Omm BW211D-40

Operating instructions
Maintenance instructions
Original operating instructions
BW 211 / 212 / 213 D-40

BW 211 / 212 / 213 PD-40
S/N 101 582 42 1940> / S/N 101 582 43 2399> / S/N 101 582 44 1209>
S/N 101 582 47 1053> / S/N 101 582 48 1239> / S/N 101 582 49 1019>
S/N 861 583 00 .... / S/N 101 583 48 1095> / S/N 101 583 49 ....
S/N 861 583 01 .... / S/N 101 583 50 ....
S/N 901 583 38 .... / S/N 210 583 04 ....
Single drum roller

Catalogue No.
008 158 81 10/2010
Foreword
These BOMAG machines are products from provided container. These operating and mainte-
F oreword
the wide product range of BOMAG machines nance instructions are part of the machine.
for earth and asphalt construction, refuse You should only operate the machine after you
compaction and stabilizing/recycling. have been instructed and in compliance with these
BOMAG’s vast experience in connection with instructions.
state-of-the-art production and testing meth- Strictly observe the safety regulations.
ods, such as lifetime tests of all important Please observe also the guidelines of the Civil En-
components and highest quality demands gineering Liability Association ”Safety Rules for
guarantee maximum reliability of your ma- the Operation of Road Rollers and Soil Compac-
chine. tors” and all relevant accident prevention regula-
tions.
This manual comprises:
l Safety regulations For your own personal safety you should only
use original spare parts from BOMAG.
l Operating instructions
In the course of technical development we re-
l Maintenance instructions
serve the right for technical modifications
l Trouble shooting without prior notification.
Using these instructions will These operating and maintenance instructions are
also available in other languages.
l help you to become familiar with the machine.
Apart from that, the spare parts catalogue is avail-
l avoid malfunctions caused by unprofessional able from your BOMAG dealer against the serial
operation. number of your machine.
Compliance with the maintenance instructions will Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines in
l enhance the reliability of the machine on con- soil and asphalt construction.
struction sites,
The above notes do not constitute an extension of
l prolong the lifetime of the machine, the warranty and liability conditions specified in the
l reduce repair costs and downtimes. general terms of business of BOMAG.
We wish you successful work with your BOMAG
BOMAG will not assume liability for the function of machine.
the machine
BOMAG GmbH
l if it is handled in a way not complying with the
Printed in Germany
usual modes of use,
Copyright by BOMAG
l if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-

age resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
BW 211/212/213 D-40/PD40 BOMAG 3

Foreword
Please fill in
............................
Machine type (Fig. 1)
............................
Serial-number (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine number (Fig. 3)
i Note Fig. 1
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 2
Fig. 3
4 BOMAG BW 211/212/213 D-40/PD40

Table of Contents
Technical Data 9
Safety regulations 17
Indicators and Controls 27
3.1 General notes 30
3.2 Description of indicators and control elements 30
3.3 Display and control elements
BTM 40
3.4 Description of indicating and control elements
BTM 41
3.5 Line diagram (EVIB) 43
3.6 Description of line diagram (EVIB) 45
3.7 Bar diagram (EVIB) 46
Operation 47
4.1 General 48
4.2 Tests before taking into operation 48
4.3 Electronic immobilizer 49
4.4 Starting the engine 49
4.5 Starting with jump wires 51
4.6 Driving the machine 52
4.7 Stopping the machine, operating the parking brake 53
4.8 Shutting down the engine 54
4.9 Switching the vibration on and off 55
4.10 What to do in events of emergency 56
4.11 Adjusting the seat 57
4.12 Operating the heating/air conditioning system 58
4.13 Operating the hood 59
4.14 Towing in case of an engine failure 60
4.15 Transport 62
4.16 BVC/BTM05 settings before start-up 64
4.17 Measuring pass with BTM 67
4.18 Finishing compaction of a track 70
4.19 Printing measuring data after completing compaction 71
4.20 Changing the paper roll in the measuring value printer 72
4.21 Changing the printer ribbon in the measuring value printer 73
Maintenance 75
5.1 General notes on maintenance 76
5.2 Fuels and lubricants 77
5.3 Table of fuels and lubricants 81
5.4 Running-in instructions 82
5.5 Maintenance table 83
5.6 Check the engine oil level 87
BW 211/212/213 D-40/PD40 BOMAG 5

Table of Contents
5.7 Checking the fuel level 87

5.8 Check the coolant level 88
5.9 Check the hydraulic oil level 89
5.10 Check, clean the water separator 89
5.11 Checking the tire pressure 91
5.12 Clean the cooling fins on engine and hydraulic oil cooler 91
5.13 Check the oil level in the drive axle 92
5.14 Checking the oil level in left/right wheel hubs 93
5.15 Check the oil level in the vibration bearings 93
5.16 Checking, replacing the refrigerant compressor V-belt 94
5.17 Changing engine oil and oil filter 97
5.18 Draining the fuel tank sludge 98
5.19 Battery service 99
5.20 Service the air conditioning 100
5.21 Cleaning the circulation air filter for the heating 102
5.22 Check, adjust the valve clearance 103
5.23 Change the fuel filter cartridge 105
5.24 Change the fuel pre-filter cartridge 106
5.25 Checking / replacing the ribbed V-belt 107
5.26 Check the engine mounts 108
5.27 Change the oil in the vibration bearings 108
5.28 Change the oil in thedrive axle 109
5.29 Changing the oil in the wheel hubes 110
5.30 Retighten the fastening of the axle on the frame 111
5.31 Tightening the wheel nuts 112
5.32 Checking the ROPS 112
5.33 Check the travel control 113
5.34 Changing hydraulic oil and breather filter 115
5.35 Changing the hydraulic oil filter 116
5.36 Changing the coolant 117
5.37 Checking the injection valves 119
5.38 Air filter maintenance 121
5.39 Adjusting the scrapers 123
5.40 Clean the machine 124
5.41 Adjust the parking brake 125
5.42 Changing the tires 126
5.43 Change the fresh air filter in the cabin 126
5.44 Fill the provision tank for the windscreen washer system 127
5.45 Tightening torques 127
5.46 Engine conservation 128
Trouble shooting 129
6.1 General notes 130
6 BOMAG BW 211/212/213 D-40/PD40

Table of Contents
6.2 Reading out faults BVC/BTM05 130

6.3 Engine 132
Cab assembly before initial start-up 135
7.1 Preparations 137
7.2 Cabin assembly 138
7.3 Final function tests and checks 144
BW 211/212/213 D-40/PD40 BOMAG 7

Table of Contents
8 BOMAG BW 211/212/213 D-40/PD40

1 Technical Data
BW 211/212/213 D-40/PD40 BOMAG 9

Technical Data
Fig. 4
Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 211 D-40 2960 2270 1500 2268 2985 490 5840 70 70 25 2130
BW 211 PD-40 2960 2270 1480 2268 2985 490 5840 70 70 25 2130
* BW 211 D-40 BW 211 PD-40
Weights
Operating weight (CECE) with ROPS-cabin kg 9500 10500
Axle load, drum (CECE) kg 5750 6750
Rear axle load (CECE) kg 3750 3750
Static linear load kg/cm 27 -
Max. operating weight kg 13000 12620
Travel characteristics
Travel speed (1) km/h 0–6 0–6
Travel speed (2) km/h 0 – 10 0 – 10
Max. gradability without/with vibration (soil de- % 45/43 49/46
pendent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2012C BF4M 2012C
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO 3046 kW 98 98
Power SAE J1995 hp 132 132
Rated speed rpm 2300 2300
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Permissible ambient temperatures °C -20 ... +50 -20 ... +50
10 BOMAG BW 211/212/213 D-40/PD40

Technical Data
* BW 211 D-40 BW 211 PD-40

Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrostatic hydrostatic
Steering/oscillation angle ±° 35/12 35/12
Inner track radius mm 3494 3494
Vibration
Frequency (1/2) Hz 30/36 30/36
Amplitude (1/2) mm 1.8/0.95 1.70/0.86
Centrifugal force (1/2) kN 236/125 275/202
Tires
Tire size 23.1-26/12PR 23.1-26/12PR
Air pressure, nominal value bar 1.4 1.4
Air pressure, range bar 0.8 - 1.4 0.8 - 1.4
Padfeet, quantity 150
Height of padfeet mm 100
Area of one padfoot cm2 137
Filling capacities
motor l approx. 10 approx. 10
Fuel l approx. 250 approx. 250
Hydraulic oil l approx. 60 approx. 60
Coolant l approx. 16 approx. 16
* The right for technical modifications remains reserved
BW 211/212/213 D-40/PD40 BOMAG 11

Technical Data
Fig. 5
mm
BW 212 D-40 2960 2250 1500 2268 2985 490 5840 60 60 25 2130
BW 212 PD-40 2960 2250 1480 2268 2985 490 5840 60 60 25 2130
* BW 212 D-40 BW 212 PD-40

Weights
Static linear load kg/cm 33.6 -
Max. gradability without/with vibration (soil depend- % 45/43 49/46
ent)
Drive
Cooling Water Water
Fuel Diesel Diesel
12 BOMAG BW 211/212/213 D-40/PD40

Technical Data
* BW 212 D-40 BW 212 PD-40

Brakes
Steering
Vibration
Frequency (1/2) Hz 30/36 30/36
Amplitude (1/2) mm 1.8/0.95 1.70/0.86
Tires
Tire size 23.1-26/12PR 23.1-26/12PR
Area of one padfoot cm2 137
Filling capacities
BW 211/212/213 D-40/PD40 BOMAG 13

Technical Data
Fig. 6
mm
BW 213 D-40 2960 2250 1500 2268 2985 490 5840 60 60 35 2130
BW 213 PD-40 2960 2250 1480 2268 2985 490 5840 60 60 25 2130
* BW 213 D-40 BW 213 PD-40

Weights
Static linear load kg/cm 36.7 -
Max. gradability without/with vibration (soil depend- % 45/43 49/46
ent)
Drive
Cooling Water Water
Fuel Diesel Diesel
14 BOMAG BW 211/212/213 D-40/PD40

Technical Data
* BW 213 D-40 BW 213 PD-40

Brakes
Steering
Vibration
Frequency (1/2) Hz 30/36 30/36
Amplitude (1/2) mm 1.90/0.96 1.70/0.86
Tires
Tire size 23.1-26/12PR 23.1-26/12PR
Area of one padfoot cm 2 137
Filling capacities
BW 211/212/213 D-40/PD40 BOMAG 15

Technical Data
16 BOMAG BW 211/212/213 D-40/PD40

2 Safety regulations
BW 211/212/213 D-40/PD40 BOMAG 17

Safety regulations
General Examples for unintended use are:

l work with vibration on hard concrete, cured bi-
This BOMAG machine has been built in com-
tumen layers or extremely frozen ground
pliance with the latest technical standard and
complies with the applicable regulations and l driving on unstable subbases or too small con-
technical rules. However, dangers for persons tact area (danger of tipping over)
and property may arise from this machine, if: l using the machine for towing
l it is used for purposes other than the ones it is l use to pull down walls or demolish buildings
intended for, Transporting persons, except the machine driver,
l it is operated by untrained personnel, is prohibited.
Starting and operation of the machine in explosive
l it is changed or converted in an unprofessional
environments and in underground mining is pro-
way,
hibited.
l the safety instructions are not observed.
Each person involved in the operation, mainte- Remaining dangers, remaining risks
nance and repair of the machine must there- Despite careful work and compliance with stand-
fore read and comply with these safety ards and regulations it cannot be ruled out that fur-
regulations. If necessary, this must be con- ther dangers may arise when working with and
firmed by obtaining the signature of the cus- handling the machine.
tomer.
Both the machine as well as all other system com-
Furthermore, the following obviously also applies: ponents comply with the currently valid safety reg-
l applicable accident prevention instructions, ulations. Nevertheless, remaining risks cannot be
ruled out completely, even when using the ma-
l generally accepted safety and road traffic reg- chine for the purpose it is intended for and follow-
ulations, ing all information given in the operating
l country specific safety regulations. It is the instructions.
duty of the operator to be acquainted with A remaining risk can also not be excluded beyond
these instructions and to apply these accord- the actual danger zone of the machine. Persons
ingly. This applies also for local regulations remaining in this area must pay particular attention
concerning different types of handling work. to the machine, so that they can react immediately
Should the recommendations in these instruc- in case of a possible malfunction, an incident or
tions be different from the regulations valid in failure etc.
your country, you must comply with the safety
regulations valid in your country. All persons remaining ion the area of the machine
must be informed about the dangers that arise
from the operation of the machine.
Intended use
This machine must only be used for: Regular safety inspections
l medium to heavy compaction work in earth Have the machine inspected by an expert (proper-
construction (road sub-bases) ly trained person) once every year.
l probably compaction of bituminous material,
e.g. road surface layers. Who is allowed to operate the ma-
chine?
Unintended use Only trained, instructed and authorized persons of
Dangers may arise from the machine when it is at least 18 years of age are permitted to drive and
used for purposes other than the one it is intended operate this machine. For operation of the ma-
for. chine the responsibilities must be clearly specified
Any danger caused by intended use is the sole re- and complied with.
sponsibility of the customer or driver/operator, the
manufacturer cannot be made liable.
18 BOMAG BW 211/212/213 D-40/PD40

Safety regulations
Persons under the influence of alcohol, medicine Environment

or drugs are not allowed to operate, service or re-
pair the machine. Sections marked like this highlight activities
for the safe and environmental disposal of fu-
Maintenance and repair work requires specific els and lubricants as well as replaced parts.
knowledge and must therefore only be performed
by trained specialists. Observe all environment protection regula-
tions.
Conversions and alterations to the ma-
chine Loading the machine
Unauthorized conversions to the machine are pro- Use only strong and stable loading ramps. The
hibited for safety reasons. ramp inclination must be lower than the gradability
of the machine.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex- Secure the machine against turning over or slip-
pressly clear that we have not tested or authorized ping off.
any original parts or special equipment not sup- Secure the machine on the transport vehicle
plied by us. The installation and/or use of such against rolling off, slipping and turning over.
products can impair the active and/or passive driv- Persons are highly endangered if
ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of l they step or stand under loads being lifted
non-original parts or accessories. l they remain in the drive range of the machine
during a demonstration or during loading.
Damage, deficiencies, misuse of safety The machine must not swing about when lifted off
installations the ground.
Machines which are not safe to operate or in traffic Use only safe lifting gear of sufficient load bearing
must be immediately taken out of service and shall capacity.
not be used, until these deficiencies have been Attach the lifting gear only to the specified lifting
properly rectified. points.
Safety installations and switches must neither be
removed nor must they be made ineffective. Towing the machine
You should generally use a tow bar.
Safety notes in the operating and main-
Max. towing speed 1 km/h (1.6 mph), max. towing
tenance instructions:
distance 500 m (1640 ft.).
Before releasing the multi-disc brakes secure the
! Danger machine properly against unintended rolling.
Sections marked like this point out possible
dangers for persons. Checking the Roll Over Protective
Structure (ROPS)
! Caution
Sections marked like this point out possible
dangers for the machine or for parts of the ma-
i Note
On machines with cab the ROPS is an integral part
chine.
of the cab.
The frame of the machine must not be warped,
i Note
bent or cracked in the area of the ROPS fastening.
Sections marked like this provide technical infor-
mation concerning the optimal economical use of The ROPS must not show any rust, damage, hair-
the machine. line cracks or open fractures.
BW 211/212/213 D-40/PD40 BOMAG 19

Safety regulations
The actual weight of the machine must not exceed l all protective devices are properly secured in
the testing weight of the ROPS. their place
The ROPS must not rattle about when driving. l steering, brakes, control elements, lighting
This indicates that it is not properly fastened. All and warning horn are in order
bolted connections must comply with the specifi-
l the seat is correctly adjusted
cations and should be absolutely tight (observe
the tightening torques). Screw and nuts must not l the mirrors (if available) are clean and correct-
be damaged, bent or deformed. ly adjusted.
With the cab assembled check also the state of the Do not start the machine if any gauges, control
cabin mounts (rubber elements and screws). lights or controls are defective.
No accessories may be welded or bolted on and Do not take any loose objects with you or fasten
no additional holes must be drilled without the con- them to the machine.
sent of the manufacturer, since this will impair the On machines with ROPS you should always wear
strength of the unit. your seat belt!
The ROPS must therefore also not be straight-
ened or repaired if it is damaged. Starting
A defect ROPS must generally be replaced with an Start and operate the machine only from the oper-
original spare part in close coordination with the ator's seat
manufacturer. For starting set all control levers to "neutral posi-
tion".
Starting the machine Do not use any starting aids such as Start Pilot or
ether.
Before starting
After starting check all gauges.
Operation of the machine is only permitted when
sitting in the operator's seat. Starting with jump leads
Use only machines which have been properly Connect plus with plus and minus with minus
serviced at regular intervals. (ground cable) - always connect the ground cable
Become acquainted with the equipment, the con- last and disconnect it first! Wrong connections
trol elements, the working mode of the machine may cause severe damage in the electric system.
and the area you will be working in. Never start the engine by bridging the electrical
Use your personal protective outfit (hard hat, safe- connections on the starter, because the machine
ty boots etc.). would probably start to move immediately.
Check before mounting the machine if: Starting in closed rooms

l there are persons or obstructions beside or Exhaust gases are toxic! Always ensure an ade-
under the machine quate supply of fresh air when starting in closed
rooms!
l the machine is free of any oily and combustible
material
Driving the machine
l all handrails, steps and platforms are free of
grease, oils, fuels, dirt, snow and ice Persons in the danger area
l the engine compartment hood is closed and If a machine has turned over and the cabin door is
locked jammed, the right hand cabin window can be used
as an escape door.
To climb onto the machine use steps and hand-
rails. Before taking up work, also after breaks, you
Check before starting, whether: should always convince yourself that the danger
zone is free of persons or obstructions, especially
l the machine shows any obvious defects when driving in reverse.
20 BOMAG BW 211/212/213 D-40/PD40

