O&M BW211 BW212

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Operating instructionsMaintenance instructions

Catalogue number

008 158 81 08/2006

BW 211 / 212 / 213 D-40

BW 211 / 212 / 213 PD-40S/N 101 582 42 . . . . S/N 101 582 43 . . . . S/N 101 582 44 . . . .

S/N 101 582 47 . . . . S/N 101 582 48 . . . . S/N 101 582 49 . . . .

Single drum roller

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Foreword

BOMAG 3BW 211/212/213 D-40

Foreword

BOMAG machines are products from the wide

range of BOMAG compaction equipment.

BOMAG’s vast experience in connection with

state-of-the-art production and testing meth-ods, such as lifetime tests of all important

components and highest quality demands

guarantee maximum reliability of your ma-

chine.

This manual comprises:

l Safety regulations

l Operating instructions

l Maintenance instructions

l Trouble shooting

Using these instructions will

l help you to become familiar with the machine.

l avoid malfunctions caused by unprofessional

operation.

Compliance with the maintenance instructions will

l enhance the reliability of the machine on con-

struction sites,

l prolong the lifetime of the machine,

l reduce repair costs and downtimes.

BOMAG GmbH will not assume liability for the

function of the machine

l if it is handled in a way not complying with the

usual modes of use,

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

provided container. These operating and mainte-

nance instructions are part of the machine.

You should only operate the machine after you

have been instructed and in compliance with these

instructions.

Strictly observe the safety regulations.Please observe also the guidelines of the Civil En-

gineering Liability Association ”Safety Rules for

the Operation of Road Rollers and Soil Compac-

tors” and all relevant accident prevention regula-

tions.

For your own personal safety you should only

use original spare parts from BOMAG.

In the course of technical development we re-

serve the right for technical modifications

without prior notification.

These operating and maintenance instructions are

also available in other languages.

Apart from that, the spare parts catalogue is avail-

able from your BOMAG dealer against the serial

number of your machine.

Your BOMAG dealer will also supply you with in-

formation about the correct use of our machines in

soil and asphalt construction.

The above notes do not constitute an extension of

the warranty and liability conditions specified in the

general terms of business of BOMAG GmbH.

We wish you successful work with your BOMAG

machine.

BOMAG GmbH

Printed in Germany

Copyright by BOMAG

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Foreword

BOMAG4 BW 211/212/213 D-40

Please fill in

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine type (Fig. 1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial No. (Fig. 1 and 2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine type (Fig. 3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine No. (Fig. 3)

i Note

Fill in the above listed data when receiving the ma-

chine.Upon receipt of the machine our organization will

instruct you about correct operation and mainte-

nance.

Please observe strictly all safety regulations and

notes on potential dangers!

Fig. 1

Fig. 2

Fig. 3

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Table of Contents

BOMAG 5BW 211/212/213 D-40

Technical Data 7

Safety regulations 15

Indicators and Controls 23

3.1 General notes 26

3.2 Description of indicators and control elements 26

3.3 Display and control elements BTM 36

3.4 Description of indicating and control elements

BTM 38

3.5 Line diagram (EVIB) 40

3.6 Description of line diagram (EVIB) 42

3.7 Bar diagram (EVIB) 43

Operation 45


4.2 Tests before starting to operate 46

4.3 Disarming the anti-theft protection 47

4.4 Starting the engine 48

4.5 Starting with jump wires 50

4.6 Driving the machine 50

4.7 Switching the vibration on and off 52

4.8 Operating the parking brake, stopping the machine 53

4.9 Shutting the engine down 54

4.10 Emergency exit 55

4.11 Adjusting the steering wheel 55

4.12 Adjusting the seat 56

4.13 Operating the hood 56

4.14 Towing in case of an engine failure 57

4.15 Transport 59

4.16 Measuring pass with BTM 61

4.17 Finishing compaction of a track 64

4.18 Printing measuri ng d ata afte r completing compaction 65

4.19 Changing the paper roll in the measuring va lue printer 66

4.20 Changing the printer ribbon in the measuring value printer 67Maintenance 69

5.1 General notes on maintenance 70

5.2 Fuels and lubricants 71

5.3 Table of fuels and lubricants 74

5.4 Running-in instructions 75

5.5 Maintenance chart 76

5.6 Check the engine oil level 79

5.7 Check, clean the water separator 79

5.8 Checking the fuel level 80

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Table of Contents

BOMAG6 BW 211/212/213 D-40

5.9 Checking the hydraulic oil level 81

5.10 Checking the coolant level 81

5.11 Checking the dust separator on the oil bath air filter 82

5.12 Checking the tire pressure 83

5.13 Clean the cooling fins on engine and hydraulic oil cooler 83

5.14 Check the oil level in the drive axle 84

5.15 Checking the oil level in left/right wheel hubs 85

5.16 Checking the oil le ve l in the vibration bearing ho usi ngs 85

5.17 Changing engine oil and oil filter cartridges 86

5.18 Draining the fuel tank sludge 87

5.19 Service the battery 88

5.20 Check condition and tension of refrigerant compressor V-belt, replace the V-

belt 89

5.21 Servicing the air conditioning 90

5.22 Check, adjust the valve clearance 93

5.23 Checking / replacing the ribbed V-belt 95

5.24 Change the fuel filter cartridge 96

5.25 Change the fuel pre-filter cartridge 97

5.26 Check the engine mounts 98

5.27 Change the oil in the drive axle 99

5.28 Changing the oil in the wheel hubs 100

5.29 Changing the oil for the vibration bearings 101

5.30 Retighten the fastening of the axle on the frame 102

5.31 Tightening the wheel nuts 102

5.32 Checking the ROPS 103

5.33 Cleaning the oil bath air filter 103

5.34 Changing the hydraulic oil and the breather filter 104

5.35 Changing the hydraulic oil filter 105

5.36 Changing the coolant 106

5.37 Checking the injection valves 108

5.38 Cleaning, changing the dry air filter cartridge 109

5.39 Adjusting the scrapers 111

5.40 Adjusting the parking brake 112

5.41 Changing the tires 113

5.42 Changing the fresh air filter in the cabin 114

5.43 Tightening torques 114

5.44 Engine conservation 115

Trouble shooting 117


6.2 Engine 119

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BOMAG 7BW 211/212/213 D-40

1 Technical Data

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Technical Data

BOMAG8 BW 211/212/213 D-40

Fig. 4

Dimensions i n

mm

A B D H H2 K L O1 O2 S W

BW 211 D-40 2960 2250 1500 2268 2972 490 5840 60 60 25 2130

BW 211 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130

* BW 211 D-40 BW 211 PD-40

Weights

Operating weight (CECE)

with ROPS and cabin

kg 9500 10500

Axle load, drum (CECE) kg 5750 6750

Rear axle load (CECE) kg 3750 3750

Static linear load kg/cm 27 -

Travel characteristics

Travel speed (1) km/h 0 ... 6 0 ... 6

Travel speed (2) km/h 0 ... 10 0 ... 10

Max. gradability (depend-

ing on soil)

% 45 49

Engine

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

Rated speed 1 rpm 2300 2300

Fuel Diesel Diesel

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Technical Data

BOMAG 9BW 211/212/213 D-40

Electrical equipment V 12 12

Drive system hydrostatic hydrostatic

Driven axles 2 2

Brakes

Service brake hydrostatic hydrostatic

Parking brake hydr.-mech. hydr.-mech.

