2003 (P/N 008 193 60)

BOMAG repair manual P/N 008 193 60, dated 04/2003, covers the BW 211 D-3 single-drum wheel-drive vibratory roller. It includes supplier documentation for the hydraulic pumps and drive motors within the machine’s repair manual.

PDF Search, Bookmarks and Diagram Detail

Search and navigation: Text search works in the main BOMAG repair chapters and parts of the supplier documentation, but not throughout the file. Embedded bookmarks cover the main repair topics and supplier section openings; several overview entries lack working destinations. Small hydraulic schematic labels require zooming.

One printable 390-page PDF contains English BOMAG instructions and supplier sections in English or German/English. Covers, section dividers, blank and notes pages, and three publisher closing/contact pages are already included in the total.

Hydraulic Diagnosis, Drum Repair and Articulation

Selected coverage: These examples outline the repair content rather than reproduce the complete contents list. Other references include metric and fine-thread fastener torque tables.

• Travel and steering: Mechanical and hydraulic neutral-position checks, travel-circuit pressure tests, and fault isolation for the steering cylinders, steering valve, and steering/charge pump.

• Vibration system: Vibrator-shaft speed checks, pressure-relief and pressure-override adjustments, and vibration-motor leakage testing.

• Circuit flushing: Travel- and vibration-circuit flushing, bleeding, hydraulic-tank cleaning, filter connections, and post-repair function checks.

• Drum and change-over weight: Step-by-step instructions for drum removal, exciter disassembly, bearing and seal replacement, change-over weight repair, and rubber-buffer replacement.

• Oscillating articulated joint: Removal, disassembly, and reassembly procedures covering rocker bearings, friction bearings, the carrier, shims, and Belleville springs.

• Supplier component service: Series 51 motor servicing, Poclain MS/MSE motor repairs, and Hydromatik A4VG and A10VG pump repair instructions.

This manual is for appropriately trained repair personnel with the measuring equipment, lifting gear, and hydraulic knowledge required for the documented work.

Hydraulic Diagnostics and Circuit Flushing

Symptom-led troubleshooting charts address creeping in neutral, loss of travel, insufficient drive power, hydraulic-oil overheating, missing vibration, and difficult steering. Pressure, pilot-signal, and leakage checks help narrow a fault to a circuit or component before removal.

The Connecting Plan identifies pump ports and valves. Separate travel- and vibration-circuit flushing diagrams show filter connections, while the supplier material adds Series 51 gauge-port views, hydraulic control schematics, and A10VG sectional views.

Flushing instructions distinguish component replacement from severe contamination caused by abrasion. They cover the associated cleaning, filtering, bleeding, and final checks, including the risk of damaging replacement components with debris left in the circuit.

Hydraulic testing requires specialized gauges and strict observance of the manual’s precautions against pressurized-fluid injuries. Tool references include BOMAG hydraulic test case 007 610 03 and vibration reed frequency meter 300 120 80.

Drum and Articulated-Joint Repair

The drum chapter separates work on the travel-motor side from the vibration-motor side. It covers coupling hubs, mechanical seals, vibrator-shaft alignment, and assembly requirements involving thermally fitted shafts and liquid-nitrogen handling.

During side-plate assembly, incorrect seating of the mechanical seal can damage its O-rings. The illustrated instructions call out this vulnerable fit.

Articulated-joint reassembly includes bearing orientation and shim selection. Its lubrication notes distinguish greased seal spaces from rocker-bearing races requiring sliding lacquer.

Supplier Guides and Repair Limits

The Poclain MS/MSE 02–18 material includes brake-piston seals, bearing supports, cam assemblies, cylinder blocks, valving, and optional speed-sensor replacement. The Series 51 service manual covers adjustments and minor repairs, including shaft seals, flushing valves, and controls; it is not a complete internal motor-overhaul guide.

A10VG instructions cover sizes 28–63, Series 10, with pump disassembly, rotary-group inspection, seal replacement, reassembly, and adjustment procedures.

A4VG scope: The machine specifications list an A4VG 71 HW travel pump, but the included A4VG Series 32 repair guide is titled for sizes 40–56. It should not be treated as a dedicated A4VG 71 overhaul manual. That guide also warns that an older, sharp-edged positioning piston can damage the newer Turcon seals.

The foreword directs routine machine care and maintenance to separate operating and maintenance instructions.

Preview of Drum Assembly Specifications

The drum assembly section specifies vibrator-shaft axial clearance of 0.6–1.8 mm, with an illustrated check at the coupling.

For the change-over weight, the instructions specify approximately 2.5 L of silicone oil, grade 47 V 1000 cSt, filled to the upper edge of the change-over weight. This quantity applies to that assembly.