Safety regulations
Give warning signals, if necessary. Stop work im- Always keep a sufficient distance when passing
mediately if persons remain in the danger zone, through subways, under bridges, tunnels, electric
despite the warning. power lines etc.
Do not step or stand in the articulation area of the Driving on inclinations and slopes
machine when the engine is running. Danger of
squashing! Do not drive on gradients exceeding the maximum
gradability of the machine.
Driving On slopes drive extremely careful and always di-
Always wear the seat belt when driving. rectly up or down the slope. Change to a lower
Do not drive on bases with insufficient load bear- gear before starting to drive.
ing capacity. Wet and loose soils considerably reduce the
Do not drive on ice and snow. ground adhesion of the machine on inclinations
and slopes. Higher risk of accident!
In events of emergency and in case of danger ac-
tuate the emergency stop switch immediately. Do Inclination
not use the emergency stop switch as service
brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop switch
has been eliminated.
If the machine has contacted high-voltage power
lines:
l do not leave the operator’s stand,
l warn others from coming close to or touching
the machine,
l if possible drive the machine out of the danger
zone,
l have the power switched off. Fig. 7
Operate the machine only from the operator’s The tipping angle was measured in static condition
stand. on level, hard ground with the machine stopped,
no steering and without vibration.
Keep the cabin doors closed.
With loose soil, acceleration/deceleration, running
Do not adjust the driver’s seat while driving. vibration, steering or attached accessoriies the tip-
Do not climb onto or off the machine while the ma- ping angle may be considerably lower.
chine is driving. Driving across slopes should therefore be strictly
Change the travel direction only at standstill. avoided, because of the high risk of tipping over
Do not use the machine to transport persons. and the related risk of severe or even fatal acci-
dents.
In case of unusual noises and development of
smoke perform trouble shooting and have the fault You should therefore always drive straight up or
corrected. down a slope.
Always keep a sufficient distance to excavation Behaviour in traffic

walls and embankments and do not use working Match the speed to the working conditions. Do not
methods that could impair the stability of the ma- make extreme steering movements when driving
chine. with high speed, danger of tipping over!
Do not work with vibration on hard concrete, cured Always give way to loaded transport vehicles.
bitumen layers or extremely frozen ground.
Switch the lights on if the visibility is poor.
Keep away from edges and embankments.
BW 211/212/213 D-40/PD40 BOMAG 21

Safety regulations
Checking the effect of vibration Fire protection measures

When compacting with vibration you must check Familiarise yourself with the location and the oper-
the effect on nearby buildings and underground ation of fire fighting equipment. Observe all fire re-
supply lines (gas, water, sewage, electric power), porting and fire fighting possibilities.
if necessary stop compaction work with vibration.
Do not activate the vibration on hard (frozen, con- Maintenance work
crete) ground. Danger of bearing damage! Comply with the maintenance work described in
the operating and maintenance instructions, in-
Parking the machine cluding the information concerning the replace-
Park the machine on horizontal, level, firm ground. ment of parts.
Before leaving the machine: Support the engine hood for all maintenance and
repair work in the engine compartment.
l Straighten the articulated joint to provide easi-
Maintenance work must only be performed by
er access to the machine.
qualified and authorized persons.
l return the control lever to neutral position
For overhead maintenance and assembly work
l apply the parking brake use the access steps and working platforms pro-
l shut the engine down, pull the ignition key off vided or other secure means. Do not use machine
parts as access steps.
l close the cabin
Keep unauthorized persons away from the ma-
l secure the machine against unintended use. chine.
Do not jump off the machine, but use hand grips Do not perform maintenance work while the ma-
and access steps. chine is driving or the engine is running.
Mark machines, which could be in the way, with a Park the machine on horizontal, level, firm ground.
clearly visible sign.
Pull the key out of the ignition switch.
Parking on slopes and inclinations Secure the articulated joint with the articulation
Secure the machine against rolling, place metal lock.
chocks in front of and behind the wheels. The
Work on hydraulic lines
wheel chocks must be provided by the operating
company. Relieve hydraulic pressures before working on hy-
draulic lines. Hydraulic oil escaping under pres-
sure can penetrate the skin and cause severe
Refuelling injury. When being injured by hydraulic oil consult
Do not inhale any fuel fumes. a medical doctor immediately, as otherwise this
Refuel only with the engine shut down. may cause severe infections.
Do not refuel in closed rooms. Do not step in front of or behind the drums/wheels
when performing adjustment work in the hydraulic
No open fire, do not smoke.
system.
Monitor the entire refuelling process.
Do not change the setting of pressure relief valves.
Do not spill any fuel. Catch running out fuel, do not
Drain the hydraulic oil at operating temperature –
let it seep into the ground.
danger of scalding!
Wipe off spilled fuel. Keep dirt and water away
Catch running out hydraulic oil and dispose of en-
from the fuel.
vironmentally.
A leaking fuel tank can cause an explosion. En-
Always catch and dispose of hydraulic oils sepa-
sure tight fit of the fuel tank cover, if necessary re-
rately.
place immediately.
Do not start the engine after draining the hydraulic
oil.
22 BOMAG BW 211/212/213 D-40/PD40

Safety regulations
Once all work is completed (with the system still Drain the engine oil at operating temperature –
depressurized!) check all connections and fittings danger of scalding!
for leaks. Wipe off spilled oil, catch running out oil and dis-
Changing hydraulic hoses pose of environmentally.
Hydraulic hoses must be visually inspected at reg- Store used filters and other oil contaminated ma-
ular intervals. terials in a separate, specially marked container
and dispose of environmentally.
Hydraulic hoses must be immediately replaced if:
Do not leave any tools or other objects, that could
l the outer layer is damaged down to the inlay cause damage, in the engine compartment.
(e.g. chafing, cuts, cracks)
The settings for idle speed and highest speed
l the outer layer is brittle (formation of cracks in must not be changed, since this would affect the
the hose material) exhaust gas values and cause damage to engine
l the hose shows deformations in pressurized and power train.
and depressurized condition, which do not Turbo chargers work with high speeds and high
comply with the genuine shape of the hydrau- temperatures. Keep hands, tools and materials
lic hose away from the intake and outlet openings of the
l the hose shows deformations in bends, e.g. nturbo charger and do not touch any hot surfaces.
squeezing, buckling, layer separation, forma- Check and change coolant only when the engine
tion of blisters is cold.
l parts of the hose are leaking. Catch coolant and dispose of environmentally.
l hoses are not correctly installed. Working on electric parts of the machine
l the hydraulic hose has separated from the fit- Before starting to work on electric parts of the ma-
ting chine disconnect the battery and cover it with insu-
l the fitting shows corrosion that impairs both lating material.
function and strength. Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire haz-
l hoses are mixed up by mistake.
ard!
l fittings are damaged or deformed, whereby
Disconnect the battery before starting welding
the function and strength of the hose/hose
work on the machine.
connection is impaired.
Only genuine BOMAG replacement hydraulic hos- Working on the battery
es ensure that the correct hose type (pressure When working on the battery do not smoke, do not
range) is used at the right location. use open fire!
Working on the engine Do not let acid come in contact with hands or
clothes! When injured by acid flush off with clear
Shut the engine down before opening the engine
water and seek medical advice.
hood.
Metal objects (e.g. tools, rings, watch straps) must
Do not work on the fuel system while the engine is
not come in contact with the battery poles – dan-
running - danger to life due to high pressures!
ger of short circuit and burning!
l Wait another minute after the engine has When recharging serviceable batteries remove all
stopped. plugs, to avoid the accumulation of explosive gas-
l Keep out of the danger zone during the initial es.
test rung. Observe the applicable instructions when starting
l In case of leaks return to the workshop imme- with an auxiliary battery.
diately. Dispose of old batteries according to regulations.
l Make sure that the engine cannot be started Switch off the charging current before removing
unintentionally during service and repair work. the charging clamps.
BW 211/212/213 D-40/PD40 BOMAG 23

Safety regulations
Ensure sufficient ventilation, especially if the bat- Do not use gasoline or other easily inflammable
tery is to be charged in a closed room. substances for cleaning.
Working on the fuel system When cleaning with steam cleaning equipment do
not subject electrical parts and insulation material
Do not inhale any fuel fumes. to the direct jet of water, or cover it beforehand.
Avoid open fire, do not smoke, do not spill any fuel.
l Do not guide the water jet into the exhaust and
Catch running out fuel, do not let it seep into the into the air filter.
ground and dispose off environmentally.
After maintenance work
Working on wheels and tires
After all maintenance work is completed reinstall
Explosion-like bursting of tires or parts of tires and all guards and safety installations.
rims can cause most severe or even deadly inju-
ries. Repair
Assemble the tires only if are sufficiently experi-
Mark a defective machine by attaching a warning
enced and with the right tools at hand. If necessary
tag to the steering wheel.
have the tires assembled in a qualified workshop.
Repair work must only be performed by qualified
Always ensure the correct tire pressure and do not
and authorized persons. Use our repair instruc-
exceed the specified maximum pressure.
tions for this work.
Check tires and wheels every day for specified
Exhaust gases are highly dangerous! Always en-
pressure, cuts, bulges, damaged rims, missing
sure an adequate supply of fresh air when starting
wheel studs or nuts. Do not drive with damaged
in closed rooms!
tires or wheels.
Do not work on the fuel system while the engine is
Ant-sticking emulsions for tires must only consist
running - danger to life!
of water and anti-sticking agent, in a concentration
in accordance with the specifications of the manu- The system is under high pressure! Keep away
facturer of the anti-sticking agent. Observe appli- from leakages in the high pressure system, be-
cable environmental regulations. cause fuel squirting out may cause severe injury.
After shutting down the engine wait for another
Working on the air conditioning minute, until the pressure has dropped to a per-
Faults on the air conditioning should only be rem- missible level. In case of leakages you should con-
edied by professional personnel. tact the Service Department of the engine
manufacturer and refrain from starting the engine.
According to the regulation for pressure reservoirs
all pressure reservoirs must be repeatedly inspect- Test
ed by a specialist. The safety of compaction equipment must be
In connection with this inspection the drier/collec- checked by a specialist as required in dependence
tor unit must be visually examined twice every on the application and the operating conditions,
year. During these inspections special attention however at least once every year.
must be paid to corrosion and mechanical dam-
age. Information and safety stickers/decals
Do not perform welding work in the vicinity of the on the machine
air conditioning. Danger of explosion!
Keep stickers/decals complete (see spare parts
Do not clean the condenser in the air conditioning catalogue) and fully legible and observe their
system with a hot water jet. Danger of explosion! meaning.
Do not release refrigerant into the atmosphere, but Replace damaged or illegible stickers/decals im-
dispose of environmentally. mediately.
Cleaning work
Do not perform cleaning work while the motor is
running.
24 BOMAG BW 211/212/213 D-40/PD40

Safety regulations
Fig. 8
Stickers and decals
1 Warning sticker "Danger of crushing"

2 Information sticker "Vehicle voltage 12 V"
3 Information sticker "Hydraulic oil"
4 Information sticker "Diesel"
5 Operation sticker "Hood handle"
6 Information sticker "Lifting point"
7 Information sticker "Lashing point"
8 Information sticker "Engine oil drain"
9 Prohibition sticker "High pressure cleaner"
10 Information sticker "Hydraulic oil and coolant
drains"
BW 211/212/213 D-40/PD40 BOMAG 25

Safety regulations
Fig. 9 Fig. 12
Instruction sticker - Always wear your seat belt Information sticker "Panolin 46"**
Fig. 10
Information sticker "Emergency exit"
Fig. 11
Information sticker "Bio Hydraulic Oil"*
* Optional equipment ** Optional equipment
26 BOMAG BW 211/212/213 D-40/PD40

3 Indicators and Controls
BW 211/212/213 D-40/PD40 BOMAG 27

Indicators and Controls
Fig. 13
28 BOMAG BW 211/212/213 D-40/PD40

1 Start switch 10 Rotary switch for travel ranges

2 Instrument cluster 11 Emergency stop push button
3 Rotary switch for cabin fan* 12 Push button for warning horn
4 Rotary switch for air conditioning system* 13 Rotary momentary contact switch for engine
speed
5 Vent for heating and ventilation, driver
14 Rotary switch for direction indicators*
6 Vent for heating and ventilation, footwell
15 Rotary switch for hazard light system*
7 Push button vibration
16 Rotary switch for lighting (StVZO)*
8 Travel lever
17 Rotary switch for working head lights*
9 Rotary switch for vibration, amplitude selection
18 Rotary switch for cabin heater*
* Optional equipment
BW 211/212/213 D-40/PD40 BOMAG 29

3.1 General notes 3.2 Description of indicators

and control elements
Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise de-
scriptions of the individual operating steps.
Fig. 14
No. 1 = Start switch
Position "P", "0"= Ignition off, key can be pulled
out
Position "I", "II" = Ignition on, all control and
warning lights in the instru-
ment cluster light up for 3 sec-
onds (test function). The oil
pressure warning light flashes,
charge control light and park-
ing brake warning light stay on.
The preheating control light
lights up in case of low temper-
atures.
i Note
The engine can only be started if both travel levers
are in “neutral”.
The starter switch is designed with a re-start lock.
For a new starting attempt the ignition key must
first be turned back to position "0".
Position
"START" = Turn further against spring
pressure, the engine starts,
turn the ignition key back to
position "I" once the engine
has started.
! Caution
Run the engine warm for a short while before
starting work. Do not rev up a cold engine to
high idle speed/full load speed.
30 BOMAG BW 211/212/213 D-40/PD40

Do not shut down the engine all of a sudden Check coolant level. Check cooling
from full load speed, but let it idle for about 2 system for leaks, repair if necessary.
minutes. f yellow = Charge control light
Lights if the battery is not being
charged.
Check the V-belt, if necessary repair
the generator.
g = not used
h red = Warning light engine overheating
Flashes if the engine overheats, the
warning buzzer sounds, the engine is
shut down after approx. 2 minutes.
Clean engine oil cooler, repair the en-
gine is necessary.
i = not used
j green = Indicator control light
k red = Parking brake warning light
Lights when the parking brake is ap-
plied
l = Operating hour meter
Fig. 15 Counts the operating hours while the
No. 2 = Instrument cluster engine is running.
All maintenance work must be per-
formed according to the indicated op-
i Note erating hours.
With the ignition switch in position "I" all control m = Fuel level gauge*
and warning lights are switched on for a moment.
a yellow = Water in fuel warning light
Lights when the water content in the
fuel pre-cleaner reaches the sensor
contacts. Warning buzzer sounds.
The engine is shut down after 2 sec-
onds.
Clean the water separator.
b yellow = Preheating control light
Lights when temperatures are low
(pre-heating for starting)
c = not used
d red = Engine oil pressure warning light
Flashes when the engine oil pressure Fig. 16
is too low, the warning buzzer No. 3 = Rotary switch for cabin fan
sounds, the engine is shut down after
Position 0 = Cabin fan switched off.
10 seconds.
Check engine oil level, repair the en- Position 1, 2 and
gine if necessary. 3 = Fan stages of different
strengths
e red = Coolant level warning lamp
Flashes if the coolant level is too low,
the warning buzzer sounds, the en-
gine is shut down after 10 seconds. * Optional equipment
BW 211/212/213 D-40/PD40 BOMAG 31