Steering

Type of steering articulated articulated

Steering operation hydrostatic hydrostatic

Vibration

Vibrating drum 1 1Drive system hydrostatic hydrostatic

Frequency Hz 30/36 30/36

Amplitude mm 1,8/0,9 1,64/0,82

Tires

Tire size 23.1-26/12 PR TL C7 23.1-26/12TL R1

Air pressure bar 1,4 1,4

Filling capacities

Engine Litres 10 10

Fuel Litres 250 250

Hydraulic oil Litres 60 60Coolant Litres 16 16

* The right for technical modifications remains reserved

* BW 211 D-40 BW 211 PD-40

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Technical Data

BOMAG10 BW 211/212/213 D-40

Fig. 5

Dimensions i n

mm


BW 212 D-40 2960 2250 1500 2268 2972 490 5840 60 60 25 2130

BW 212 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130

* BW 212 D-40 BW 212 PD-40

Weights


with ROPS and cabin

kg 10900 11350



Static linear load kg/cm 33,6 -


Travel speed (1) km/h 0 ... 6 0 ... 6

Travel speed (2) km/h 0 ... 10 0 ... 10


ing on soil)

% 45 49

Engine



Cooling Water Water


Rated power DIN ISO

3046

kW 98 98


Fuel Diesel Diesel

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Technical Data

BOMAG 11BW 211/212/213 D-40



Driven axles 2 2

Brakes



Steering



Vibration



Amplitude mm 1,8/0,9 1,64/0,82

Tires



Filling capacities

Engine Litres 10 10

Fuel Litres 250 250



* BW 212 D-40 BW 212 PD-40

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Technical Data

BOMAG12 BW 211/212/213 D-40

Fig. 6

Dimensions i n

mm


BW 213 D-40 2960 2250 1500 2268 2972 490 5840 60 60 35 2130

BW 213 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130

* BW 213 D-40 BW 213 PD-40

Weights


with ROPS and cabin

kg 12420 12870



Static linear load kg/cm 36,7 -


Travel speed (1) km/h 0 ... 6 0 ... 6

Travel speed (2) km/h 0 ... 10 0 ... 10


ing on soil)

% 45 49

Engine



Cooling Water Water


Rated power DIN ISO

3046

kW 98 98


Fuel Diesel Diesel

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Technical Data

BOMAG 13BW 211/212/213 D-40



Driven axles 2 2

Brakes



Steering



Vibration



Amplitude mm 1,8/0,9 1,64/0,82

Tires



Filling capacities

Engine Litres 10 10

Fuel Litres 250 250



* BW 213 D-40 BW 213 PD-40

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Technical Data

BOMAG14 BW 211/212/213 D-40

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BOMAG 15BW 211/212/213 D-40

2 Safety regulations

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Safety regulations

BOMAG16 BW 211/212/213 D-40

General

This BOMAG machine is built in accordance

with the latest technical standard and the valid

technical rules and regulations. There is, how-

ever, a risk of danger for persons and property

if:

l the machine is used for purposes other than

those it is intended for

l the machine is operated by untrained person-

nel

l the machine is modified or converted in an un-

professional way

l the applicable safety regulations are not ob-

served.

Each person involved in operation, mainte-

nance and repair of the machine must there-

fore read and apply these safety regulations.

This should be confirmed by obtaining the sig-

natures of the customer, if necessary.

Furthermore the following regulations and instruc-

tions are obviously also valid:

l applicable accident prevention instructions

l generally acknowledged safety and road traffic

regulations

l country specific safety regulations. It is the

duty of the operator to know and observe

these regulations. This applies also for local

regulations and the regulations for various

types of manual work. If the recommendations

in this manual differ from the regulations valid

in your country, you must strictly observe the

regulations in your country.

Intended use

This machine must only be used for:

l compaction of bituminous materials, e.g. road

surface layers. (AC and AD machines only)

l medium and heavy compaction tasks in earth

work (road sub-bases)

l This machine must only be operated with fully

functional safety equipment.

l The machine should be checked by an expert

once every year.

Unintended use

Dangers may, however, arise from the machine if

it is used by untrained personnel in an unprofes-

sional way or if it is used for purposes other thanthose mentioned in these instructions.

Do not work with vibration on hard concrete, on a

cured concrete layer or heavily frozen ground.

Starting and operation of the machine in an explo-

sive environment is prohibited.

Who is allowed to work with the ma-chine?

The machine must only be operated by trained

and authorized persons which are at least 18

years of age. The responsibilities for the operationof the machine must be clearly specified and com-

plied with.

Persons under the influence of alcohol, medica-

tion or drugs must not operate, service or repair

the machine.

Maintenance and repair tasks require specific

knowledge and must therefore only be carried out

by trained and qualified personnel.

Conversions and alterations to the ma-

chineUnauthorized conversions to the machine are pro-

hibited for safety reasons.

Original parts and accessories have been special-

ly designed for this machine. We wish to make ex-

pressly clear that we have not tested or authorized

any original parts or special equipment not sup-

plied by us. The installation and/or use of such

products can impair the active and/or passive driv-

ing safety. The manufacturer expressly excludes

any liability for damage resulting from the use of

non-original parts or accessories.

Safety notes in the operating and main-tenance instructions:

! Danger

Sections marked like this point out possible

dangers for persons.

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Safety regulations

BOMAG 17BW 211/212/213 D-40

! Caution

Sections marked like this point out possible

dangers for the machine or for parts of the ma-

chine.

i Note

Sections marked like this provide technical infor-

mation concerning the optimal economical use of

the machine.

Environment

Sections marked like this highlight activities

for the safe and environmental disposal of fu-

els and lubricants as well as replaced parts.

Observe all environment protection regula-

tions.

Information and safety stickers/decalson the machine

Keep stickers/decals complete (see spare parts

catalogue) and fully legible and observe their

meaning.

Replace damaged or illegible stickers/decals im-

mediately.

Loading the machine

Use only strong and stable loading ramps. The

ramp inclination must be lower than the gradability

of the machine.

Secure the machine against turning over or slip-

ping off.

Secure the machine on the transport vehicle

against rolling off, slipping and turning over.

Persons are highly endangered if

l they step or stand under loads being lifted

l they remain in the drive range of the machine

during a demonstration or during loading.

The machine must not swing about when lifted off

the ground.

Use only safe lifting gear of sufficient load bearing

capacity.

Attach the lifting gear only to the specified lifting

points.

Towing the machine

You should generally use a tow bar.

Max. towing speed 1 km/h (1.6 mph), max. towing

distance 500 m (1640 ft.).

Before releasing the multi-disc brakes secure the

machine properly against unintended rolling.

Checking the Roll Over ProtectionStructure (ROPS)

i Note

On machines with cabin the ROPS is an integral

part of the cabin.

The machine frame must not be distorted, bent orcracked in the area of the ROPS fastening points.

The ROPS must not show any signs of corrosion,

damage, hairline cracks or open fractures.

The ROPS must not rattle about during driving.

This would mean that it is not properly fastened.

All bolted connections must be in accordance with

the prescribed specifications and correctly tight-

ened (observe the tightening torque values).

Screws and nuts must not be damaged, bent or

deformed.

With the cabin installed check also the condition ofthe cabin mounts (rubber elements and screws).

Neither must any additional parts be welded or

bolted on, nor must anyholes be drilled without the

permission of the manufacturer, since this may im-

pair the strength of the structure.

Starting the machine

Before starting

Operation of the machine is only permitted when

sitting in the operator's seat.

Use only machines which have been properly

serviced at regular intervals.

Become acquainted with the equipment, the con-

trol elements, the working mode of the machine

and the area you will be working in.

Use your personal protective outfit (hard hat, safe-

ty boots etc.).

Check before mounting the machine if:

l there are persons or obstructions beside or

under the machine

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Safety regulations

BOMAG18 BW 211/212/213 D-40

l the machine is free of anyoily and combustible

material

l all handrails, steps and platforms are free of

grease, oils, fuels, dirt, snow and ice

l the engine compartment hood is closed and

locked

To climb onto the machine use steps and hand-

rails.

Check before starting, whether:

l the machine shows any obvious defects

l all protective devices are properly secured in

their place

l steering, brakes, control elements, lighting

and warning horn are in order

l the seat is correctly adjusted

l the mirrors (if available) are clean and correct-

ly adjusted.

Do not start the machine if any gauges, control

lights or controls are defective.

Do not take any loose objects with you or fasten

them to the machine.

On machines with ROPS you should always wear

your seat belt!

Starting

Start and operate the machine only from the oper-

ator's seat

For starting set all control levers to "neutral posi-

tion".

Do not use any starting aids such as Start Pilot or

ether.

After starting check all gauges.

Starting with jump leads

Connect plus with plus and minus with minus

(ground cable) - always connect the ground cablelast and disconnect it first! Wrong connections

may cause severe damage in the electric system.

Never start the engine by bridging the electrical

connections on the starter, because the machine

would probably start to move immediately.

Starting in closed rooms

Exhaust gases are toxic! Always ensure an ade-

quate supply of fresh air when starting in closed

rooms!

Driving the machine

Persons in the endangered area

If the machine has turned over and the cabin dooris jammed, use the right hand cabin window as an

emergency exit.

Before starting or resuming work and especially

when driving backwards, check that there are no

persons or obstructions in the endangered area.

If necessary give warning signals. Stop work im-

mediately if persons remain in the danger area de-

spite the warning.

Do not step or stand into the articulation area of

the machine while the engine is running. Danger of

squashing!

Driving

In events of emergency actuate the emergency

stop switch immediately. Do not use the emergen-

cy stop push button as service brake.

Restart the machine only after the danger, that has

caused the actuation of the emergency stop, has

been eliminated.

If the machine has come in contact with high-volt-

age power lines:

l do not leave the operator's stand

l warn others from coming too close to the ma-

chine or touching it

l if possible drive the machine out of the danger

zone

l have the power shut off.

Operate the machine only from the operator's

seat.

Keep the cabin doors closed.

Do not adjust the seat while driving.

Do not climb onto or off the machine while driving.

Change the travel direction only while the machine

is standing.

Do not use the machine to transport persons.

Stop the machine if you notice unusual noises or

the development of smoke. Investigate the cause

and have the fault corrected.

Keep a sufficient distance to excavations and em-

bankments and make sure that you work does not

impair the stability of the machine.

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Safety regulations

BOMAG 19BW 211/212/213 D-40

Do not work with vibration on hard concrete, on a

cured concrete layer or heavily frozen g round.

When passing under flyovers, bridges, tunnels,

electric power lines etc. keep a sufficient distance.

Driving on slopes and gradients

Do not drive up and down gradients, which exceed

the max. gradability of the machine.

On lopes always drive directly up or down. Change

to the lower speed range before approaching the

slope.

Wet and loose soils reduce the ground adhesion of

the machine and inclinations and slopes consider-

ably. Higher risk of accident!

Behaviour in trafficMatch the speed of the machine to the working

conditions.

Always allow loaded transport vehicles to pass.

Switch the lights on when the visibility is poor.

Keep clear of edges and embankments.

Check the effect of vibration

When compacting with vibration check the effect

of the vibration on nearby buildings and under-

ground supply lines (gas, water, sewage, electric

power supply), stop vibratory compaction if neces-sary.

Do not work with vibration on hard (frozen, con-

crete) ground. Risk of bearing damage!

Parking the machine

Park the machine on level and firm ground.

Before leaving the machine:

l straighten the articulated joint to allow easy

access to and from the machine.

l

return the travel lever to neutral positionl apply the parking brake

l shut the engine down a nd pull the ignition key

out.

l lock the cabin

l secure the machine against unauthorized use.

Do not jump off the machine, use access steps

and hand rails.

Always secure parked machines, which could be

in the way, with appropriate measures.

Parking on slopes and gradients

Secure the machine against rolling, place metal

chocks in front of and behind the drums.

Filling the fuel tank

Do not inhale fuel fumes.

Refuel only after shutting the engine and the aux-

iliary heater down.

Do not refuel in closed rooms.

No open fire, do not smoke.

Do not spill any fuel. Catch running out fuel, do not

let it seep into the ground.

Wipe off spilled fuel. Keep fuel free of dirt and wa-

ter.Leaking fuel tanks can cause explosions. Ensure

tight fit of the fuel tank filling cover, replace it if nec-

essary.

Fire protection measures

Make yourself acquainted with the location and the

operation of fire extinguishers. Observe fire warn-

ing and fire fighting installations.

Maintenance

Observe the maintenance tasks described in the

operating and maintenance instructions, including

the exchange of parts.

For service and repair work in the engine compart-

ment support the engine compartment hood.

Maintenance work must only be carried out by

qualified and authorized personnel.