Fig. 17 Fig. 19
No. 4 = Rotary switch for air conditioning No. 8 = Travel lever
system* Position "mid-
dle" = Braking position service brake
i Note Position "middle,
Only switch the air conditioning system on when right" = Parking brake, to start the en-
the rotary switch for the cabin fan in position 1, 2 gine
or 3. Position "I" = Forward travel
Position 0 = Air conditioning switched off. Position "II" = Backwards travel
Position min. and
max. = Air conditioning control seg- i Note
ment
If the engine speed drops under load when driving
No. 5 = Vents for air conditioning, heating on steep gradients, take the travel lever slightly
and ventilation, driver back towards neutral. This relieves the hydraulic
No. 6 = Vents for air conditioning, heating system and reduces the load on the diesel engine.
and ventilation, footwell**
Fig. 20
Fig. 18 No. 9 = Rotary switch for vibration, amplitude
No. 7 = Push button vibration selection
. = Switching the vibration on Position left = low amplitude, high frequency
press again = Switching the vibration off Position "mid-
dle" = Vibration off
** Optional equipment
Position right = high amplitude, low frequency
32 BOMAG BW 211/212/213 D-40/PD40

unlock = turn the button clockwise and

release it.
to drive = move the travel lever first to
braking position, then start the
engine and choose the travel
direction.
For safety reasons the travel system of the ma-
chine will only be enabled after the travel lever has
been shifted back to braking position.
Fig. 21
No. 10 = Rotary switch for speed range selec-
tion
Position "turtle" = Working speed
Position "rab-
bit" = Transport speed
Fig. 23
No. 12 = Push button for warning horn
Fig. 22
No. 11 = Emergency stop switch
The engine will be shut down and the brake will
close.
!Danger Fig. 24
Danger of accident! No. 13 = Rotary momentary contact switch for

engine speed
Operate only in emergency situations during
Electric engine speed adjustment
operation, do not use as a service brake.
Momentary con-
The machine should only be started again after
tact position left = Idle speed position
the danger, that caused the actuation of the
emergency stop switch, has been removed.
operate = push the button completely i Note
down, it will automatically lock Normal position for engine start.
in end position.
BW 211/212/213 D-40/PD40 BOMAG 33

Momentary con-
tact position
right = Full throttle position, operating
position for driving and vibra-
tion
! Caution
Always drive and vibrate with max. engine
speed! Control the travel speed with the travel
lever.
Fig. 26
No. 15 = Rotary switch for hazard light system
**
Position "left" = Hazard light system switched

off
Position "right" = Hazard light system switched
on. All flashing lamps and the
flashing control light in the in-
strument cluster are flashing.
Fig. 25
No. 14 = Rotary switch for direction indica-
tors*
Position "mid-
dle" = Direction indicators disabled
Position "left or
right" = Front and rear direction indica-
tors on the corresponding side
are flashing. Indicator control
light in instrument cluster
flashes.
Fig. 27
No. 16 = Rotary switch for light system (StV-
ZO)***
Position "left" = Light off
Position "mid-
dle" = Sidelights on, with ignition
switch in position "I" or "P"
Position "right" = Travel light on, with ignition
switch in position "I".
* Optional equipment *** Optional equipment
34 BOMAG BW 211/212/213 D-40/PD40

Fig. 28 Fig. 30
No. 17 = Rotary switch for working lights* No. 19 = 2-pole socket
Position "left" = Light off Current only with the ignition switch in position "I"
Position "right" = Working lights on, with ignition or when the engine is running.
switch in position "I".
Fig. 31
Fig. 29 No. 20 = Fuses in electric junction box

No. 18 = Rotary switch for cabin heater
Position "0" = Cabin heater switched off Danger
!
Position red Fire hazard!

range = Temperature selection for cab- Do not use fuses with higher ampere ratings
in heating and do not bridge fuses.
(15) 30A = (F13) Start switch
(16) 5A = (F68) Electronic immobilizer
(17) 20A = (F105) Engine speed
(18) 15A = (F11) Front head lights **
(19) 15A = (F07) Hazard light
(21) 15A = (F22) Working headlights, rear
(22) 15A = (F19) Working headlights, rear
(23) 15A = (F09) Parking and tail light, left*
* Optional equipment ** Optional equipment
BW 211/212/213 D-40/PD40 BOMAG 35

(24) 15A = (F10) Parking and tail light, right*

i Note
(25) 15A = (F08) Direction indicators* The main fuse is located in the battery compart-
(26) 10A = (F18) Pre-fuse for working head ment
lights
(27) 15A = (F14) Engine solenoid
(28) 10A = (F23) Warning horn
(29) 10A = (F25) solenoid valve for driving and
braking
(30) 15A = (F39) Main fuse for cabin
(31) 10A = (F24) Instruments
(32) 15A = (F03) Vibration
(33) 10A = (F148) Control MESX, potential 15*
(34) 10A = (F84) control, contact 54
(35) 15A = (F146) Control MESX, potential 30*
(37) 25A = (F124) Fuel pre-heating* Fig. 34
No. 22 = Toggle switch, cabin
a = toggle switch for flashing beacon
b = toggle switch for front windscreen wiper/

washer
up = windscreen wiper moves to
end position and stops.
down = Switches on front windscreen
wiping.
Push button = Front windscreen is sprayed
during wiping.
c = toggle switch for rear windscreen wiper/

Fig. 32 washer
(80) 5A = (F150) GPS Receiver* up = windscreen wiper moves to
end position and stops.
down = Switches on wiping of rear
windscreen.
Push button = Rear windscreen is sprayed
during wiping.
Fig. 33
No. 21 = Main fuse for battery
80A = (F00)
36 BOMAG BW 211/212/213 D-40/PD40

d = toggle switch for rear windscreen heating i = reading and dashboard light
j = toggle switch for reading and dashboard

light
k = toggle switch for cabin light
l = cabin light
Fig. 35
! Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
(1) 15A = (F43) Wiper/washer, rear Fig. 37
(2) 15A = (F44) Wiper/washer, front No. 24 = Air filter maintenance indicator
(3) 10A = (F130) Night light With the maintenance indicator the actual contam-
ination level of the air filter can be checked even
(4) 25A = (F31) Cabin ventilator when the engine is stopped.
(5) 10A = (F41) Flashing beacon Filter service is only required when the yellow pis-
(6) 15A = (F144) Cab socket ton has reached the red writing "Service".
(7) 15A = (F143) Rear windscreen heating After completion of the filter service reset the indi-
(8) 10A = (F42) Cab lights cator back to "Zero" by pressing the button.
Fig. 38
Fig. 36
No. 23 = Cabin light No. 25 = Service indicator hydraulic oil filter
l Check the service indicator at operating tem-
perature and with the engine running.
l If necessary press the pin in.
BW 211/212/213 D-40/PD40 BOMAG 37

Pin remains
pressed in = hydraulic oil filter element o.k.
Pin pops out = replace the hydraulic oil filter
element
Fig. 41
No. 28 = Tachometer for diesel engine**
shows the rotational speed of the diesel engine.
Scale value x 100 = revolutions per minute
Fig. 39
No. 26 = Fuel gauge
shows the fuel level in the fuel tank.
Fig. 42
No. 29 = Vibration frequency display***
Shows the vibration frequency.
Fig. 40 outer scale = Frequency in min-1 x 100
*
No. 27 = Speedometer inner scale = Frequency in Hz
Shows the travel speed of the machine.
outer scale = km/h
inner scale = mph
* Optional equipment *** Optional equipment
38 BOMAG BW 211/212/213 D-40/PD40

Fig. 43
No. 30 = EVIBdisplay*
is a compaction measuring unit for continuous dis-
play of the load bearing characteristics (MN/m2)
during the compacting pass.
EVIB value
Increase = higher load bearing capacity
Constant = end of compaction
i Note
Modular upgrading to BTM plus / BTM prof and/or
BCM 05 possible.
BW 211/212/213 D-40/PD40 BOMAG 39

3.3 Display and control ele-

ments
BTM*
Fig. 44
1 EVIBdisplay 11 not used

2 Display for jump operation 12 not used
3 Push button F5 START 13 not used
4 Push button F6 STOP 14 not used
5 Push button F7 PRINT (only BTM prof) 15 not used
6 Push button F8 DELETE 16 not used
7 Vibration frequency display 17 Speed display
8 Rotary switch setting of nominal value 18 Amplitude display
9 Push button F14 nominal value increase 19 Printer for measuring values (only BTM prof)
10 Push button F13 nominal value decrease 20 Fault light
40 BOMAG BW 211/212/213 D-40/PD40

To print out the measuring data saved during the

3.4 Description of indicating last pass press button F7 PRINT.
and control elements short actuation = Line diagram
BTM long actuation ≥5
sec. = Bar chart
Control field F7 goes out and the measuring value
i Note printer starts to print out measuring data.
The BTM plus can be upgraded to BTM prof and/
or BCM 05.
i Note
After the printing process has finished any amount
Surface covering dynamic compaction of diagrams can be printed out by pressing the
control (SCCC) same button F7 (PRINT).
The BOMAG compaction measuring systems No. 6 = Button F8 DELETE
EVIB-meter (BEM) and Terrameter BTM plus/prof
press = All stored faults are deleted.
are integrated in the work process for continuous
and surface covering evaluation of compaction
and load bearing capacity of soils and non-bonded ! Caution
bearing courses. If the increase of the measuring value is to be
The EVIB-value, designated as vibration modulus, calculated on a track press button F8 DELETE
with the unit MN/m2 is directly linked with the de- only when changing the track.
formation modules EV1 or EV2 known from the
No. 7 = Frequency display
plate load test acc. to DIN 18134.
No. 1 = EVIB-display with vibration switched on this instrument shows
the frequency (rotating speed) of the exciter shaft.
Display of the dynamic soil stiffness in MN/m2.
No. 8 = Rotary switch P3 pre-setting of nomi-
No. 2 = Display for jump operation nal values
yellow The desired maximum dynamic stiffness modulus
symbol = Drum jumps EVIB [MN/m2] can be pre-selected in 6 stages (45,
red 80, 100, 120,150 and Max.).
symbol = Drum jumps excessively or The selected value is shown on the screen in field
tumbles „P3“
Select a smaller amplitude, if necessary! No. 9 = Button F14 increase of nominal value
No. 3 = Button F5 START With each actuation of the button the presetting is
press = Starts recording of measuring raised by one stage.
values The selected value is shown on the screen in field
Control field "F5" flashes green on the screen. „P3“
No. 4 = Button F6 STOP No. 10 = Button F13 reduction of nominal val-
press = Stops recording of measuring ue
values With each actuation of the button the presetting is
The green control field "F7" PRINT on the screen reduced by one stage.
lights up.
i Note
Depending on the measuring result the green con-
trol field "F5" CONTINUE or the red control field
"F6" FINISHED will light up.
No. 5 = Button F 7 Print* * only with BTM prof
BW 211/212/213 D-40/PD40 BOMAG 41

The selected value is shown on the screen in field

„P3“
No. 11 = Button F11 is not used
No. 14 = Rotary switch P1 is not used
No. 17 = Travel speed display
Shows the travel speed of the machine.
No. 18 = Amplitude display
This gauge shows the current vertical amplitude of
the machine.
No. 19 = Printer for measuring values*
To print out the measuring data saved during the
last pass press button (7) "PRINT".
No. 20 = Fault light
Infor the BOMAG After Sales Service if it lights up.
42 BOMAG BW 211/212/213 D-40/PD40

3.5 Line diagram* (EVIB)
* only BTM prof
Fig. 45
BW 211/212/213 D-40/PD40 BOMAG 43

1 Pass-No. 11 EVIB-change
2 Travel direction 12 Medium frequency
3 Machine equipment (BTM 05/BTM-E) 13 Mean travel speed
4 Software status of the measuring equipment 14 Track length
5 Machine number 15 Raster division in longitudinal direction
6 Machine type 16 Marking (thick line) excessive jumping, tum-
7 Amplitude bling of the drum
8 Maxiumum EVIB value 17 Longitudinal raster line
9 Miniumum E VIB value 18 Measuring value raster line
19 Diagram line
10 Mean EVIB-value
20 Marking (thin line) jumping of the drum
44 BOMAG BW 211/212/213 D-40/PD40

Graduation of the measuring track (track length in

*
3.6 Description of line diagram printout) into fixed sections.
(EVIB) No. 16 = Marking of jump information
Indicates excessive jumping/tumbling of the drum
on the marked track section (thick line).
No. 1 = Pass
Total number of measured passes on this track.
No. 2 = Travel direction
i Note
Select a smaller amplitude, if necessary!
No. 3 = Machine equipment
No. 4 = Software status of the measuring No. 17 = Longitudinal raster line
equipment No. 18 = Measuring value raster line
No. 5 = Machine number No. 19 = Diagram line
No. 6 = Machine type Shows the EVIB-value at any point of the rolled
No. 7 = Amplitude track. The raster line enables the location related
assignment of the EVIB-value and the location of a
This gauge shows the vertical amplitude the ma-
fault (over or under compaction).
chine has worked with on this track.
No. 20 = Marking of jump information
No. 8 = Maxiumum EVIB value
Indicates jumping of the drum on the marked track
No. 9 = Miniumum E VIB value
section (thin line).
No. 10 = Mean EVIB-value
This gauge shows the vertical amplitude the ma-
chine is currently working with on this track.
No. 11 = EVIB-change
EVIB-change in %. This always refers to the previ-
ous pass in the same direction of travel.
No. 12 = Medium frequency
No. 13 = Mean travel speed
shows the mean value of speed driven during this
pass.
i Note
Always shows the same travel speed in order to
avoid a falsification of the measuring results.
No. 14 = Track length
Measured track length between START and
STOP.
No. 15 = Raster division in longitudinal direc-
tion
Is used to pinpoint individual measuring values on
the measuring curve.
i Note
The raster lines mark measuring track sections of
5 m length.
* only BTM prof
BW 211/212/213 D-40/PD40 BOMAG 45

3.7 Bar diagram* (EVIB)
The bar diagram differs from the line diagram only

by the graphic representation of measuring val-
ues. In the bar diagram the mean values of 5 m
sections are shown as bars. In addition, the EVIB
changes of the individual 5 m sections are speci-
fied in percent after the second pass in the same
travel direction.
* only BTM prof
46 BOMAG BW 211/212/213 D-40/PD40

4 Operation
BW 211/212/213 D-40/PD40 BOMAG 47

Operation
4.1 General 4.2 Tests before taking into op-

eration
If you are not yet acquainted with the controls
and indicating elements on this machine you Before the everyday use or before a longer work-
should thoroughly read chapter 3 “Indicators ing period the following tests and inspections must
and control elements” before starting work. be performed.
All indicators and control elements are de-
scribed in detail in this chapter. ! Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
l Park the machine on ground as level as possi-
ble.
Check:
l fuel tank and fuel lines for leaks
l screw joints for tight fit
l function of steering
l function of emergency stop
l machine for cleanliness, damage
l presence of the appropriate operating and
maintenance instructions
l proper maintenance of the machine
i Note
For a description of the following tasks refer to the
chapter "maintenance every 10 operating hours".
l Engine oil level, top up if necessary
l Fuel level, top up if necessary.
l Coolant level, top up if necessary
l Hydraulic oil level, top up if necessary.
l Water separator, clean if necessary
48 BOMAG BW 211/212/213 D-40/PD40

Operation
4.3 Electronic immobilizer* 4.4 Starting the engine
Before starting the engine the anti-theft protection*

must be disarmed by entering a code. ! Danger
Danger of accident!
Start the engine only from the operator’s seat.
! Caution
In this chapter it is assumed that the operator
is fully acquainted with the function of the dif-
ferent control elements on the machine.
Fig. 46
i Note
With the electronic immobilizer armed, the light
emitting diode (a) (Fig. 46) flashes slowly.
l Slowly enter the six-digit user code.
i Note Fig. 47
When entering the code, the light emitting diode l Fasten your seat belt (Fig. 47).
(6) lights up with every digit.
l Press the diamond button.
l The electronic immobilizer is now disarmed
and the engine can be started within the next
30 seconds.
i Note
After entering the service code (for maintenance
work) the electronic immobilizer remains switched
off.
Fig. 48
l Check, whether the travel lever (Fig. 48) is en-

gaged to the right in brake position.
BW 211/212/213 D-40/PD40 BOMAG 49

Operation
Fig. 49 Fig. 52
l Switch the rotary switch for vibration amplitude All control and warning lights (Fig. 52) in the instru-
pre-selection (Fig. 49) to position "0". ment cluster light up for a moment.
The engine oil pressure warning light (d) flashes,
the charge control light (f) and the parking brake
warning light (k) stay on.
Under cold ambient temperatures the preheating
control lamp (b) will also light up. Do not start be-
fore the preheating control lamp (b) has gone out.
! Caution
Run the starting process for maximum 20 sec-
onds without interruption and pause for a
minute between starting attempts.
If the engine has not started after two attempts
Fig. 50 perform trouble shooting.
l Check, whether the emergency stop switch
(Fig. 50) is unlocked. i Note
The starter switch is designed with a re-start lock.
For a new starting attempt the ignition key must
first be turned back to position "0".
Fig. 51
l Turn the ignition key (Fig. 51) to position "I".
50 BOMAG BW 211/212/213 D-40/PD40

Operation
4.5 Starting with jump wires
Fig. 53
l Turn the ignition key (Fig. 53) through position

"II" to position "III", the starter will crank the en-
gine. Fig. 54
l As soon as the engine ignites return the igni-

tion key to position "I". !Caution
The engine oil pressure warning light and the A wrong connection will cause severe damage
charge control light go out. The parking brake in the electric system.
warning light stays on.
l Bridge the machine only with a 12 Volt auxilia-
ry battery.
!Caution l When jump starting with an external battery
Run the engine warm for a short while before connect both plus poles first.
starting work. Do not rev up a cold engine to
l Then connect the ground cable first to the mi-
high idle speed/full load speed.
nus pole of the current supplying auxiliary bat-
tery and then to engine or chassis ground, as
far away from the battery as possible (Fig. 54).
l Start as described under 'Starting the engine'.
l Once the engine is running switch on a power-
ful consumer (working light, etc.).
! Caution
If no powerful consumer is switched on volt-
age peaks may occur when separating the con-
necting cables between the batteries, which
could damage electrical components.
l After starting disconnect the negative poles
(ground cable) first and the positive poles af-
ter.
l Switch off the consumer.
BW 211/212/213 D-40/PD40 BOMAG 51