When performing maintenance work above body

height use the access steps on the machine or any

other safe ladders and working platforms. Do not

use machine parts as access steps.

Keep unauthorized persons away from the ma-

chine.

Do not perform maintenance work with the ma-

chine driving or the engine running.

Park the machine on horizontal, level and stable

ground.

Pull the key out of the ignition switch.

Lock the articulated joint with the articulation lock.

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Safety regulations

BOMAG20 BW 211/212/213 D-40

Working on hydraulic lines

Always relieve the pressure in the hydraulic circuit

before working on hydraulic lines. Hydraulic oil es-

caping under pressure may penetrate through theskin and cause severe injury. In case of being in-

jured by hydraulic oil you should immediately seek

medical advice, as otherwise this may lead to se-

rious infections.

When adjusting the hydraulic system do not stand

behind or in front of the drum/wheels.

Do not change the setting of high pressure relief

valves.

Drain hydraulic oil at operating temperature - dan-

ger of scalding!

Catch running out hydraulic oil and dispose of en-vironmentally.

Always catch and dispose of biological hydraulic

oils separately.

Do not start the engine after draining off the hy-

draulic oil.

Once all work is completed (with the system de-

pressurized!) check all connections and fittings for

tight and leak-free fit.

Changing hydraulic hoses

All hydraulic hoses must be inspected visually at

regular intervals.

Hydraulic hoses must be changed immediately if:

l the outer layer is worn down to the metal lining

(e.g. chafing, cuts, cracks)

l embrittlement of the outer layer (development

of cracks in the hose material)

l deformation under pressurized and depressu-

rized condition, which are not in accordance

with the normal shape of the hydraulic hose

l deformation in bends, e.g, squeezes, kinks,

layer separation, formation of blisters

l leakages.

l non-observance of the installation require-

ments

l separation of the hydraulic hose from the fit-

ting

l corrosion of the fitting, which impairs the func-

tion and the strength.

l Do not mix up hoses by mistake.

l damage or deformation of the fitting, which im-

pairs the function and strength of the hose/

hose connection.

Only genuine BOMAG hydraulic hoses ensure

that the correct type of hose (pressure range) is

used at the right place.

Working on the engine

Shut the engine down before opening the engine

compartment hood.

Drain the engine oil at operating temperature -

danger of scalding!

Wipe off spilled oil, catch running out oil and dis-

pose of environmentally.Store used filters and other oily materials in a sep-

arate, specially marked container and dispose of

environmentally.

Do not leave any tools or other objects, which

could cause damage, in the engine compartment.

Idle speed and full load speed must not be

changed, since this would have a negative effect

on the exhaust gas values and cause damage to

engine and drive.

Turbo chargers work with high speeds and high

temperatures. Keep hands, tools and materialsaway from the intake and outlet openings of the

turbo charger and do not touch any hot surfaces.

Check and replace the coolant only when the en-

gine is cold.

Catch running out coolant and dispose of environ-

mentally.

Working on electrical equipment

Before working on electrical equipment disconnect

the battery and cover it with insulating material.

Do not use any fuses with higher ampere ratings

or repair a fuse with a piece of wire. Fire hazard!

Always disconnect the battery before starting to

wled on the machine.

Working on the battery

When working on the battery do not smoke, do not

use open fire.

Do not let acid come in contact with skin and

clothes. If being injured by acid flush off with clear

water and seek for medical advice.

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Safety regulations

BOMAG 21BW 211/212/213 D-40

Metal objects (e.g. tools, rings, wrist watches)

must not contact the battery poles - danger of

short circuit and burns!

When recharging maintenance free batteries re-move the plugs to avoid the accumulation of explo-

sive gases.

When using an external battery to start the ma-

chine follow the respective instructions.

Dispose of old batteries environmentally.

Switch the charging current off before removing

the charge clamps.

Ensure good ventilation, especially when charging

the battery in a closed room.

Working on the fuel systemDo not inhale fuel fumes.

No open fire, do not smoke, do not spill any fuel.

Catch running out fuel, do not let it seep into the

ground and dispose of environmentally.

Working on wheels and tires

Explosion like bursting of tires and parts of rims

and tires can cause severe or even deadly injuries.

Assemble tires only with the appropriate knowl-

edge and tools. If necessary have the tires assem-

bled in a special workshop.

Ensure correct tire pressure and do not exceed the

highest specified pressure.

Check wheels and tires every day for specified

pressure, cuts, bulges, damaged wheel rims,

missing wheel studs and nuts. Do not drive with

damaged tires or wheels.

Anti-stick emulsions for tires must only be mixed

using water and concentrated anti-stick agent ac-

cording to the specifications of the manufacturer of

the anti-stick agent. Observe the regulations for

the protection of the environment.

Cleaning

Do not clean the machine while the engine is run-

ning.

Do not use gasoline or other combustible sub-

stances for cleaning purposes.

When using steam cleaning equipment do not

subject electrical components and insulating ma-

terials to the direct water jet, but cover them be-

forehand.

l Do not guide the water jet into the exhaust or

into the air filter.

After maintenance work

Reinstall all protective devices after completing

the maintenance work.

Repair

Attach a warning tag to the steering wheel if the

machine is defective.

Repairs must only be performed by qualified per-

sons who have been instructed for this purpose.

Use our repair instructions.Exhaust gases are highly dangerous! Always en-

sure an adequate supply of fresh air when starting

in closed rooms!

Test

Depending on the type of application and the op-

erating conditions vibratory equipment has to be

examined by a specialist whenever required, but

at least once every year.

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Safety regulations

BOMAG22 BW 211/212/213 D-40

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BOMAG 23BW 211/212/213 D-40

3 Indicators and Controls

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Indicators and Controls

BOMAG24 BW 211/212/213 D-40

Fig. 7

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BOMAG 25BW 211/212/213 D-40

1 Ignition switch

2 Instrument cluster

3 Vent for heating and ventilation, driver

4 Vent for heating and ventilation, footwell

5 Push button vibration

6 Travel lever

7 Rotary switch vibration, high/low frequency

8 Rotary switch for speed range selection

9 Emergency stop push button

10 Push button for warning horn

11 Rotary momentary contact switch for engine

speed

12 Rotary switch for direction indicators left/right*

13 Rotary switch for hazard light system*

14 Rotary switch for lighting (StVZO)*

15 Rotary switch for working head lights*

16 Steering wheel adjustment lever*

* Optional equipment

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BOMAG26 BW 211/212/213 D-40

3.1 General notes

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.

3.2 Description of indicators

and control elements

Fig. 8

No. 1 = Ignition switch

Position "P"/"0" = ignition off, the key can be

pulled out, engine not running.

Position "I" = ignition on, all control and

warning lights on the fault

monitoring board light up for a

moment. The lighting can be

switched on.

i Note

The engine can only be started when the travel le-

ver is in braking position.