Operation
4.6 Driving the machine
! Danger
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclina-
tions and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive up and down inclinations exceed-
ing the maximum gradability of the machine Fig. 56
(see technical data). l Select the desired travel speed range (Fig.
Do not drive without wearing your seat belt. 56).
Always give way to loaded transport vehicles!
Before starting to drive make sure that the
drive range is absolutely safe.
! Caution
Always keep the cabin door closed while driv-
ing with the machine. With the door opened
and the machine fully articulated extreme os-
cillations of the machine may damage the
door.
Fig. 57
l Turn the rotary momentary contact switch for

engine speed (Fig. 57) clockwise to "MAX".
Fig. 55
l Close the cabin door (Fig. 55).
52 BOMAG BW 211/212/213 D-40/PD40

Operation
4.7 Stopping the machine, op-

erating the parking brake
Fig. 58
l Shift the travel lever (Fig. 58) out of braking po-

sition to the left to disengage.
l Move the travel lever slowly to forward or re-
verse. Fig. 59
The machine drives forward or backward with a l Return the travel lever (Fig. 59) slowly to "neu-
speed that corresponds with the actuation of the tral"-position and engage it to the right in brak-
travel lever. ing position.
l Return the travel lever to position "0". The machine is automatically braked by the hydro-
static drive and the parking brake is applied.
The machine decelerates to standstill.
! Danger
Danger of accident!
When stopping on inclinations and slopes pull
the travel lever to the right and lock it in brak-
ing position.
Important notes on travel operation
! Caution
When changing the travel direction hold the
travel lever for a moment in "0"-position, until Fig. 60
the machine has stopped, before actuating to
the new travel direction. The parking brake warning lamp (k) (Fig. 60) lights
up.
Do not operate jerkily! Control the travel speed
with the travel lever.
i Note
When driving up and down inclinations move
The parking brake also closes automatically when
the travel lever slowly back towards neutral to
shutting the engine down.
brake the machine.
If the engine speed drops under load when
driving on steep gradients, take the travel lever
slightly back towards neutral.
BW 211/212/213 D-40/PD40 BOMAG 53

Operation
4.8 Shutting down the engine
! Caution
Straighten the articulated joint to provide easi-
er access to the machine.
Fig. 63
l Turn the momentary contact switch for engine

speed (Fig. 63) anti-clockwise to position
"MIN" (idle speed).
Caution
!
Do not shut down the engine all of a sudden

Fig. 61 from full load speed, but let it idle for about 2
minutes.
l Return the travel lever (Fig. 61) slowly to "neu-
tral"-position and engage it to the right in brak-
ing position.
The machine is automatically braked by the hydro-
static drive and the parking brake is applied.
Fig. 64
l Turn the starter switch (Fig. 64) to position "0"

or "P" and pull the ignition key out.
Fig. 62 i Note
The parking brake warning lamp (k) (Fig. 62) lights The parking brake closes automatically when
up. shutting the engine down.
i Note Danger
!
The parking brake also closes automatically when Danger of accident!

shutting the engine down.
Secure the machine against unauthorized use,
pull the ignition key out, lock the cabin door.
54 BOMAG BW 211/212/213 D-40/PD40

Operation
Pre-selecting the vibration

4.9 Switching the vibration on
and off
! Danger
Risk of damage!
When compacting with vibration you must
check the effect of nearby buildings and un-
derground supply lines (gas, water, sewage,
electric power), if necessary stop compaction
with vibration.
Caution
!
Fig. 66
Danger of bearing damage!
l Preselect the desired amplitude with the rotary
Do not activate the vibration on hard (frozen, switch for vibration amplitude preselection
concrete) ground. (Fig. 66).
Switching the vibration on
Caution
!
Switch the vibration on only at max. engine

speed.
Fig. 65
l Turn the rotary switch for travel speed range

selection (Fig. 65) to position "turtle".
Fig. 67
l Turn the rotary momentary contact switch for

engine speed (Fig. 67) clockwise to "MAX".
BW 211/212/213 D-40/PD40 BOMAG 55

Operation
4.10 What to do in events of

emergency
Actuating the emergency stop switch
Danger
!
Danger of accident!
In events of emergency and in case of danger
actuate the emergency stop switch immediate-
ly.
Fig. 68
Start travel operation of the machine only after
l Press the vibration push button (Fig. 68) in the the danger that caused the actuation of the
travel lever while driving. emergency stop switch has been eliminated.
Switching the vibration off

!Caution
l Press the vibration push button (Fig. 68) Do not use as service brake. The deceleration
again. is extremely high. In case of frequent use the
wear on the multi-discs brakes will be very
high.
Fig. 69
l After the end of work switch the rotary switch

for vibration amplitude pre-selection (Fig. 69) Fig. 70
to position "0". l Press the button of the emergency stop switch
(Fig. 70) completely down, it automatically
locks in fully pressed position.
i Note
Shuts the engine down and closes the brake.
l Turn the button clockwise to unlock the emer-
gency stop switch.
l Start the engine again, see chapter "Starting
the engine".
56 BOMAG BW 211/212/213 D-40/PD40

Operation
Emergency exit
4.11 Adjusting the seat
! Danger
Danger of accident!
Do not adjust the driver’s seat while driving.
Fig. 71
l If a machine has turned over and the cabin

door is jammed, the right hand cabin window
can be used as an escape door.
Fig. 72
l To adjust the seat in longitudinal direction pull

the lever (Fig. 72) up and push the seat for-
ward or back.
Fig. 73
l To adjust the weight adjust the lever accord-

ingly.
l To adjust the inclination of the backrest turn
the knob and tilt the backrest forward or back.
BW 211/212/213 D-40/PD40 BOMAG 57

Operation
Cooling the interior

4.12 Operating the heating/air
l Close all windows completely.
conditioning system* l Direct the air flow towards the body/face (a).
l Switch on the fan (c).
Danger
! l If necessary switch off the heating (b).
Danger of suffocation! l Switch on the air conditioning system with ro-
Always keep the air inlet slots on the cabin free tary switch (d) and regulate the temperature.
of snow, foliage and similar!
Reducing the humidity
i Note l In case of damp weather direct the air flow to-
The heating power depends on the coolant tem- wards the windscreen and door screens.
perature. l Switch on the fan with the rotary switch (c).
The air conditioning system only works when the l Regulate the temperature to "Max" with the ro-
engine is running and the fan is switched on. tary switch (b).
Operation of the air conditioning system increases l Switch the air conditioning (d) on.
the fuel consumption.
Heating the interior

l Close all windows completely.
Fig. 74
l Turn the air nozzles a (Fig. 74) to direct the air

flow down into the footwell.
l In case of cold or damp weather direct the air
flow towards the windscreen and door
screens.
l Switch on the fan with the rotary switch (c).
l Regulate the temperature with the rotary
switch (b).
58 BOMAG BW 211/212/213 D-40/PD40

Operation
4.13 Operating the hood
! Danger
Danger of accident!
If the hood needs to be opened further for
maintenance or repair work, support it safely.
Bottom position
Fig. 77
l Pull the spring pin (Fig. 77) out of the bracket.

l Secure the hood i´n the protection tube with
spring plug.
Fig. 75
l Unlock the lock (Fig. 75).

l To open the hood press in the button and turn
the handle.
Fig. 76
l Pull the support out of the bracket and support

the hood (Fig. 76).
Top position
l Push the hood to top position.
BW 211/212/213 D-40/PD40 BOMAG 59

Operation
4.14 Towing in case of an engine

failure
! Danger
Secure the machine with wheel chocks against
unintentional rolling.
Danger of accident!
When using towing ropes tow the machine
only uphill.
When towing downhill you must use a rigid Fig. 79
towing device.
l Slacken the middle hexagon on both valves
The machine cannot be steered. (Fig. 79) for approx. 2 to 3 turns.
Use a towing vehicle with sufficient traction
and braking power for the unbraked towed
load. Caution
!
Do not turn the valves out completely.

l Secure the machine with wheel chocks
against unintentional rolling.
Fig. 80
Fig. 78 l To release the brake turn counter nuts 1 (Fig.

80) approx. 8 mm back.
l Attach chains (Fig. 78) or towing ropes to the
lifting hooks. l Turn the brake releasing screws (2) complete-
ly in against the stop.
! Caution
! Caution
Towing speed 1 km/h, max. towing distance
500 m. From this stop turn the screw in for maximum
another turn to release the brake!
l Open the tailgate.
Turn the screws in evenly on both sides.
l Turn the screws in alternately for ¼ turn at a
time.
l Repeat this measure on the opposite wheel
side.
60 BOMAG BW 211/212/213 D-40/PD40

Operation
After towing i Note

If necessary replace the seal ring under the coun-
!Caution ter nut if it is leaking.
Before detaching the tow bar block the ma- For this purpose completely unscrew the brake re-
chine with chocks to prevent unintended roll- leasing screw, replace the seal ring and lubricate
ing. the screw with silicone grease.
l Turn the high pressure relief valve cartridges Reinstall the screw with a new seal ring and adjust
tightly back in. the protrusion as described above.
l Turn all brake releasing screws of the axle
evenly back out, until they are light moving
again.
Fig. 81
l Turn the brake releasing screws (Fig. 81) back

in again, until they abut against the brake pis-
ton.
Fig. 82
l Unscrew the brake releasing screws (Fig. 82)

for two turns and tighten the counter nuts.
l Repeat this adjustment procedure on the op-
posite wheel side.
BW 211/212/213 D-40/PD40 BOMAG 61

Operation
4.15 Transport
! Danger
Danger of accident! Life hazard!
Use only stable loading ramps of sufficient
load bearing capacity.
Make sure that persons are not endangered by
the machine tipping or sliding off.
Always use shackles on the lifting points for
loading or tying the machine down.
Fig. 84
Check all lifting and lashing points for damage
before lifting or lashing down the machine. l Engage the articulation lock and secure it with
the spring pin (Fig. 84).
Lift the machine only with suitable lifting gear.
Weights: see chapter "Technical Data".
During demonstration and when loading the
machine do not remain in the danger zone of
the machine.
Do not stand or step under loads being lifted.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
After transport release the articulation lock
again and store it in the receptacle.
Fig. 85
l Lash the machine on the transport vehicle

(Fig. 85), use the four lashing eyes on front
and rear frame for this purpose.
l Support the front frame to avoid overstressing
of the rubber buffers.
Fig. 83
l Pull the spring pin (Fig. 83) out.

l Lift up the articulation lock and swivel it by
180°.
62 BOMAG BW 211/212/213 D-40/PD40

Operation
Fig. 86 Fig. 88
l For lifting use also the four lifting eyes (Fig. 86) l After the transport loosen the articulation lock
and appropriate lifting gear. (Fig. 88) again, fix it in its receptacle and lock
it with the spring plug.
Danger
!
Danger of accident!
The machine cannot be steered if the articula-
tion lock is applied.
Fig. 87
Position of centre of gravity (Fig. 87):
Machine L [mm] H [mm]
BW 211 – 214 -4 1150 ± 240 860 ± 60
i Note
The tolerances account for all possible options,
such as cabin, additional weight etc.
BW 211/212/213 D-40/PD40 BOMAG 63

Operation
4.16 BVC/BTM05 settings before i Note

The menu appears on the screen.
start-up
Changing the units system
i Note
The Asphalt Manager control unit can be used to
change from metric units (km/h, °C) to imperial
units (mph, °F) in both the display and the print-
out*.
Fig. 91
l Press key "F4" (Fig. 91).
i Note
The screen page to select the unit system appears
on the screen.
Fig. 89
i Note
The control unit shows the start screen.
Fig. 92
l Press key "F5" (Fig. 92) and choose the units

system.
Imperial 0 = metric units
Imperial 1 = imperial units
Fig. 90
l Press key ’’?“ (menu) (Fig. 90).
64 BOMAG BW 211/212/213 D-40/PD40

Operation
Fig. 93 Fig. 95
l After the desired change press key "F14" (Fig. l Turn the ignition key to position "I" (Fig. 95).
93). The "Save" symbol on the screen lights up
green for a moment as confirmation.
i Note
The control unit shows the start screen.
i Note
After releasing key "F14" the system returns auto-
matically to the start screen and restarts.
Fig. 96
Fig. 94
l Switch the ignition off and on again (Fig. 94). i Note

i Note
Both Asphalt Manager control unit and printer
have been set to the new units system.
Setting the printer language*
i Note
With a printer* connected the language in the
printout can be changed via the Asphalt Manager
control unit.
BW 211/212/213 D-40/PD40 BOMAG 65

Operation
Fig. 97 Fig. 99
l Press key "F6" (Fig. 97). l Press key "F14" to save the language setting
(Fig. 99). The "Save" symbol on the screen
lights up green for a moment as confirmation.
i Note
The printer language screen page appears.
Fig. 100
Fig. 98
l Press key "ESC" (Fig. 100) to return to the
start screen.
l Use keys "F11" or "F12" to choose the desired
printer language (Fig. 98).
i Note
The screen shows country flags, which represent
the associated language.
66 BOMAG BW 211/212/213 D-40/PD40

Operation
4.17 Measuring pass with BTM*
General notes
i Note
The soil measuring values (EVIB) recorded during
different passes can only be compared if the re-
cording of measuring values took place in operat-
ing mode "Manual" with the same amplitude,
frequency and travel speed and on exactly the
same track. Fig. 102
Measuring values must only be compared for l Control field F5 (Fig. 102) lights green.
passes performed in the same direction.
The following description describes an measuring
pass in forward. Measuring passes in reverse
must be performed accordingly.
Measuring pass
Fig. 103
l Turn the ignition key (Fig. 103) to position „II

engine start.
Fig. 101
l Turn the ignition key (Fig. 101) to position "I"

The BTM plus/prof performs a self-test.
BW 211/212/213 D-40/PD40 BOMAG 67

Operation
Fig. 105
l Pre-select working speed (Fig. 105) .
Fig. 104
l Mark the track to be compacted (Fig. 104).
! Caution
Since the transducer unit is mounted on the
left hand side of the drum, it is necessary to ar-
range the tracks so that track 1 is processed
first, followed by further tracks offset to the
left.
Fig. 106
l Turn the rotary switch (Fig. 106) for engine

i Note
speed to position "MAX".
Maximum track length 150 m.
Forward:
Mark 1 = Start of track
Mark 2 = End of track
i Note
The operator may also remember the start and the
end of the track by means of distinct points.
Fig. 107
l Shift the travel lever (Fig. 107) fully to position

„I“.
The machine accelerates up to the pre-adjusted
travel speed.
68 BOMAG BW 211/212/213 D-40/PD40

Operation
!Caution
Differences in the travel speeds falsify the
measuring result!
Fig. 110
l When the end of the track, mark 2, is reached,

press the button F6 “STOP” (Fig. 110).
l Stop the machine.
Fig. 108
l Switch the vibration on (Fig. 108).

i Note
The first forward pass is finished.
!Caution
Control field F5 lights green. This means, that the
Before reaching mark 1 the nominal exciter compaction is not yet completed. One or several
shaft speed must have been reached and a val- passes are still required.
id Evib-value should be displayed.
Fig. 109
l When mark 1 is reached, press button F5

“START” (Fig. 109).
Control field to the left of F5 lights green.
The EVIB- display shows the present value.
BW 211/212/213 D-40/PD40 BOMAG 69

Operation
4.18 Finishing compaction of a

track
Fig. 111
l Drive forward and reverse passes on a track Fig. 112

until the green control field to the left of F5 (Fig.
l Repeat the complete compaction process on
111) goes out and the red control field F6 be-
the next track (Fig. 112) to record measuring
low lights up after pressing the stop button F6.
values.
The compaction process on this track is finished.
Criterion for a finished track:

Compared with the previous track the increase of
the EVIB-value in the same travel direction was
less than 10%. This criterion is also fulfiled if the
EVIB decreases.
i Note
Another pass on this track does not make any
sense, because an increase in load bearing ca-
pacity is hardly possible with this machine.
l If necessary print out the measuring data for
this track (see following section).
70 BOMAG BW 211/212/213 D-40/PD40

Operation
4.19 Printing measuring data af-

ter completing compaction*
i Note
Measuring data can be printed after completion of
any pass.
Always check the paper provision before starting
work.
Change the paper roll if a red stripe appears on the
paper. Fig. 114
l If no further printouts of this track are needed,

press the button F8 “DELETE” (Fig. 114) when
the red control lamp F6 “FINISHED” lights up.
The red control field F6 “FINISHED” goes out and
the green control field F5 “CONTINUE” lights up.
BTM plus/prof is ready to compact the next track.
Fig. 113
l At the end of the measurement press push

button F7 "PRINT" (Fig. 113).
short actuation = Line diagram
long actuation ≥5
sec. = Bar chart
Control field F7 goes out and the measuring value
printer starts to print out measuring data.
i Note
After the printing process has finished any amount
of diagrams can be printed out by pressing the
same button F7 (PRINT).
* only BTM prof
BW 211/212/213 D-40/PD40 BOMAG 71

Operation
4.20 Changing the paper roll in

the measuring value printer*
i Note
Use a new paper roll if a red stripe appears on the
paper.
Fig. 117
l Insert a new paper roll (Fig. 117).

l Feed the paper into the guide (1) on the print-
er.
l Actuate the toggle switch (2) in direction of ar-
row, until the paper comes out of the printer.
l Reassemble the cover.
Fig. 115
l Unscrew the star handles (Fig. 115) and re-

move the cover.
Fig. 116
l Remove shaft 1 (Fig. 116) with the rest of the

paper roll (2).
* only BTM prof
72 BOMAG BW 211/212/213 D-40/PD40

Operation
4.21 Changing the printer ribbon

in the measuring value
printer*
i Note
In case of faint or poorly legible diagrams the print-
er ribbon needs to be replaced.
Fig. 118
l Unscrew the star handles (Fig. 118) and re-

move the cover.
Fig. 119
l Lift the tongue at point 1 (Fig. 119) and take

the printer ribbon (2) out of the printer.
l Insert the new printer ribbon into the printer,
then press in the tongue (1) on the right.
l Tension the printer ribbon by turning the rotary
button (3) in direction of arrow.
l Reassemble the cover.
* only BTM prof
BW 211/212/213 D-40/PD40 BOMAG 73

Operation
74 BOMAG BW 211/212/213 D-40/PD40

5 Maintenance
BW 211/212/213 D-40/PD40 BOMAG 75

Maintenance
l Drums with inside zinc lining are not suitable to

5.1 General notes on mainte- store fuel.
nance l When choosing the storage place for fuel
make sure that spilled fuel will not harm the en-
When performing maintenance work always com- vironment.
ply with the appropriate safety regulations. l Do not let the hose stir up the slurry at the bot-
Thorough maintenance of the machine guaran- tom of the drum.
tees far longer safe functioning of the machine and l The fuel drum must rest for a longer period of
prolongs the lifetime of important components. time before drawing off fuel.
The effort needed for this work is only little com-
pared with the problems that may arise when not l The rest in the drum is not suitable for the en-
observing this rule. gine and should only be used for cleaning pur-
poses.
The terms right/left correspond with travel direc-
tion forward.
Notes on the performance of the en-
l Support the engine hood for all maintenance
and repair work.
gine
On diesel engines both combustion air and fuel in-
l Always clean machine and engine thoroughly
jection quantities are thoroughly adapted to each
before starting maintenance work.
other and determine power, temperature level and
l For maintenance work stand the machine on exhaust gas quality of the engine.
level ground.
If your engine has to work permanently in "thin air"
l Perform maintenance work only with the motor (at higher altitudes) and under full load, you should
switched off. consult the customer service of BOMAG or the
l Relieve hydraulic pressures before working on customer service of the engine manufacturer.
hydraulic lines.
Notes on the cooling system
l Before working on electric parts of the ma-
chine disconnect the battery and cover it with Prepare and check coolant with highest care,
insulation material. since otherwise the engine may be damaged by
corrosion, cavitation and freezing.
l When working in the area of the articulated
joint attach the articulation lock (transport Coolant is prepared by adding an ethylene-glycol
lock). based anti-freeze agent with corrosion inhibiting
properties to the cooling water.
Mixing with cooling system protection agent is
Environment
necessary in all climatic zones. It prevents corro-
During maintenance work catch all oils and fu- sion, lowers the freezing point and raises the boil-
els and do not let them seep into the ground or ing point of the coolant.
into the sewage system. Dispose of oils and fu-
els environmentally.
Notes on the hydraulic system
Keep used filters in a separate waste container
During maintenance work on the hydraulic system
and dispose of environmentally.
cleanliness is of major importance. Make sure that
Catch biodegradable oils separately. no dirt or other contaminating substances can en-
ter into the system. Small particles can produce
Notes on the fuel system flutes in valves, cause pumps to seize, clog noz-
zles and pilot bores, thereby making expensive re-
The lifetime of the diesel engine depends to a
pairs inevitable.
great extent on the cleanliness of the fuel.
l If, during the daily inspection of the oil level the
l Keep fuel free of contaminants and water,
hydraulic oil level is found to have dropped,
since this will damage the injection elements
check all lines, hoses and components for
of the engine.
leaks.
76 BOMAG BW 211/212/213 D-40/PD40

Maintenance
l Seal external leaks immediately. If necessary

inform the responsible customer service. 5.2 Fuels and lubricants
l Do not store drums with hydraulic oil outdoors,
or at least under a cover. Water can be drawn
Engine oil
in through the bunghole when the weather
changes. Quality
l We recommend to use the BOMAG filling and For use in DEUTZ engines the lubrication oils are
filtering unit with fine filter to fill the system. classified in DEUTZ Lubrication Oil Quality Class-
This ensures finest filtration of the hydraulic es (DQC).
oil, prolongs the lifetime of the hydraulic oil fil-
ter and protects the hydraulic system. Approved engine oils
l Clean fittings, filler covers and the area around Deutz ACEA * API** DHD
such parts before disassembly to avoid enter-
ing of dirt. DQC II-05 E3-96, CG-4, DHD-1
E5-02, CH-4,
l Do not leave the tank opening unnecessarily
E7-04, CI-4,
open, but cover it so that nothing can fall in.
E4-07, CI-4 Plus,
E6-04 CJ-4
DQC II-05 - - -
DQC IV-05 - - -
* Association des Constructeurs European d’Automobiles
** American Petroleum Institute
The list of approved lubrication oils is also availa-

ble in the Internet under the following address:
www.deutz.com
de >>SERVICE >> Betriebsstoffe und Diag-
nose >> DeutzQualityClass >> DQC-Frei-
gabeliste
en >>SERVICE >> Fuels and lubricants and
diagnostics >> DeutzQualityClass >>DQC-
release list
Consult your local service station if in doubt.

l Use winter grade engine oil for winter opera-
tion!
Oil viscosity
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class) .
Too high viscosity can cause starting difficulties,
too low ´viscosity can jeopardize the lubrication ef-
fect and result in a high lubrication oil consump-
tion.
BW 211/212/213 D-40/PD40 BOMAG 77

Maintenance
!Caution
When using fuels with a sulphur content of
more than 0,5% to 1% or under permanent am-
bient temperatures below -10°C and when us-
ing biodegradable diesel fuel the oil change
intervals must be halved.
Fuels
You should only use commercially available brand
diesel fuel with a sulphur content of less than 0.5%
and ensure strict cleanliness when filling in. A
higher sulphur content has a negative effect on the
oil change intervals.
The fuel level should always be topped up in due
time so that the fuel tank is never run dry, as oth-
erwise filter and injection lines need to be bled.
Quality
The following fuel specifications are permitted:
l EN 590
l DIN 51628
l ASTM D975 Grade-No. 1-D and 2-D.
l JIS K 2204 Grade Fuel 1 and Grade Fuel 2
with lubrication properties acc. to EN 590
Winter fuel
Fig. 120
For winter operation use only winter diesel fuel, to
Optimal operating conditions can be achieved by avoid clogging because of paraffin separation.
using the oil viscosity chart (Fig. 120) as a refer- Diesel fuels suitable for temperatures down to -44
ence. °C are available for arctic climates. At very low
At ambient temperatures below -40 °C the lubrica- temperatures disturbing paraffin separation can
tion oil must be pre-heated (e.g. by parking the also be expected when using winter diesel fuel.
machine indoors). The admixture of petroleum and the addition of
The viscosity is classified acc. to SAE. Multi-pur- "flow enhancing additives" (fuel additives) is not
pose oils should generally be used. permitted.
Oil change intervals

Coolant
The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the follow- For fluid cooled engines the cooling fluid must be
ing oil change intervals are not reached over a pe- prepared by admixing a cooling system protection
riod of 1 year, the oil change should be performed agent to the fresh water and should be checked
at least once per year, irrespective of the operating within the specified maintenance intervals.
hours reached. This prevents damage caused by corrosion, cavi-
DQC II, tation, freezing and overheating.
DQC III, Fresh water quality
DQC IV = 500 operating hours
The correct quality of water is highly important
when preparing coolant. Clear and clean water
within the boundaries of the following analysis val-
ues should generally be used.
78 BOMAG BW 211/212/213 D-40/PD40

Maintenance
If our cooling system protection agent is not avail-

able for any important reasons, you may, in excep-
Fresh water analysis values
tional cases, use products that have been
pH-value at 20 °C 6.5 - 8.5
approved by the engine manufacturer.
Chloride ion content (mg/l) (ppm) max. 100
Sulphate ion content (mg/l) max. 100 The list of approved cooling system protection
(ppm) agents can be found in the internet under
Total hardness [°dGH] 3 - 12 www.deutz.com >>SERVICE >> Fuels and lubri-
corresponds with a potash ion 0.54 - 3.56 cants and diagnostics >> Collig system protection
content (mmol/l) of >>Technical circular Cooling System Protection
Carbon hardness proportion of min. 3 Agents.
the total hardness (°d) Products of the same product group (see Deutz
corresponds with a content of min. 53.4 Technical Circular Cooling System Protection
CaCO3 (mg/l) (ppm) Agents) can be mixed with each other.
Information concerning the water quality can be The BOMAG cooling system protection agent cor-
obtained from the waterworks. responds with product group A.
If the fresh water analysis values are unknown,

these must be determined with the help of a water ! Caution
analysis. Do not mix different coolants and additives of
If the values of the analysis deviate, the water any other kind.
must be treated accordingly. Before changing the product you must clean
l pH-value too low the entire cooling system.
Adding of caustic lye of soda or caustic potash Consult your local service station if in doubt.
solution.
To ensure proper corrosion protection you must
l Total hardness or chlorides and/or sulphates use the cooling system protection agent all year
too high: around, whereby the following concentration must
Mixing with dehardened water (e.g. distilled not be fallen short of or exceeded.
water).
l Total hardness or carbonate hardness too low: Mixing ratio
Mixing with hardened water (harder water is in
Cooling sys- Fresh water Cold protec-
most cases available in the form of drinking
tem protection tion down to
water).
agent
min. 35% 65% -22 °C
Caution
! 40% 60% -28 °C
Another analysis must be made after the fresh max. 45% 55% -35 °C
water has been prepared.
Caution
!
Cooling system protection agent
A proportion of more than 45% of cooling sys-
As a protection against frost, corrosion and boiling tem protection agent causes a drop in cooling
point anti-freeze agents must be used under any power.
climatic conditions.
The use of corrosion protection oils as cooling
Coolant for fluid cooled engines is prepared by
system protection agents is not permitted.
adding an ethylene-glycol based anti-freeze agent
with corrosion inhibiting properties to the cooling
water. i Note
We therefore highly recommend our BOMAG cool- When working at temperature below -35 °C you
ing system protection agent (BOMAG part-no. 009 should consult our local service representative.
940 08)..
BW 211/212/213 D-40/PD40 BOMAG 79

Maintenance
Environment Lubrication grease

Coolant must be disposed of environmentally. For lubrication purposes use an EP-high pressure
grease, lithium saponified (penetration 2), acc. to
Mineral oil based hydraulic oil DIN 51502 KP 2G.
The hydraulic system is operated with hydraulic oil

HV 46 (ISO) with a kinematic viscosity of
46 mm2/s at 40 °C. For topping up or for oil chang-
es use only high-quality hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils
type HV according to ISO 6743/3. The viscosity in-
dex (VI) should be at least 150 (observe informa-
tion of manufacturer).
Bio-degradable hydraulic oil

The hydraulic system can also be operated with a
synthetic ester based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil
Panolin HLP Synth.46 meets all demands of a
mineral oil based hydraulic oil according to
DIN 51524.
In hydraulic systems filled with Panolin HLP
Synth.46 always use the same oil to top up.
When changing from mineral oil based hydraulic
oil to an ester based biologically degradable oil,
you should consult the lubrication oil service of the
oil manufacturer for details.
! Caution
Check the filter more frequently after this
change.
Perform regular oil analyses for content of wa-
ter and mineral oil.
Replace the hydraulic oil filter element every
500 operating hours.
Oil for drive axle

Quality
Forthe drive axle use only multi-purpose gear oils
of API-GL5-class, SAE 90.
This is a hypoid lubricant of highest quality class
for extremely loaded transmissions.
The additives in this oil ensure low wear lubrication
under all operating conditions.
80 BOMAG BW 211/212/213 D-40/PD40

Maintenance
5.3 Table of fuels and lubri-

cants
Assembly Fuel or lubricant Quantity
Summer Winter Attention

Observe the level marks
Engine
- Engine oil ACEA: E3-96, E5-02, E7-04, E4-07, E6-04 approx. 10 litres incl. oil fil-
API: CG-4, CH-4, CI-4, CI-4 Plus, CJ-4 ter
SAE 10W-40 (-15 °C to +40 °C)
SAE 15W-40 (-5 °C to +40 °C)
SAE 5W-40 (-30 °C to +40 °C)
- Fuel Diesel Winter diesel fuel approx. 250 litres
- Coolant Mixture of water and anti-freeze agent * approx. 16 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. Viscosity approx. 60 litres
46 mm2/s at 40 °C with viscosity index (VI) >150 or
ester based biodegradable hydraulic oil
Vibration bearings SAE 15W-40 approx. 0.8 litres
Drive axle SAE 90, API GL5 approx. 9.5 litres
Wheel hubs SAE 90, API GL5 approx. 1.9 litres (per
side)
Tires Water approx. 295 litres
Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg

(MgCl2)
Air conditioning system Refrigerant R134a approx. 1500 g

* see chapter "Fuels and Lubricants - Colant"
BW 211/212/213 D-40/PD40 BOMAG 81

Maintenance
5.4 Running-in instructions
The following maintenance work must be per-

formed when running in new machines or
overhauled engines:
! Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes

l Retighten the V-belt
After 250 operating hours

l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.
l Retighten all wheel fastening screws with the
specified tightening torque.
l Changing engine oil and oil filter
l 1. Oil change vibration bearings
l Oil change in drive axle
l Oil change in wheel hubs
After 500 operating hours

l 2. Oil change vibration bearings
82 BOMAG BW 211/212/213 D-40/PD40

Maintenance
5.5 Maintenance table
every 10 operating hours, daily
every 1000 oper. hours


No. Maintenance work Comment
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the fuel level X
5.8 Check the coolant level Inspection glass X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check, clean the water separator X
5.11 Check the tire pressure X
5.12 Clean the cooling fins on engine and hy- X
draulic oil cooler
5.13 Check the oil level in the drive axle X
5.14 Checking the oil level in left/right wheel X
hubs
5.15 Check the oil level in the vibration bear- X
ings
5.16 Checking, replacing the refrigerant com- X
pressor V-belt
5.17 Change engine oil and oil filter* see foot note X
min. 1x per year
5.18 Drain the fuel tank sludge X
5.19 Battery service pole grease X
5.20 Service the air conditioning X
5.21 Clean the circulation air filter for the heat- X
ing
5.22 Check, adjust the valve clearance Intake: 0.3 mm X
Exhaust: 0.5 mm
BW 211/212/213 D-40/PD40 BOMAG 83

Maintenance


as required
5.23 Replace the fuel filter cartridge X
5.24 Change the fuel pre-filter cartridge X
5.25 Checking / replacing the ribbed V-belt X
5.26 Check the engine mounts X
5.27 Change the oil in the vibration bearings** see foot note X
min. 1x per year
5.28 Change the oil in the drive axle*** see foot note X
min. 1x per year
5.29 Change the oil in the wheel hubs**** see foot note X
min. 1x per year
5.30 Retighten the fastening of the axle on the X
frame
5.31 Tighten the wheel nuts**** see foot note X
5.32 Check the ROPS X
5.33 Check the travel control X
5.34 Changing hydraulic oil and breather fil- at least every 2 years X
ter*****
5.35 Change the hydraulic oil filter***** at least every 2 years X
5.36 Changing the coolant at least every 2 years X
5.37 Check the injection valves X
5.38 Air filter maintenance min. 1x per year, X
Safety cartridge at
least every 2 years
5.39 Adjust the scrapers X
5.40 Clean the machine X
5.41 Adjust the parking brake X
84 BOMAG BW 211/212/213 D-40/PD40

Maintenance


as required
5.42 Change the tires X
5.43 Change the fresh air filter in the cabin X
5.44 Fill the provision tank for the windscreen X
washer system
5.45 Tightening torques X
5.46 Engine conservation X
* oil change after 250 and 500 operating hours, then every 500 operating hours
** Running-in instructions: oil change after 250, 500 and 1000 operating hours, then every 1000 operating hours
*** Running-in instructions: oil change after 250 and 1000 operating hours, then every 1000 operating hours
**** Running-in instructions: oil change after 250 and 1000 operating hours, then every 1000 operating hours
*****Also in case of repair in the hydraulic system.
BW 211/212/213 D-40/PD40 BOMAG 85

Maintenance
86 BOMAG BW 211/212/213 D-40/PD40

Every 10 operating hours
Every 10 operating hou rs
5.6 Check the engine oil level 5.7 Checking the fuel level
! Danger ! Caution
Danger of injury! Do not drive the fuel tank dry, as otherwise the
fuel system needs to be bled.
Support the engine hood for all maintenance
and repair work.
i Note
The machine must be parked horizontally with the
engine shut down.
Fig. 122
l Check the fuel level on the fuel gauge (Fig.