The ignition switch is provided with a lock against

repetitive starting. To repeat the starting proce-

dure you must first turn the ignition switch back to

"0"-position.

Position "II" = turn further against spring

pressure, the engine starts, re-

turn the ignition key to position

"I" when the engine starts

! Caution

Run the engine warm for a short while before

starting to work. Do not let the engine run at

idling speed for longer than 10 minutes.

Do not shut the engine down all of a sudden

from full speed, but let it idle for a while for

temperature equalization.

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BOMAG 27BW 211/212/213 D-40

Fig. 9

No. 2 = Instrument cluster

i Note

With the ignition switch in position I all gauges and

instruments are switched on for 3 seconds.

a red = flashes when the engine overheats,

the warning buzzer sounds, the en-

gine is shut down after 2 minutes.

Switch off vibration, run engine with

idle speed or shut down engine if

necessary, clean engine oil cooler

and radiator, if necessary repair en-

gine.b red = flashes if engine oil pressure too low,

engine is shut down after 10 sec-

onds. Check engine oil level, repair

the engine if necessary.

c yellow = not used

d yellow = Charge control light, lights if battery is

not being charged.

Check V-belt, if necessary repair the

generator.

e yellow = not used

f yellow = not usedg red = Parking brake, with lever shifted to

parking brake position, with driver’s

seat unoccupied.

h green = Direction indicator*, flashes when the

direction indicator switch is actuated.

i yellow = Water separator in fuel pre-cleaner.

Lights when the water proportion in

the transparent section of the fuel fil-

ter reaches the contacts.

j red = not used

k yellow = not used

l red = Hazard light*, flashes when the haz-

ard light is activated

m = Operating hour meter, counts the op-

erating hours while the engine is run-

ning. All maintenance work must be

performed according to the indicated

operating hours.

n = not used

No. 3 = Vents for air conditioning, heating

and ventilation, driver

No. 4 = Vents for air conditioning, heating

and ventilation, footwell**

Fig. 10

No. 5 = Push button for vibration

l Select or actuate the frequencies with the vi-

bration selector switch.

l Switch the vibration on or off by pressing the

push button.

* Optional equipment ** Optional equipment

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BOMAG28 BW 211/212/213 D-40

Fig. 11

No. 6 = Travel lever

Position "mid-dle" = Braking position service brake

Position "middle,

right" = Parking brake, to start the en-

gine

Position "I" = Forward travel

Position "II" = Backwards travel

i Note

If the engine speed drops under load when driving

on steep gradients, take the travel lever slightly

back towards neutral. This relieves the hydraulic

system and reduces the load on the diesel engine.

Fig. 12

No. 7 = Rotary switch for vibration

Position "Mid-

dle" = Vibration off

Position "Right" = low amplitude, high frequency

Position "Left" = high amplitude, low frequency

Fig. 13

No. 8 = Rotary switch for speed range selec-

tionPosition "turtle" = Working speed

Position "rab-

bit" = Transport speed

Fig. 14

No. 9 = Emergency stop switch

The engine will be shut down and the brake will

close.

! DangerDanger of accident!

Operate only in emergency situations during

operation, do not use as a service brake.

The machine should only be started again after

the danger, that caused the actuation of the

emergency stop switch, has been removed.

operate = push the button completely

down, it will automatically lock

in end position.

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BOMAG 29BW 211/212/213 D-40

unlock = turn the button clockwise and

release it.

to drive = move the travel lever first to

braking position, then start theengine 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. 15

No. 10 = Push button for warning horn

Fig. 16No. 11 = Rotary momentary contact switch for

engine speed

Electric engine speed adjustment

Position left = Idle speed position

i Note

Normal position for e ngine start.

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. 17

No. 12 = Rotary switch for direction indicators

left / right*

Position "mid-

dle" = Direction indicators disabled

Position "left or

right" = Front and rear direction indica-

tors for the corresponding side

of the machine light up, the

control light in the instrument

cluster flashes.

Fig. 18

No. 13 = Rotary switch for hazard light system**

Position "left" = Hazard light switched off, con-

trol lights off.


** Optional equipment

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BOMAG30 BW 211/212/213 D-40

Position "right" = Hazard light switched on, con-

trol light 1 in instrument cluster

lights up.

Fig. 19

No. 14 = 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".

Fig. 20

No. 15 = Rotary switch for working lights**

Position "left" = Light off

Position "right" = Working lights on, with ignition

switch in position "I".

Fig. 21

No. 16 = Lever, steering wheel adjustment

! Danger

Danger of accident!

Do not adjust the steering wheel while driving.

pull up = adjust height of steering wheel

press down = adjust inclination of steering

wheel

Fig. 22

No. 17 = 2-pole socket

Current only with the ignition switch in position "I"

or when the engine is running.


** Optional equipment

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BOMAG 31BW 211/212/213 D-40

Fig. 23

No. 18 = Fuses in electric installation box

F03, 15A = Vibration

F05, 15A = Socket

F07, 15A = Hazard light*

F09, 10A = Parking tail l ight, left*

F10, 10A = Parking tail l ight, right*

F11, 15A = Head lights, StVZO*

F13, 30A = Starting

F14, 15 A = Engine solenoid

F18, 10A = Working head lights, relay*

F19, 15A = Working head lights, front, left*F22, 15A = Working head lights, rear*

F23, 10A = Warning horn

F24, 10A = Monitoring, gauges

F25, 10A = Solenoid valve brake/travel

F39, 15A = Cab*

F70, 15A = Indicator*

F105, 20A = Engine speed control

! Danger

Fire hazard!

Do not use fuses with higher ampere ratings

and do not bridge fuses.

Fig. 24

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 wiping of front

windscreen.

Push button = Front windscreen is sprayed

during wiping.

c = toggle switch for rear windscreen wiper/

washer

up = windscreen wiper moves to

end position and stops.

down = Switches on wiping of rear

windscreen.

Push button = Rear windscreen is sprayed

during wiping.

d = toggle switch for rear windscreen heating

Fig. 25

No. 19 = Fuse box, cabin* Optional equipment

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BOMAG32 BW 211/212/213 D-40

! Danger

Fire hazard!

Do not use fuses with higher ampere ratingsand do not bridge fuses.

(1), 15A = (F43) wiper/washer, rear

(2), 15A = (F44) wiper/washer, front

(3), 10A = (F130) relay for rear windscreen

heating, reading light

(4), 25A = (F31) cabin fan

(5), 10A = (F41) flashing beacon

(6), 15A = (F144) cab socket

(7), 15A = (F143) rear windscreen heating

(8), 5A = (F42) potential 30, cab light

Fig. 26

No. 20 = Control panel for ventilator, air condi-

tioning, heating

e = Rotary switch for cabin ventilator

Position ’’Off“ = cabin ventilator switched off.