122).
Refuelling
Fig. 121
l Pull the dipstick (Fig. 121) out, wipe it off with ! Danger
a lint-free, clean cloth and reinsert it until it bot- Fire hazard!
toms. When working on the fuel system do not use
l Pull the dipstick back out again. open fire, do not smoke, do not spill any fuel.
l If the oil level is below the "MAX" mark fill in oil. Do not refuel in closed rooms.
l If the oil level is above the “Max” mark deter- Shut down the engine.
mine the cause and drain the oil off.
Danger
!
Caution
! Health hazard!
Before longer work periods you should always Do not inhale any fuel fumes.
top the oil up to the "MAX"-mark.
For quality and quantity of oil refer to the table Caution

!
of fuels and lubricants.

Monitor the entire refuelling process.
For quality and quantity of fuel refer to the "ta-
ble of fuels and lubricants".
Environment
Catch running out fuel, do not let it seep into
the ground.
BW 211/212/213 D-40/PD40 BOMAG 87

5.8 Check the coolant level
! Danger
Danger of scalding!
Fill up coolant only when the engine is cold.
! Caution
If, during the daily inspection the coolant level
is found to have dropped, check all lines, hos-
es and engine for leaks.
Fig. 123
l Shut down the engine. Do not use radiator sealant to seal leaks.
l Clean the area around the filler opening. For quality and quantity of coolant refer to the
"table of fuels and lubricants".
l Open the fuel tank cover (Fig. 123).
! Caution
Contaminated fuel can cause malfunction or
even damage of the engine.
If necessary, fill in fuel through a funnel with
screen.
l Top up with fuel (diesel or winter diesel).
l Screw the fuel tank cover back on.
Fig. 124
l Check the coolant level (Fig. 124).

l To top up unscrew the filler cap and fill in cool-
ant up to the MAX-mark.
88 BOMAG BW 211/212/213 D-40/PD40

5.9 Check the hydraulic oil level 5.10 Check, clean the water sep-
arator
! Caution
In hydraulic systems filled with Panolin HLP ! Danger
Synth. 46 always use the same oil to top up.
Danger of injury!
With other ester based oils consult the lubrica-
tion oil service of the respective oil manufac- Support the engine hood for all maintenance
turer. and repair work.
i Note
The service intervals for the water separator de-
pend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should therefore
check the water separator every day for signs of
water.
If a to high quantity is drained off, the filter must be
refilled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.
Environment
Fig. 125
Catch running out fuel and dispose of environ-
l Check the hydraulic oil level in the inspection
mentally.
glass (Fig. 125).
Normal level
approx. 3 cm below the top edge of the inspection
glass.
Minimum level
Middle of inspection glass.
! Caution
If, during the daily inspection of the oil level
the hydraulic oil level is found to have
dropped, check all lines, hoses and compo-
nents for leaks.
Fig. 126
l If necessary fill in hydraulic oil through the filler
neck. l Slacken the drain plug (Fig. 126) for a few
turns and catch running out fuel / water.
For quality and quantity of oil refer to the table l Tighten the drain plug again and check for
of fuels and lubricants. leaks, if necessary replace the seal ring.
BW 211/212/213 D-40/PD40 BOMAG 89

90 BOMAG BW 211/212/213 D-40/PD40

Every 250 oper ating hours
5.11 Checking the tire pressure 5.12 Clean the cooling fins on
engine and hydraulic oil
! Caution
cooler
Always close the valves with the dust cap.
Danger
!
Danger of injury!
Perform cleaning work only after the engine
has cooled down and with the engine stopped.
Caution
!
Do not damage any cooling fins on the cooler

core when cleaning.
i Note
Dirt on fan blades and oil cooler reduce the cooling
Fig. 127 effect. Dirt deposits in these areas are substantial-
ly supported by oil and fuel on these surfaces. For
l Check the tire pressure with a pressure gauge this reason you should always seal any oil or fuel
and the tire inflation valve 1 (Fig. 127) in top leaks in the vicinity of the cooling fan or the oil
position. cooler and clean the cooling surfaces after.
Nominal value see "Technical Data".
Cleaning with compressed air
i Note
Ensure even pressure in all tires.
l Screw the valve caps back on.
Fig. 128
i Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 128) out with com-
pressed air.
BW 211/212/213 D-40/PD40 BOMAG 91

Cleaning with cold cleansing agent

5.13 Check the oil level in the
! Caution
drive axle
Protect electrical equipment such as genera-
l Park the machine on level ground.
tor, regulator and starter against the direct wa-
ter jet.
l Spray the engine with a suitable cleansing
agent, e.g. cold cleanser, let it soak in for a
while and spray it off with a strong water jet.
l Run the engine warm for a while to avoid cor-
rosion.
Fig. 129
l Unscrew the oil level inspection plug (Fig. 129)

and check the oil level.
i Note
The second level inspection plug as at the back.
After filling in oil wait until the oil has evenly distrib-
uted inside the axle.
The oil level must reach the bottom edge of the
level bore.
l Top up oil, if necessary.
For quality of oil refer to the table of fuels and

lubricants.
l Turn the level inspection plug tightly back in.
92 BOMAG BW 211/212/213 D-40/PD40

5.14 Checking the oil level in left/ 5.15 Check the oil level in the vi-
right wheel hubs bration bearings
i Note
Check only at operating temperature after running
the machine approx. 1/2 hour with vibration.
Caution
!

Make sure that no dirt falls into the exciter
housing.
Fig. 130
l Move the machine until the oil level inspection

plug 1 (Fig. 130) is in horizontal position.
l Clean and unscrew the plug.
The oil level must reach the bottom edge of the
bore.
l Top up oil, if necessary.

lubricants.
l Screw the plug back in tightly.
Fig. 131
l Repeat this inspection on the other side.
l Move the drum, until oil level inspection plug 1
(Fig. 131) on the left hand side of the drum is
in bottom position.
l Thoroughly clean the area around the level in-
spection and filler plug.
l Unscrew level inspection plug (1).
Some oil should run out of the inspection bore.
l If necessary unscrew oil filler plug (2) and fill in
some oil through the oil filler bore (2), until oil
starts to drip out through the inspection bore.

lubricants.
l Screw oil filler (2) and level inspection plug (1)
back in tightly.
l Repeat this inspection on the other side.
BW 211/212/213 D-40/PD40 BOMAG 93

Caution
!
5.16 Checking, replacing the re-
If a loss of oil is found perform trouble shoot-
ing, repair the drum if necessary. frigerant compressor V-
belt*
Danger
!
Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.
Check the V-belt
Fig. 132
l Inspect the entire circumference of the V-belt

(Fig. 132) visually for damage and cracks. Re-
place damaged or cracked V-belts.
l Check with thumb pressure whether the V-belt
can be depressed more than 10 to 15 mm (0.4
– 0.6 inches) between the V-belt pulleys,
retighten if necessary.
94 BOMAG BW 211/212/213 D-40/PD40

Tighten the V-belt.
Fig. 133
l Slightly slacken fastening screws 1, 2 and 3

(Fig. 133).
l Press the compressor in direction of arrow, un-
til the correct V-belt tension is reached.
l Retighten all fastening screws.
Changing the V-belt

l Slightly slacken the fastening screws 1, 2 and
3.
l Press the compressor against the direction of
arrow completely against the engine.
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
! Caution
Check the V-belt tension after a running time of
30 minutes.
BW 211/212/213 D-40/PD40 BOMAG 95

96 BOMAG BW 211/212/213 D-40/PD40

Every 500 oper ating hours
5.17 Changing engine oil and oil

filter
! Danger
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil fil-
ter.
Caution
! Fig. 135
Drain the oil only when the engine is warm. l Thoroughly clean the outside of the filter car-
For quality and quantity of oil refer to the "table tridge (Fig. 135).
of fuels and lubricants". l Unscrew the filter cartridge using an appropri-
ate filter wrench.
Environment l Clean the sealing face on the filter carrier from
Catch running out oil and dispose of environ- any dirt.
mentally together with the oil filter cartridge. l Slightly oil the rubber seal on the new filter car-
tridge.
Fig. 134
l Unscrew the drain plug (Fig. 134) and catch Fig. 136
running out oil. l Turn the new filter cartridge (Fig. 136) on by
l Turn the drain plug tightly back in. hand, until the seal contacts.
l Tighten the filter element for another half turn.
BW 211/212/213 D-40/PD40 BOMAG 97

5.18 Draining the fuel tank

sludge
! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke.
Do not spill any fuel.
Fig. 137
the ground.
l Fill in new engine oil (Fig. 137). Do not inhale any fuel fumes.
l Tighten the oil filler cap properly.

l After a short test run check the oil level on the
dipstick . The oil level should reach the MAX-
mark, top up oil if necessary.
l Check filter cartridge and drain plug for leaks.
Fig. 138
l Unscrew the drain plug (Fig. 138) from the bot-

tom of the fuel tank and drain off approx. 5 li-
tres of fuel.
l Screw the drain plug back in with a new seal-
ing ring.
98 BOMAG BW 211/212/213 D-40/PD40

Caution
5.19 Battery service !
Exhausted batteries (batteries with formation

of sulphate on the plates) are not covered un-
der warranty!
! Danger
Danger of cauterisation ! Danger of explosion! l Remove the battery cover.
When working on the battery do not use open

fire, do not smoke!
The battery contains acid. Do not let acid come
in contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
For recharging remove the plugs from the bat-
tery to avoid the accumulation of highly explo-
sive gases.
Environment
Dispose of the old battery environmentally. Fig. 139
l Remove the battery (Fig. 139) and clean the

i Note battery compartment.
Maintenance free batteries also need care. Main- l Clean the outside of the battery.
tenance free only means that the fluid level does
not need to be checked. Each battery suffers un- l Clean battery poles and pole clamps and
der self-discharge, which may, in not checked oc- grease them with pole grease (Vaseline).
casionally, even cause damage to the battery as a l Check the fastening of the battery.
result of exhaustive discharge.
l On serviceable batteries check the acid level,
The following therefore applies for the service if necessary top up to the filling mark with dis-
life: tilled water.
l Switch off all consumers (e.g. ignition, light, in-
side light, radio).
l Check open-circuit voltage of the battery at
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l Recharge the battery immediately after an
open-circuit voltage of 12.25 V or less is
reached. Do not perform quick charging.
The open-circuit voltage of the battery occurs ap-
prox. 10 hours after the last charging process or
one hour after the last discharge.
l After each charging process allow the battery
to rest for one hour before taking it into service.
l For resting periods of more than one month
you should always disconnect the battery. Do
not forget to perform regular open-circuit volt-
age measurements.
BW 211/212/213 D-40/PD40 BOMAG 99

Checking the refrigerant level

5.20 Service the air conditioning* l Start the engine.
Clean the condenser
Danger
!
Danger of accident!
Do not clean with a hot water jet. Heat will
cause extreme overpressure, which could
cause damage or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
! Caution Fig. 141

A soiled condenser results in a considerable
l Turn the rotary switch for the cab ventilator
reduction of air conditioning power.
(Fig. 141) to position "1".
Under extremely dusty conditions it may be
necessary to clean the condenser several
times per day.
If, during operation of the air conditioning sys-
tem, the warning buzzer sounds switch the air
conditioning off and clean the condenser.
In case of formation of foam have the air con-
ditioning system inspected by the service de-
partment.
Fig. 142
l Choose a cooling temperature with the rotary

switch for the air conditioning system (Fig.
142) in the blue section.
l Open the air outlet nozzles.
l Check, whether the out flowing air is noticea-
bly cooler.
Fig. 140 i Note
l Unscrew the condenser fastening screws (Fig. The adjusted temperature must be below the actu-
140) and fold the condenser forward. al temperature inside the cabin, so that the com-
pressor will be switched on.
l Clean the condenser fins on front and back
with compressed air or cold water .
100 BOMAG BW 211/212/213 D-40/PD40

Checking the moisture level of the dry-

ing agent
Fig. 143
l Check whether the white float (Fig. 143) inside

the inspection glass of the drier/collector unit
floats right at the top. Fig. 145
l Check the moisture indication pearl (Fig. 145)

inside the inspection glass of the drier/collec-
i Note
tor unit.
The refrigerant level is correct.
orange = Drying agent o.k.
colour-
less = moisture level of drying agent too
high.
l Inform the service department. Replace drier/
collector unit, check air conditioning system.
!Caution
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.
Fig. 144
Checking the condition of the drier/col-
lector unit
l If the white float (Fig. 144) inside the inspec-
tion glass of the drier/collector unit floats at the
bottom, inform the service department. !Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeated-
i Note
ly inspected by a specialist. In this sense
The refrigerant level is not correct.
repeated inspections are external examina-
l Refrigerant must be filled up, if necessary tions, normally on pressure reservoirs in oper-
check the air conditioning system for leaks. ation. In connection with this inspection the
drier/collector unit must be visually examined
twice every year. During these inspections
special attention must be paid to corrosion
and mechanical damage. If the reservoir is not
in proper condition it must be replaced for
safety reasons, as a precaution to protect op-
erators and third parties against any danger
BW 211/212/213 D-40/PD40 BOMAG 101

arising from the handling and operation of

pressure reservoirs. 5.21 Cleaning the circulation air
filter for the heating*
! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be re-
placed, to avoid bursting and further damage.
Fig. 147
l Unscrew screws (1) (Fig. 147).

l Pull the filter (2) downwards out.
l Clean the filter, replace if necessary.
Fig. 146
l Assemble the filter and tighten the screws.
l Check the drier/collector unit (Fig. 146) for me-
chanical damage or rust.
102 BOMAG BW 211/212/213 D-40/PD40

5.22 Check, adjust the valve

clearance
! Caution
Before checking the valve clearance let the en-
gine cool down for at least 30 minutes. The en-
gine oil temperature must be less than 80 °C.
After a short test run check the engine for
leaks.
Valve adjustment schematic Fig. 149
Crankshaft position 1 (Fig. 149) (4 cylinder en-

gine)
l Crank the engine with the starter or a spanner
by the V-belt pulley until both valves on cylin-
der 1 are “overlapping”.
Overlapping means: Exhaust valve not yet closed,
intake valve starts to open.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram "crankshaft posi-
tion 1", black mark.
l For control purposes mark the respective rock-
er arm with while chalk once the correspond-
Fig. 148 ing valve is adjusted.
Valve 1 (Fig. 148) white = not adjustable
Valve (2) black = adjustable
Fig. 150
Crankshaft position 2 (Fig. 150) (4 cylinder en-

gine)
l Turn the crankshaft one revolution (360°) fur-
ther.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram "crankshaft posi-
tion 2", black mark.
BW 211/212/213 D-40/PD40 BOMAG 103

Check the valve clearance Adjusting the valve clearance

l Loosen the crankcase ventilation valve and
swing it to the side.
Fig. 153
l Slightly slacken the counter nut. Adjust set-

Fig. 151 screw 7 (Fig. 153) with a screwdriver, until the
l Remove the valve cover (Fig. 151). feeler gauge (6) can be inserted and pulled out
with little resistance after retightening the
l Crankshaft position as per "valve adjustment counter nut.
schematic".
l Perform tests and adjustments on all other ad-
justable valves.
l Check the gasket of the valve cover, replace it
if necessary.
l Reassemble the cylinder head cover.
l Swivel the ventilation valve back to correct po-
sition and fasten it.
l Fasten the air filter again and ensure correct fit
of combustion air hoses and clamps.
Fig. 152
l Check valve clearance 2 (Fig. 152) between

rocker arm (1) and valve (3) with a feeler
gauge.
Intake valve = 0,3 mm
Exhaust valve = 0,5 mm
The feeler gauge must fit with little resistance.
l If the gap is too narrow or too wide for the feel-
er gauge, the valve must be adjusted.
104 BOMAG BW 211/212/213 D-40/PD40

l Fill the filter cartridge with clean diesel fuel.

5.23 Change the fuel filter car-
l Turn the new filter cartridge on by hand, until
tridge the seal contacts.
l Tighten the filter element for another half turn.
! Danger l Check the filter cartridge for leaks after a short

test run.
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.
the ground.
Do not inhale any fuel fumes.
Fig. 154
l Loosen and unscrew the fuel filter cartridge

(Fig. 154) using an appropriate filter wrench.
l Clean the sealing face on the filter carrier from
any dirt.
Fig. 155
l Slightly oil the rubber seal (Fig. 155) on the

new filter cartridge.
BW 211/212/213 D-40/PD40 BOMAG 105

l (2) Loosen and unscrew the fuel pre-filter car-

5.24 Change the fuel pre-filter tridge using an appropriate filter wrench.
cartridge l (3) Unscrew the water separator from the filter
cartridge.
l (4) Apply a thin coat of oil to the rubber seal of
! Danger the water separator.
Fire hazard! Health hazard!
l (5) Turn the water separator on by hand, until
When working on the fuel system do not use the seal contacts, then tighten hand-tight.
open fire, do not smoke and do not spill any fu- l (6) Apply a thin coat of oil to the rubber seal of
el. the filter element (5).
Do not inhale any fuel fumes.
l (7) Turn the filter cartridge on by hand, until the
seal contacts, then tighten hand-tight.
!Caution l Plug the water sensor cable back on.
Ensure strict cleanliness! Thoroughly clean
the area around the fuel filters. Bleed the fuel system
The filter cartridge must never be filled before-
hand.
i Note
After work on the fuel system bleed the sys- Air in the fuel system causes irregular running of
tem, perform a test run and check for leaks. the engine, a drop in engine power, stalls the en-
Additional bleeding of the fuel system by a 5 gine and makes starting impossible.
minute test run in idle speed or low load is
Therefore bleed the fuel system after changing the
mandatory.
fuel pre-filter or working on the fuel system.
Environment
Catch running out fuel and dispose of environ-
mentally.
Change the fuel pre-filter cartridge
Fig. 157
l Slacken the bleeding screw (Fig. 157) on the

fuel pre-filter for 2 to 3 turns.
l Operate the hand pump manually, until fuel
flows out of the slackened bleeding screw
without air bubbles.
Fig. 156
l Then tighten the bleeding screw while pump-
l Tighten the cable on the water separator (Fig. ing.
156).
l Check the filter cartridge for leaks
l (1) Loosen the bleeding screw and drain off
fuel from the bleeding screw.
106 BOMAG BW 211/212/213 D-40/PD40

Changing the ribbed V-belt

5.25 Checking / replacing the
ribbed V-belt
! Danger
Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.
Checking the wear limit of the ribbed V-

belt
Fig. 159
l Unscrew the fastening screws (Fig. 159) and

slide the fan forward.
Fig. 158
l Check the distance between the tongue of the

moveable tensioner arm and the fixed tension-
er housing (Fig. 158).
l If measurement "a" is smaller than 3 mm, re- Fig. 160
place the ribbed V-belt. l Release the idler pulley (Fig. 160) in direction
of arrow until the ribbed V-belt is free.
l Pull the ribbed V-belt first to the smallest pul-
ley.
l Install the new ribbed V-belt.
l Release the idler pulley against the direction
of arrow until the V-belt is tensioned.
l Measure the V-belt tension, tighten if neces-
sary.
i Note
Retighten the new fan V-belt after a running time
of 20 minutes.
BW 211/212/213 D-40/PD40 BOMAG 107

5.26 Check the engine mounts 5.27 Change the oil in the vibra-
tion bearings
! Caution
Change the oil at operating temperature. For
this purpose run the machine approx. half an
hour with vibration.
Caution
!

Make sure that no dirt falls into the exciter
housing.
Fig. 161
Environment
l Tighten fastenings of intake and exhaust man-
ifolds (Fig. 161) on the cylinder heads. Catch running out oil and dispose of environ-
mentally.
l Check sockets and clamps between air filter,
exhaust turbocharger and charge air line as
well as the lubrication air line for tight fit and
leaks.
l Retighten the fastening screws for oil sump
and engine mounts.
Fig. 162
l Move the drum, until the drain plug 1 (Fig. 162)

is in bottom position.
l Thoroughly clean the area around the level in-
spection and filler plug.
l Unscrew the drain plug, let the oil run out and
catch it.
l Turn the oil drain plug back in tightly after all oil
has run out.
108 BOMAG BW 211/212/213 D-40/PD40

5.28 Change the oil in thedrive

axle
! Danger
Danger of scalding when draining off hot oil!
Caution
!
Drain oil only at operating temperature.

For quality and quantity of oil refer to the "table
Fig. 163 of fuels and lubricants".
l Unscrew oil level inspection plug 1 (Fig. 163)
on the drum and fill in oil through the filler Environment
opening (2), until it starts to drip out from the Catch running out oil and dispose of environ-
level inspection bore. mentally.
For quality and quantity of oil refer to the table
of fuels and lubricants. i Note
l Screw oil filler (2) and level inspection plug (1) On other axle versions drain and filler plugs are of
back in tightly. slightly different design. Perform the oil change ac-
cordingly.
l Repeat the oil change on the opposite side.
l Check the oil level once again at operating
temperature (after running the machine for
about half an hour with vibration).
! Caution
Overfilling causes overheating of vibration
bearings!
Fig. 164
l Clean and unscrew all level inspection and

drain plugs (Fig. 164).
l Drain and catch all oil.
l Clean the drain plug and turn it back in with a
new seal ring.
BW 211/212/213 D-40/PD40 BOMAG 109

5.29 Changing the oil in the

wheel hubes
! Danger
Danger of scalding!
Danger of scalding when draining off hot gear
oil!
Caution
!
Fig. 165 Drain oil only at operating temperature.

l Fill in oil through the oil level inspection bores Change the oil on both sides of the axle.
(Fig. 165), until it has reached the bottom edge For quality and quantity of oil refer to the "table
of the bore. of fuels and lubricants".
i Note Environment
The second level inspection plug as at the back. Catch running out oil and dispose of environ-
After filling in oil wait until the oil has evenly distrib- mentally.
uted inside the axle.
l Retighten the filler and level inspection plug.
Fig. 166
l Move the drive wheel, until the plug (Fig. 166)

is in bottom position.
l Clean and unscrew the plug.
l Drain and catch all oil.
110 BOMAG BW 211/212/213 D-40/PD40

5.30 Retighten the fastening of

the axle on the frame
Fig. 167
l Move the drive wheel, until the plug (Fig. 167)

is in horizontal position on the housing.
l Fill in oil, until it reaches the bottom edge of the
bore . Fig. 168
l Turn the plug tightly back in. l Check all fastening nuts on axle mounting
bolts (Fig. 168) for tight fit.
l Change the oil also on the opposite side.
BW 211/212/213 D-40/PD40 BOMAG 111

5.31 Tightening the wheel nuts 5.32 Checking the ROPS
i Note
On machines with a fitted cabin the ROPS (roll
over protection structure) is integrated in the cab-
in.
Please observe also the respective section in the
safety regulations in this manual.
Fig. 169
l Tighten the wheel nuts (Fig. 169) in a cross-

type pattern.
Fig. 170
l Check the cabin, especially the ROPS (Fig.

170) for cracks, corrosion, damage and miss-
ing fastening elements.
i Note
Unusual movements and noises (vibrations) dur-
ing operation indicate damage or loose fastening
elements.
l Check the fastening screws for the cabin
(ROPS) to the operator's platform for tight fit.
l Check the suspension buffers for the opera-
tor's stand for tight fit.
l Check the condition and the fastening of the
seat belt.
112 BOMAG BW 211/212/213 D-40/PD40

5.33 Check the travel control
Fig. 171
l Move the travel lever (Fig. 171) forward, back-

wards and to braking position. Thereby check
for function, light movement, clearance and
damage.
l In case of malfunction perform trouble shoot-
ing and replace the corresponding parts.
!Caution
Only operate the machine after the travel con-
trol has been repaired.
BW 211/212/213 D-40/PD40 BOMAG 113

114 BOMAG BW 211/212/213 D-40/PD40

5.34 Changing hydraulic oil and

breather filter
i Note
See also the notes on the hydraulic system in the
chapter "General notes on maintenance".
Danger
!
Danger of scalding!
When draining off hot hydraulic oil! Fig. 172
l Unscrew the plug (Fig. 172) and drain off all

Caution
! hydraulic oil.
The hydraulic oil must also be changed after l Check the seal ring, replace if necessary and
major repairs in the hydraulic system. turn the plug tightly back in.
Perform the oil change when the hydraulic oil
is warm.
Replace the hydraulic oil filter elements with
every hydraulic oil change.
Change the filter only after the hydraulic oil
change and after the test run.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hy-
draulic oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
Fig. 173
For quality and quantity of oil refer to the "table
of fuels and lubricants". l Remove the filler cap (Fig. 173).
When changing from mineral oil based hydrau- l Fill in new hydraulic oil through the screen.
lic oil to an ester based biologically degradable
oil, you should consult the lubrication oil serv-
ice of the oil manufacturer for details. i Note
We recommend to use the BOMAG filling and fil-
tering unit with fine filter to fill the system. This en-
Environment sures finest filtration of the hydraulic oil, prolongs
Catch running out hydraulic oil and dispose of the lifetime of the hydraulic oil filter and protects
environmentally. the hydraulic system.
l Check the oil level in the inspection glass.
Nominal value:
approx. 3 cm below the upper edge of the inspec-
tion glass
BW 211/212/213 D-40/PD40 BOMAG 115

i Note
5.35 Changing the hydraulic oil
The breather filter for the hydraulic oil tank is inte-
grated in the filler cap. You should therefore re- filter
place the complete filler cap.
l Close the tank with a new cover.
! Danger
Danger of scalding!
There is a danger of scalding by hot oil when
unscrewing the filter.
! Caution
If the filter has to be changed together with the
hydraulic oil, the filter should in any case be
changed after the oil change and the test run.
Do not use the oil in the filter bowl.
Environment
Catch running out oil, dispose of oil and filter
element environmentally.
i Note
The filter element must be changed with every hy-
draulic oil change and after major repairs in the hy-
draulic system.
Fig. 174
l Unscrew the cap nut 4 (Fig. 174) and take the

filter bowl (5) with the filter element (3) off.
l Examine the sealing face on the filter element
thoroughly for any visible dirt.
! Caution
Visible impurities may be an early indicator for
a failure of system components and predict the
116 BOMAG BW 211/212/213 D-40/PD40

possible malfunction of important parts. In

such a case you should perform trouble shoot- 5.36 Changing the coolant
ing and replace or repair the defective compo-
nents. Nonobservance may lead to total
damage of the hydraulic system. ! Danger
Do not clean or reuse the filter element. Danger of scalding!
l Take the old filter element (3) out and clean Change the coolant only when the engine is
the filter bowl and the thread. cold.
l Reinstall the filter bowl with the new filter ele-
ment, check the condition of the O-rings (1) ! Caution
and (2), replace if necessary. Do not start the engine after draining off the
l After a test run check the filter for leaks. coolant.
In case of lubrication oil entering into the cool-
ing system or a suspicious turbidity caused by
corrosion residues or other suspended matter,
the coolant must be drained off and the com-
plete cooling system needs to be cleaned. Lu-
brication oil can damage the sealing materials
used in the engine.
When changing the coolant without any signs
of contamination, cleaning of the cooling sys-
tem is not necessary.
!Caution
For quality and quantity of coolant refer to the
"table of fuels and lubricants".
Do not mix different coolants and additives,
see section "Fuelds and Lubricants - Coolant".
Environment
Catch coolant and dispose of environmentally.
Fig. 175
l Unscrew the cover (Fig. 175) from the com-

pensation tank.
BW 211/212/213 D-40/PD40 BOMAG 117

Fig. 176 Fig. 177
l Unscrew the plug, let the coolant run out and l Fill in coolant (Fig. 177) up to the MAX-mark
catch it (Fig. 176). and screw the filler cap back on.
l Check the condition of the coolant. l Start the diesel engine and run it warm to op-
erating temperature.
!Caution l Check the coolant level again, top up if neces-
Thoroughly flush the cooling system if the sary.
coolant is contaminated by corrosion residues
or other suspended matter.
If lubrication oil has entered you must add a
cleansing agent in order to remove any resi-
dues from the system. Follow the instructions
of the manufacturer. If in doubt consult your
local service station or the engine manufactur-
er.
l Remove the thermostat.
l Fill in clean water.
l Start the diesel engine and run it warm to op-
erating temperature.
l Allow the engine to cool down to approx. 50
°C.
l Drain all water off.
l Repeat the flushing process twice using a
cleansing agent with clear water.
l Screw the plug back in once all coolant has run
out.
l Reinstall the thermostat .
Caution
!
The anti-freeze concentration (additive) must

be at least 35 Vol% and maximum 45 Vol%.
118 BOMAG BW 211/212/213 D-40/PD40

5.37 Checking the injection

valves
i Note
This work must only be performed by authorized
service personnel.
The injection valves must be replaced every
12000 operating hours.
BW 211/212/213 D-40/PD40 BOMAG 119

120 BOMAG BW 211/212/213 D-40/PD40

As required
As r equired
5.38 Air filter maintenance
! Caution
Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter ele-
ment.
Do not use gasoline or hot fluids to clean the
filter element.
After cleaning the filter element must be in-
spected for damage using a torch. Fig. 179
Air filter elements with damaged paper bellows l Open the engine hood (Fig. 179) completely
or seal lips must be replaced in any case. and secure it.
The main filter element must be replaced after
3 times cleaning, but at the latest after one
year, irrespective of the operating hours.
Each cleaning interval must be marked with a
cross on the cover of the filter element.
Cleaning does not make sense if the air filter
element is covered with a sooty deposit. Use a
new filter element.
Incorrectly handled inserts may become inef-
fective because of damage (e.g. cracks) and
cause damage to the engine.
Fig. 180
l Fold three clips up and take the filter hood (Fig.

180) off.
l Clean filter hood and dust discharge valve.
Fig. 178
Servicing of the dry air filter is necessary when the
yellow piston (Fig. 178) has reached the red un-
derlayed inscription "Service", but at the latest af-
ter one year.
l After completion of the filter service reset the
indicator back to "Zero" by pressing the button. Fig. 181
l Carefully loosen the main filter element (Fig.

181).
BW 211/212/213 D-40/PD40 BOMAG 121

As required
The main filter element is located directly on the air Caution

!
intake tube, thereby providing a seal on the inside
of the filter cover. Carefully remove the main filter The safety element must not be cleaned. It
element, in order to reduce the released amount of must be replaced after three times cleaning of
dust. To release the seal pull the main filter ele- the main filter element, but at least once every
ment carefully up, down and sideways or turn it year.
(Fig. 181) . Do not run the engine without an intact safety
and main filter element.
! Caution l Clean or replace the main filter element.
Avoid contact between main filter element and
housing. i Note
We generally recommend to change the filter ele-
ment. A new filter element is far less expensive
than a possible engine damage.
l Examine the main filter element thoroughly for
damage.
Before installing the new main filter element check
it for possible damage from transport, cleaning or
incorrect handling. Especially on the inside of the
open end (sealing area). Do not install damaged
filter elements.
l If necessary use safety elements.
Fig. 182
l Pull the main filter element (Fig. 182) carefully

out of the housing.
Fig. 184
l Insert the main filter element (Fig. 184).

The radial sealing area is located at the inside of
the open filter edge. This critical sealing area must
Fig. 183 be under slight tension after the filter has been in-
l Clean the sealing face on the outlet tube (Fig. stalled. In order to achieve a tight seal apply pres-
183). sure to the outer edge of the filter and not to the
moveable centre.
Dust on the outer diameter of the outlet tube can
impair effective sealing. l Reinstall the filter hood with the dust discharge
valve.
l Check the old main filter element.
l If the main filter element is damaged, the safe-
ty element must be replaced as well.
122 BOMAG BW 211/212/213 D-40/PD40

As required
Caution
!
5.39 Adjusting the scrapers
The dust discharge valve must point vertically
downwards.
smooth drum only
Dry cleaning of the main filter element
! Danger
Eye injury!
Wear protective clothing (goggles, gloves).
Fig. 186
l Check the condition and adjustment of the

front and rear scrapers, adjust or replace the
scraper rubber if necessary.
l To adjust the scrapers 1 (Fig. 186) loosen the
fastening screws (2) in the slots and push the
Fig. 185
scraper bracket towards the drum until the
scraper touches.
i Note
l Retighten the fastening screws.
For cleaning purposes fit a tube to the compressed
air gun (Fig. 185), the end of which should be bent
for approx. 90°.
padfoot drum only
The length should reach down to the bottom of the
element.
l Blow the main filter element out with com-
pressed air (max. 5 bar) from inside to outside
by moving the tube up and down inside the el-
ement, until it if free of dust.
l Examine the main filter element with a torch
for cracks and holes in the paper bellows.
! Caution
Do not continue to use a damaged main filter
element. If in doubt use a new main filter ele-
Fig. 187
ment.
l Check condition and adjustment of scrapers 2
(Fig. 187), adjust or replace the teeth if neces-
sary.
l To adjust the scrapers (2) slacken the fasten-
ing screws (1) in the slots and move the scrap-
BW 211/212/213 D-40/PD40 BOMAG 123

As required
er towards the drum, leaving a gap of approx.