Position 1, 2 and

3 = ventilator stages of different

strengths

f = Push button for air conditioning*

press = a ir conditi oning switched on.

i Note

The lights above the push buttons light up.

With rotary switch (g) the air conditioning unit can

be regulated within the blue range.

press again = air conditioning switched off.

i Note

The light goes out.

g = Rotary switch for cabin heater (tempera-ture selector switch)

Position ’’Off“ = cabin heater switched off.

Position blue

range = temperature selection for air

conditioning.

Position red

range = Temperature selection for cab-

in h eater.

Fig. 27

No. 21 = Cabin light


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BOMAG 33BW 211/212/213 D-40

i = reading and dashboard light

j = toggle switch for reading and dashboard

light

k = toggle switch for cabin light

l = cabin light

Fig. 28

No. 22 = Main fuse for battery

80A = (F00)

i Note

The main fuse is located in the battery compart-

ment

Fig. 29

No. 23 = Air filter service indicator

With the service indicator the real degree of filter

contamination can even be checked when the en-

gine is stopped.

The filter must be service when the yellow piston

reaches the inscription "Service" in front of the red

background.

After the filter service reset the indicator to "zero"

by pressing the push button.

Fig. 30

No. 24 = 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.

Pin remains

pressed in = hydraulic oil filter element o.k.

Pin pops out = replace the hydraulic oil filter

element

Fig. 31

No. 25 = Fuel gauge

shows the fuel level in the fuel tank.

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BOMAG34 BW 211/212/213 D-40

Fig. 32

No. 26 = Anti-theft protection*

prevents unauthorized starting of the engine.

Keypad = Input of user and service code (main-

tenance).

i Note

Enter the user code with the ignition switched

off !

After entering the user code you should start the

engine within 30 seconds.

After entering the service code the anti-theft pro-

tection remains switched off.red LED

display

flashes

slowly = anti-theft protection active.

LED dis-

play lights

green = every time a digit of the user or serv-

ice code is entered.

i Note

After shutting down the engine it can be restarted within a period of 12 seconds, in any other case

the user code needs to be entered again.

Fig. 33

No. 27 = 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 p rof and/or

BCM 05 possible.

* Optional equipment ** Optional equipment

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BOMAG 35BW 211/212/213 D-40

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BOMAG36 BW 211/212/213 D-40

3.3 Display and control ele-

ments BTM*

Fig. 34


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BOMAG 37BW 211/212/213 D-40

1 EVIBdisplay

2 Display for jump operation

3 Push button F5 START

4 Push button F6 STOP

5 Push button F7 PRINT (only BTM prof)

6 Push button F8 DELETE

7 Vibration frequency display

8 Rotary switch setting of nominal value

9 Push button F14 nominal value increase

10 Push button F13 nominal value decrease

11 not used

12 not used

13 not used

14 not used

15 not used

16 not used

17 Travel speed display

18 Amplitude display

19 Printer for measuring values (only BTM prof)

20 Fault light

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BOMAG38 BW 211/212/213 D-40

3.4 Description of indicating

and control elements

BTM

i Note

The BTM plus can be upgraded to BTM prof and/

or BCM 05.

Surface covering dynamic compactioncontrol (SCCC)

The BOMAG compaction measuring systems

EVIB-meter (BEM) and Terrameter BTM plus/prof

are integrated in the work process for continuousand surface covering evaluation of compaction

and load bearing capacity of soils and non-bonded

bearing courses.

The EVIB-value, designated as vibration modulus,

with the unit MN/m2 is directly linked with the de-

formation modules EV1 or EV2 known from the

plate load test acc. to DIN 18134.

No. 1 = EVIB-display

Display of the dynamic soil stiffness in MN/m2.

No. 2 = Display for jump operation

yellow

symbol = Drum jumps

red

symbol = Drum jumps excessively or

tumbles

Select a smaller amplitude, if necessary!

No. 3 = Button F5 START

press = Starts recording of measuring

values

Control field "F5" flashes green on the screen.

No. 4 = Button F6 STOPpress = Stops recording of measuring

values

The green control field "F7" PRINT on the screen

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*

To print out the measuring data saved during the

last pass press button F7 PRINT.

short actuation = Line diagram

long actuation ≥5sec. = 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).

No. 6 = Button F8 DELETE

press = All stored faults are d eleted.

! Caution

If the increase of the measuring value is to be

calculated on a track press button F8 DELETE

only when changing the track.

No. 7 = Frequency display

with vibration switched on this instrument shows

the frequency (rotating speed) of the exciter shaft.

No. 8 = Rotary switch P3 pre-setting of nomi-

nal values

The desired maximum dynamic stiffness modulus

EVIB [MN/m2] can be pre-selected in 6 stages (45,

80, 100, 120,150 and Max.).

The selected value is shown on the screen in field

„P3“

No. 9 = Button F14 increase of nominal value

With each actuation of the button the presetting is

raised by one stage.


„P3“

No. 10 = Button F13 reduction of nominal val-ue

With each actuation of the button the presetting is

reduced by one stage.

* only with BTM prof

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BOMAG 39BW 211/212/213 D-40


„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.

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BOMAG40 BW 211/212/213 D-40

3.5 Line diagram* (EVIB)

Fig. 35

* only BTM prof

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BOMAG 41BW 211/212/213 D-40

1 Pass-No.

2 Travel direction

3 Machine equipment (BTM 05/BTM-E)

4 Software status of the measuring equipment

5 Machine number

6 Machine type

7 Amplitude

8 Maxiumum EVIB value

9 Miniumum EVIB value

10 Mean EVIB-value

11 EVIB-change

12 Medium frequency

13 Mean travel speed

14 Track length

15 Raster division in longitudinal direction

16 Marking (thick line) excessive jumping, tum-

bling of the drum

17 Longitudinal raster line

18 Measuring value raster line

19 Diagram line

20 Marking (thin line) jumping of the drum

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BOMAG42 BW 211/212/213 D-40

3.6 Description of line diagram *

(EVIB)

No. 1 = Pass

Total number of measured passes on this track.

No. 2 = Travel direction

No. 3 = Machine equipment

No. 4 = Software status of the measuring

equipment

No. 5 = Machine number

No. 6 = Machine type

No. 7 = Amplitude

This gauge shows the vertical amplitude the ma-

chine has worked with on this track.

No. 8 = Maxiumum EVIB value

No. 9 = Miniumum EVIB value

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 frequencyNo. 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.

Graduation of the measuring track (track length in

printout) into fixed sections.

No. 16 = Marking of jump information

Indicates excessive jumping/tumbling of the drumon the marked track section (thick line).

i Note

Select a smaller amplitude, if necessary!

No. 17 = Longitudinal raster line

No. 18 = Measuring value raster line

No. 19 = Diagram line

Shows the EVIB-value at any point of the rolled

track. The raster line enables the location related

assignment of the EVIB-value and the location of afault (over or under compaction).

No. 20 = Marking of jump information

Indicates jumping of the drum on the marked track

section (thin line).

* only BTM prof

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BOMAG 43BW 211/212/213 D-40

3.7 Bar diagram* (EVIB)

The bar diagram differs from the line diagram onlyby 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 EVIBchanges of the individual 5 m sections are speci-

fied in percent after the second pass in the same

travel direction.

* only BTM prof

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BOMAG44 BW 211/212/213 D-40

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BOMAG 45BW 211/212/213 D-40

4 Operation

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Operation

BOMAG46 BW 211/212/213 D-40

4.1 General notes

Please read section 3 Indicators and Control Ele-ments thoroughly before operating the machine if

you are not yet fully familiar with the indicators and

control elements of the machine.

All indicators and control elements are described

in detail in this chapter.

4.2 Tests before starting to op-

erate

The following tests must be performed before

each work day or before a longer work period.

! Danger

Danger of accident!

Please observe strictly the safety regulations

in chapter 2 of these operating and mainte-

nance instructions!

l Park the machine on level ground.

Check:

l Fuel tank and fuel lines for leaks

l Bolted connections for tight fit

l Function of the steering

l Check the machine for cleanliness and dam-

age

l availability of the appropriate operating and

maintenance instructions,

l check if the machine has been properly serv-

iced.

i Note

For a description of the following work refer to the

section "maintenance every 10 operating hours"

l engine oil level

i Note

Hydraulic systems, which are filled with Panolin

HLP Synth. 46, the same oil must be used for fill-

ing up. In case of any other ester based oil consult

the lubrication service department of the respective oil manufacturer.

l Check the hydraulic oil level, top up if neces-

sary.

l Check the coolant level, top up if necessary.

! Danger

Fire hazard!

Do not refuel in closed rooms

l Check the fuel level, top up if necessary.

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Operation

BOMAG 47BW 211/212/213 D-40

l Check water separator in the fuel system,

drain if necessary.

l Adjust the scrapers if necessary

l Tire pressure. Pressure see technical data.

! Caution

Ensure equal pressure in both tires.

4.3 Disarming the anti-theft*

protection

Before starting the engine the anti-theft protection

must be disarmed by entering a code while the ig-

nition is still off.

! Caution

If the anti-theft protection is disarmed with the

ignition switched on, the diesel engine will run

in limp home program!

Fig. 36

i Note

With the anti-theft protection armed light emitting

diode a (Fig. 36) flashes slowly in red.

l Slowly enter the six-digit user code while the

ignition is switched off.

i Note

With each digit of the code the light emitting diode

lights green.

l Press the confirmation key ’’VAL“.

l The anti-theft protection is now disarmed and

the engine must be started within the next 30

seconds.

i Note

After the engine has been shut down restarting is

possible within 12 seconds. After this the anti-theft

protection will be armed again. The red LED flash-

es at intervals of one second.


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Operation

BOMAG48 BW 211/212/213 D-40

After entering the service code (for maintenance

work) the anti-theft protection remains disarmed. 4.4 Starting the engine

! Danger

Danger of accident!

Always wear your seat belt.

Fig. 37

l Check, whether the travel lever (Fig. 37) is en-

gaged to the right in brake position.

Fig. 38

l Turn the rotary vibration selector switch (Fig.

38) to position "0", vibration off.

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Operation

BOMAG 49BW 211/212/213 D-40

Fig. 39

l Check, whether the emergency stop switch

(Fig. 39) is unlocked.

Fig. 40

l Turn rotary switch (Fig. 40) to position "Min"

(idle speed).

Fig. 41

l Turn the ignition key (Fig. 41) to position "I".

Fig. 42

All control and warning lights (Fig. 42) in the fault

monitoring board light up for a moment.The battery control (d) and brake warning lights (g)

light up, the engine oil pressure warning light (b)

flashes.

! Caution

Perform the starting process for maximum 20

seconds without interruption and pause for a

minute between starting attempts.

If the engine has not started after two attempts

perform trouble shooting.

Fig. 43

l Turn the ignition key to position "II" (Fig. 43),

the starter will crank the engine.

l As soon as the engine ignites return the igni-

tion key to position "I".

! Caution

Do not allow the engine to run longer than 10

minutes with idle speed.

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Operation

BOMAG50 BW 211/212/213 D-40

4.5 Starting with jump wires

Fig. 44

! Caution

A wrong connection will cause severe damage

in the electric system.

l Bridge the machine only with a 12 Volt auxilia-

ry battery.

l When jump starting with an external battery

connect both plus poles first.

l

Then connect the ground cable first to the mi-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. 44).

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, whichcould damage electrical components.

l After starting disconnect the negative poles

(ground cable) first and the positive poles af-

ter.

l Switch off the consumer.

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

(see technical data).

Do not drive without wearing your seat belt.

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.

i Note

The machine is equipped with a seat contact

switch (safety feature).

If the driver gets up from his seat while driving, the

signal horn is activated and the machine is slowed

down to standstill after four seconds. When the

driver sits down again the machine will continue

the travel.

Before resuming operation sit down on the seat,

engage the travel lever in "0"-position (brake posi-

tion), then operate the travel lever again to the de-

sired travel direction.

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Operation

BOMAG 51BW 211/212/213 D-40

Fig. 45

l Close the cabin door (Fig. 45).

Fig. 46

l Sit on the driver's seat (Fig. 46) and fold down

the armrest.

Fig. 47

l Fasten your seat belt (Fig. 47).

l "Start engine", see previous sections.

Fig. 48

l Select the desired travel speed range (Fig.

48).

Fig. 49

l Turn the rotary switch (Fig. 49) to "Max" posi-

tion (full throttle).

Fig. 50

l Push the travel lever (Fig. 50) to the left out of

braking position and move it slowly to the de-

sired travel direction.

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Operation

BOMAG52 BW 211/212/213 D-40

i Note

Shift the travel lever out of "0"-position slowly to

forward or reverse, the machine will drive forward

or reverse at a speed which corresponds with the displacement of the travel lever.

Returning the travel lever towards neutral will

brake the machine and in "0"-position of the travel

lever the machine will stop.

! 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

the machine has stopped, before actuating to

the new travel direction.

Do not operate jerkily!

When driving up and down inclinations move

the travel lever slowly back towards neutral tobrake the machine.

If the engine speed drops when driving up ex-

treme inclinations move the ravel lever slightly

back, if necessary change to the lower speed

range.

4.7 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.

Do not activate the vibration on hard (frozen,

concrete) ground. Danger of bearing damage!