25 mm. 5.40 Clean the machine
l Retighten the fastening screws.
! Caution
When using a steam cleaner for cleaning do
not subject electrical parts and insulation ma-
terial to the direct jet or cover these items be-
forehand.
Allow the engine to cool down before cleaning.
Fig. 188
l Clean the machine (Fig. 188) thoroughly at

least once per week.
When used on highly cohesive soils, on cement or
trass-lime mortar or for similar work, the machine
must be thoroughly cleaned every day.
Please observe that the correct function of the
scrapers is ensured and that no material will build
up between rollers and frame.
124 BOMAG BW 211/212/213 D-40/PD40

As required
5.41 Adjust the parking brake
! Caution
Have adjustment work on the brakes only car-
ried out by a specialist! Always adjust both
sides.
l Secure the machine with wheel chocks
against rolling.
l Start the diesel engine to relieve the brake.
Fig. 191
l In order to adjust the brake clearance turn the

square 1 (Fig. 191) three turns back in clock-
wise direction.
l Fasten the locking plate again.
l Pull the plug off the brake solenoid valve and
perform the drive test.
The machine must be braked.
Fig. 189
l Disengage the travel lever (Fig. 189) to the

left, but do not move to position "I" or "II".
The parking brake is released
Fig. 190
l Unscrew locking plate 2 (Fig. 190).

l Turn the square (1) in anti-clockwise direction
against the stop.
BW 211/212/213 D-40/PD40 BOMAG 125

As required
5.42 Changing the tires 5.43 Change the fresh air filter in
the cabin
! Danger
Danger of accident!
Observe all safety notes for the lifting of loads.
l Place a jack (min. 5 t bearing capacity) under
the rear frame and jack the machine up so that
the wheel can turn freely.
l Unscrew the wheel nuts and take the wheel
off.
Fig. 193
l Unscrew fastening screws for the ventilation

grid (Fig. 193) and remove the filter.
l Insert a new filter and reassemble the ventila-
tion grid.
Fig. 192
l Attach the wheel (Fig. 192) and tighten the

wheel nuts crosswise with 550 Nm (405 ft. lb.).
l Check the tire pressure, see technical data.
126 BOMAG BW 211/212/213 D-40/PD40

As required
5.44 Fill the provision tank for 5.45 Tightening torques

the windscreen washer*
system
Fig. 195
* Strength classes for screws with untreated, non-
lubricated surface. Screw quality designations are
stamped on the screw heads.
8.8 = 8G
Fig. 194
10.9 = 10K
l Check the fluid level in the tank (Fig. 194), top
up if necessary. 12.9 = 12K
l For winter operation fill in the appropriate l Axle - frame

amount of ant-freeze agent; refer to the speci- M 22x1.5 = 710 Nm
fications of the manufacturer of the ant-freeze
l Wheel nuts
agent.
M 22x1.5 = 550 Nm
The values result in a 90% utilization of the screw
yield point at a coefficient of friction μ total = 0,14.
When using lubricant MOS2 the specified tighten-
ing torques do not apply.
i Note
Self-locking nuts must always be replaced once
they have been unscrewed.
BW 211/212/213 D-40/PD40 BOMAG 127

As required
5.46 Engine conservation

If the engine is to be shut down for a longer period
of time (e.g. over winter), please consult the serv-
ice department of the engine manufacturer for fur-
ther details.
128 BOMAG BW 211/212/213 D-40/PD40

6 Trouble shooting
BW 211/212/213 D-40/PD40 BOMAG 129

Trouble shooting
6.1 General notes 6.2 Reading out faults BVC/

BTM05
The following work must only be carried out by
qualified and trained personnel or by the sales
service.
Please observe strictly the safety regulations

in chapter 2 of these operating and mainte-
nance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serv-
iced. Therefore, whenever a fault occurs, read
through these instructions on correct operation
and maintenance. If you cannot locate the cause
of the fault or eliminate it yourself by following the
trouble shooting charts, you should contact our
customer service departments at our branch office
or dealers. Fig. 196

! Danger
Danger of injury!
Keep away from rotating parts of the engine.
Fig. 197
i Note
130 BOMAG BW 211/212/213 D-40/PD40

Trouble shooting
Fig. 198
l Press key "F5" (diagnostics) (Fig. 198).
i Note
The screen with the currently available fault codes
is displayed.
Fig. 199
l Currently present faults are indicated by a cor-

responding fault code in the field "Actual Er-
rors".
l Press key "ESC" (Fig. 199) to leave the screen
page with the actual fault codes.
BW 211/212/213 D-40/PD40 BOMAG 131

Trouble shooting
6.3 Engine
Faults Possible cause Remedy
The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank
Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.
Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.
Fuel lines leaking Check all line connections for leakages

and tighten the fittings.
Battery discharged or not connected Tighten the pole clamps, check the cable
connections
Injection valves or injection pump defec- Have examined by a specialist

tive
The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature
Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Incorrect valve clearance Adjust the valve clearance
Injection valve defective Have examined by a specialist
Injection lines leaking Check the lines for leakages
Turbo charger defective Have examined by a specialist
Dry air filter dirty clean, replace if necessary
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary
132 BOMAG BW 211/212/213 D-40/PD40

Trouble shooting
Faults Possible cause Remedy
Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance
Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Engine oil level too low Top up engine oil to the upper dipstick
mark
Filling capacity of the injection pump not Have adjusted by a specialist

correctly adjusted
Cooling air flow restricted Clean the cooling air duct
V-belt loos or broken Tension or replace the V-belt
Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark
Dry air filter dirty clean, change if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Charge air hose leaking Check fastening and connections
Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine oil pressure" lights, the warning
buzzer sounds)
Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective
BW 211/212/213 D-40/PD40 BOMAG 133

Trouble shooting
134 BOMAG BW 211/212/213 D-40/PD40

7 Cab assembly before initial start-up
BW 211/212/213 D-40/PD40 BOMAG 135

Cab assembly before initial start-up
General safety regulations for assem- The manufacturer explicitly excludes any liability
bly for damage caused by the use of non-original
parts or accessories.
When installing the cabin to your machine you
must strictly comply with the valid accident Notes on safety in the assembly in-
prevention instructions or the country specific
structions
regulations. However, dangers for persons
and property may still arise, if:
l the lifting gear used has a too low bearing ca- ! Danger
pacity Paragraphs marked like this highlight possible
dangers for persons.
l damaged or worn lifting tackle is used
l unqualified personnel is entrusted with the in-
Caution
!
stallation
Paragraphs marked like this highlight possible
l the safety instructions are not observed dangers for machines or parts of the machine.
Each person involved in the installation of the
cabin must therefore read and comply with i Note
these safety regulations. If necessary, the cus-
Paragraphs marked like this contains technical in-
tomer must demand a written confirmation
formation and hints for optimal assembly.
with signature.
Moreover, the following instructions and regula-
tions must obviously also be complied with: Environment
Paragraphs marked like this point out practic-
l applicable accident prevention instructions
es for safe and environmental disposal of fuels
l generally accepted safety and road traffic reg- and lubricants as well as replacement parts.
ulations
Strictly observe the national regulations for
l country specific safety regulations. It is the the protection of the environment.
duty of the operator to be acquainted with
these instructions and to apply these accord- Information and safety stickers/decals
ingly. This applies also for local regulations
concerning different types of handling work.
on the cabin
Should the recommendations in these instruc- Keep stickers/decals in good and legible condition
tions be different from the regulations valid in (see spare parts catalogue) and comply with their
your country, you must comply with the safety meaning.
regulations valid in your country. Replace damaged stickers/decals
Changes and conversions to the cabin/ Work on heating lines

machine
Before starting work on heating pipes relieve any
Unauthorized changes to the cabin are prohibited pressure and let them cool down - danger of scald-
for safety reasons. ing!
Original parts and accessories have been special- After completing work on the heating system of the
ly designed for this machine. We wish to make ex- machine check all connections and fittings for
plicitly clear that we have not tested or approved leaks.
any parts or accessories not supplied by us. The
installation and/or use of such products may have Working on electric parts of the ma-
an adverse effect on the active and/or passive
driving safety.
chine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
136 BOMAG BW 211/212/213 D-40/PD40

Do not use fuses with higher ampere ratings and

do not repair fuses with a piece of wire. Fire haz- 7.1 Preparations
ard.
! Danger
Danger of accident!
For transport purposes the driver's seat must
be tied down with cable straps thus to operate
the seat contact switch. Before resuming oper-
ation of the machine these cable straps must
strictly be removed to ensure safe and reliable
function of the seat contact switch.
Check the 4 lifting eyes on the cabin roof for
tight fit.
Fasten the lifting gear to all four lifting eyes.
Use lifting gear (chains or ropes) of sufficient
load bearing capacity. The minimum load bear-
ing capacity of the crane must be 1000 kg.
Fig. 200
l Make sure that all fastening screws, washers,

spacers and nuts to fasten the cabin are avail-
able (Fig. 200).
l Check whether rear rack, foot mat, step plate
and fastening kit are available.
BW 211/212/213 D-40/PD40 BOMAG 137

7.2 Cabin assembly
! Danger
Danger of accident!
Use lifting gear (chains or ropes) of sufficient
load bearing capacity. The minimum load bear-
ing capacity of the crane must be 1000 kg.
l Clean the operator's stand of dirt, oil and mois-
ture.
Fig. 201
l Fasten the lifting gear to the four lifting eyes 1

(Fig. 201).
l Loosen possible fastening on the transport
pallet.
l Slowly list the crane with a crane.
Danger
!
Danger of accident!
Fig. 202
l Stick the supplied sealing tape 1 (Fig. 202)

along the edge of the operator's stand.
! Caution
Only unroll and stick the sealing tape on just
before mounting the cab to the operator's
stand. The sealing tape will swell a few min-
utes after being unrolled. In this case the cabin
can no longer be mounted!
138 BOMAG BW 211/212/213 D-40/PD40

Fig. 203 Fig. 205
l Stick the sealing tape 1 (Fig. 203) all around l Slowly lower the cabin vertically to the opera-
the operator's stand. tor's stand (Fig. 205).
l Do not run the sealing tape across the front re-
cess in the operator's stand (2), since this is Caution
!
the air inlet for the cabin ventilation. The cabin must be lowered vertically onto the
operator's stand.
i Note
Mount the cabin immediately after sticking on the
sealing tape, because the sealing tape will swell.
Fig. 206
! Caution
Fig. 204
Take care that none of the hoses and electric
l Spray the sealing tape with soapsuds (Fig. cables become squashed (Fig. 206).
204), to be able to slide the cabin on the oper-
l Run cables and hoses from inside the cabin
ator's stand.
through the operator's stand to the outside.
BW 211/212/213 D-40/PD40 BOMAG 139

Fig. 207 Fig. 209
l Turn both fastening screws (Fig. 207) at the l Tighten the bottom fastening screw on the ac-
rear of the cabin in hand tight. cess side (Fig. 209) with 578 Nm.
Fig. 208 Fig. 210
l Loosen both fastening screws (Fig. 210) at the

i Note rear of the cabin again.
If the bores do not match the cabin can be moved
into position by means of a crow bar (Fig. 208). i Note
The cabin will now slide into final assembly posi-
tion.
l Tighten both fastening screws (Fig. 210) at the
rear of the cabin with 578 Nm.
140 BOMAG BW 211/212/213 D-40/PD40

Fig. 211 Fig. 214
l Tighten the rear lateral fastening screw on the l Turn nuts with washers onto both studs and
left hand side with 578 Nm (Fig. 211). tighten with 200 Nm (Fig. 214).
Fig. 212 Fig. 215
l Tighten the rear lateral fastening screw on the l Tighten the front lateral fastening screw on the
right hand side with 578 Nm (Fig. 212). right hand side with 578 Nm (Fig. 215).
Fig. 213 Fig. 216
l Tighten the rear inside fastening screw on the l Tighten the front lateral fastening screw on the
right hand side with 578 Nm (Fig. 213). left hand side with 578 Nm (Fig. 216).
BW 211/212/213 D-40/PD40 BOMAG 141

Fig. 217 Fig. 220
l Cover all lateral fastening screws with plastic l Insert the dashboard and fasten it with four
caps (Fig. 217). fastening screws (Fig. 220).
Fig. 218 Fig. 221
l Insert the foot mat 1 (Fig. 218). l Remove all cable straps from the seat console
(Fig. 221) to activate the seat contact switch.
Fig. 219
Fig. 222
l Attach the step plate 1 (Fig. 219) and tighten
the three fastening screws (2). l Insert the rear rack and knock both plastic fas-
teners carefully into the bores with a hammer
(Fig. 222).
142 BOMAG BW 211/212/213 D-40/PD40

Fig. 223 Fig. 225
l Connect the feed 1 (Fig. 223) and the return l Plug on the hoses for the washing water sup-
flow (2) for the air conditioning system with ply to front and rear windscreens 1 (Fig. 225).
quick release couplings.
l Connect the feed (4) and the return flow (3) of i Note
the heating. (Observe the marks on the hos- Check the function of the washing water system
es). within the scope of the function test.
i Note
Run the connecting lines for the heating parallel to
each other (do not cross).
i Note
Check the function of air conditioning and heating
within the scope of the function test.
Observe identical hose diameters when connect-
ing.
Fig. 226
l Insert the plug 1 (Fig. 226) into the socket (2).

l Close the bayonet catch by turning the corru-
gated cap nut in clockwise direction against
the stop.
! Danger
Before starting to work on electric parts of the
machine disconnect the battery and cover it
with insulating material.
Fig. 224
l Plug on both connecting plugs for the washing

water pumps (Fig. 224).
BW 211/212/213 D-40/PD40 BOMAG 143

7.3 Final function tests and

checks
! Caution
Make sure that all screws have been tightened
with the specified torque.
i Note
After the cabin assembly the following tests must
be performed to assure that all cables and lines
Fig. 227 are correctly connected.
l Connect the plug connection of the air condi- l Insert the ignition key and turn clockwise to po-
tioning system (Fig. 227). sition "1".
l Operate the switches for headlights, direction
indicators and interior light to check their func-
tion.
l Operate the switches for front and rear wind-
screen washer system and check their correct
function.
i Note
If the function of the windscreen washer system is
reversed, the two washing water hoses must be in-
terchanged.
l Start the engine.
l Switch the air conditioning on by the switch.
After a five minute operation the cabin must
become noticeably cooler.
l Switch the air heater on by the switch. After a
five minute operation the cabin must become
noticeably warmer.
l Function of the seat contact switch.
Caution
!
The machine must not be operated if the seat

contact switch is not functioning correctly.
144 BOMAG BW 211/212/213 D-40/PD40

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Operating instructions

BW 211 / 212 / 213 D-40

Single drum roller

No warranty claims can be lodged in case of dam-

BW 211/212/213 D-40/PD40 BOMAG 3

4 BOMAG BW 211/212/213 D-40/PD40

BW 211/212/213 D-40/PD40 BOMAG 5

5.7 Checking the fuel level 87

6 BOMAG BW 211/212/213 D-40/PD40

6.2 Reading out faults BVC/BTM05 130

BW 211/212/213 D-40/PD40 BOMAG 7

8 BOMAG BW 211/212/213 D-40/PD40

BW 211/212/213 D-40/PD40 BOMAG 9

* BW 211 D-40 BW 211 PD-40

10 BOMAG BW 211/212/213 D-40/PD40

* BW 211 D-40 BW 211 PD-40

BW 211/212/213 D-40/PD40 BOMAG 11

* BW 212 D-40 BW 212 PD-40

12 BOMAG BW 211/212/213 D-40/PD40

* BW 212 D-40 BW 212 PD-40

BW 211/212/213 D-40/PD40 BOMAG 13

* BW 213 D-40 BW 213 PD-40

14 BOMAG BW 211/212/213 D-40/PD40

* BW 213 D-40 BW 213 PD-40

BW 211/212/213 D-40/PD40 BOMAG 15

16 BOMAG BW 211/212/213 D-40/PD40

BW 211/212/213 D-40/PD40 BOMAG 17

General Examples for unintended use are:

18 BOMAG BW 211/212/213 D-40/PD40

Persons under the influence of alcohol, medicine Environment

BW 211/212/213 D-40/PD40 BOMAG 19

Check before mounting the machine if: Starting in closed rooms

20 BOMAG BW 211/212/213 D-40/PD40

Always keep a sufficient distance to excavation Behaviour in traffic

BW 211/212/213 D-40/PD40 BOMAG 21

Checking the effect of vibration Fire protection measures

22 BOMAG BW 211/212/213 D-40/PD40

BW 211/212/213 D-40/PD40 BOMAG 23

24 BOMAG BW 211/212/213 D-40/PD40

Stickers and decals

1 Warning sticker "Danger of crushing"

BW 211/212/213 D-40/PD40 BOMAG 25

Information sticker "Emergency exit"

Information sticker "Bio Hydraulic Oil"*

* Optional equipment ** Optional equipment

26 BOMAG BW 211/212/213 D-40/PD40

BW 211/212/213 D-40/PD40 BOMAG 27

28 BOMAG BW 211/212/213 D-40/PD40

1 Start switch 10 Rotary switch for travel ranges

BW 211/212/213 D-40/PD40 BOMAG 29

3.1 General notes 3.2 Description of indicators

30 BOMAG BW 211/212/213 D-40/PD40

BW 211/212/213 D-40/PD40 BOMAG 31

32 BOMAG BW 211/212/213 D-40/PD40

unlock = turn the button clockwise and

Danger of accident! No. 13 = Rotary momentary contact switch for

BW 211/212/213 D-40/PD40 BOMAG 33

Position "left" = Hazard light system switched

34 BOMAG BW 211/212/213 D-40/PD40

Fig. 29 No. 20 = Fuses in electric junction box

Position red Fire hazard!

* Optional equipment ** Optional equipment

BW 211/212/213 D-40/PD40 BOMAG 35