Fig. 51

l Switch to working speed (Fig. 51) (turtle).

Pre-selecting the vibration

Fig. 52

l Pre-select amplitude/frequency with the rotary

switch (Fig. 52).

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Operation

BOMAG 53BW 211/212/213 D-40

Switch the vibration on

Fig. 53

l Turn the rotary switch (Fig. 53) to position

"Max" (full throttle).

! Caution

Switch the vibration on only at max. engine

speed.

Fig. 54

l Press the push button (Fig. 54) in the travel le-

ver while driving, the drum will vibrate.

Switching the vibration off

l Press the push button again and after work

switch the rotary vibration switch to position

"0".

4.8 Operating the parking

brake, stopping the ma-

chine

Fig. 55

l Return the travel lever (Fig. 55) slowly to "neu-

tral"-position and engage it to the right parking

brake position.

The machine is automatically braked by the hydro-

static drive and parking brake closes.

i NoteThe parking brake also closes automatically when

shutting the engine down.

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Operation

BOMAG54 BW 211/212/213 D-40

4.9 Shutting the engine down

! Caution

Straighten the articulated joint to provide easi-

er access to the machine.

Fig. 56

l Return the travel lever (Fig. 56) slowly to "neu-

tral"-position and engage it to the right in brak-

ing position.

Fig. 57

l Turn rotary switch (Fig. 57) to position "Min"

(idle speed).

i Note

Do not shut the engine down all ofthe sudden from

full speed, but let it idle for a while for temperature

equalization.

Fig. 58

l Turn the ignition switch (Fig. 58) to position "0"

or "P" and pull the ignition key out.

i Note

The parking brake closes automatically when

shutting the engine down.

! Danger

Danger of accident!

Secure the machine against unauthorized use,

pull the ignition key out, lock the cabin door.

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Operation

BOMAG 55BW 211/212/213 D-40

4.10 Emergency exit

If the machine should turn over and the cabin dooris closed, the right hand side cabin window can be

used as an emergency exit.

4.11 Adjusting the steering

wheel*

Fig. 59

l Adjustment of steering wheel in height, pull le-

ver (Fig. 59) up and move the steering wheel

to the desired height.

l Adjustment of steering wheel inclination, press

lever down and adjust the inclination of the

steering wheel.

! DangerDanger of accident!

After the adjustment make sure that the steer-

ing wheel adjustment is securely locked in

place.


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Operation

BOMAG56 BW 211/212/213 D-40

4.12 Adjusting the seat

! Danger

Danger of accident!

Do not adjust the seat while driving.

Fig. 60

l To adjust the seat in longitudinal direction dis-

engage the lever 1 (Fig. 60) and slide the seat

forward or back.

l To adjust the weight actuate the lever (3).

l To adjust the inclination of the backrest actu-ate the lever (2) and tilt the backrest forward or

back.

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. 61

l Unlock the lock (Fig. 61).

l To open the hood press in the button and turnthe handle.

Fig. 62

l Pull the support out of the bracket and support

the hood (Fig. 62).

Top position

l Push the hood to top position.

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Operation

BOMAG 57BW 211/212/213 D-40

Fig. 63

l Pull the spring pin (Fig. 63) out of the bracket.

l Secure the hood i´n the protection tube with

spring plug.

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

towing device.

The machine cannot be steered.

l Secure the machine with wheel chocks

against unintentional rolling.

Fig. 64

l Attach chains (Fig. 64) or towing ropes to the

lifting hooks.

! Caution

Towing speed 1 km/h, max. towing distance

500 m.

l Open the tailgate.

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Operation

BOMAG58 BW 211/212/213 D-40

Fig. 65

l Slacken the middle hexagon on both valves

(Fig. 65) for approx. 2 to 3 turns.

! Caution

Do not turn the valves out completely.

Fig. 66

l To release the brake turn counter nuts 1 (Fig.

66) approx. 8 mm back.

l Turn the brake releasing screws (2) complete-

ly in against the stop.

! Caution

From this stop turn the screw in for maximum

another turn to release the brake!

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.

After towing

! Caution

Before detaching the tow bar block the ma-

chine with chocks to prevent unintended roll-

ing.

l Turn the high pressure relief valve cartridges

tightly back in.

l Turn all brake releasing screws of the axle

evenly back out, until they are light moving

again.

Fig. 67

l Turn the brake releasing screws (Fig. 67) backin again, until they abut against the brake pis-

ton.

Fig. 68

l Unscrew the brake releasing screws (Fig. 68)

for two turns and tighten the counter nuts.

l Repeat this adjustment p rocedure on the op-

posite wheel side.

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Operation

BOMAG 59BW 211/212/213 D-40

i Note

If necessary replace the seal ring under the coun-

ter nut if it is leaking.

For this purpose completely unscrew the brake re-

leasing screw, replace the seal ring and lubricate

the screw with silicone grease.

Reinstall the screw with a new seal ring and adjust

the protrusion as described above.

4.15 Transport

! Danger

Danger of accident!

Use only stable loading ramps of sufficient

load bearing capacity. Make sure that persons

are not endangered by the machine tipping or

sliding off.

Lash the machine down, so that it is secured

against rolling, sliding and turning over.

Do not stand or step under loads being lifted.

Always use shackles on the lifting points for

loading, tying or lifting the machine.

Fig. 69

l Pull the spring pin (Fig. 69) out.

l Engage the articulation lock and secure it with

the spring pin.

Fig. 70

l Engage the articulation lock and secure it with

the spring pin (Fig. 70).

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Operation

BOMAG 61BW 211/212/213 D-40

4.16 Measuring pass with BTM*

General notes

i Note

The soil measuring values (E VIB ) 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.

Measuring values must only be compared for

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. 74

l Turn the ignition key (Fig. 74) to position "I"

The BTM plus/prof performs a self-test.

Fig. 75

l Control field F5 (Fig. 75) lights green.

Fig. 76

l Turn the ignition key (Fig. 76) to position „II en-

gine start.


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Operation

BOMAG62 BW 211/212/213 D-40

Fig. 77

l Mark the track to be compacted (Fig. 77).

! 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.

i Note

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. 78

l Choose the maximum forward speed (Fig. 78).

The adjusted travel speed is indicated by a greenring segment in the tachometer on the LCD display*unit.

Fig. 79

l In the starting distance set the rotary switch for

engine speed (Fig. 79) to "ECO" or "MAX".

* only DH-4 machines

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Operation

BOMAG 63BW 211/212/213 D-40

Fig. 80

l Shift the travel lever (Fig. 80) fully to position

„I“.The machine accelerates up to the preadjusted

travel speed.

! Caution

Differences in the travel speeds falsify the

measuring result!

Fig. 81

l Switch the vibration on (Fig. 81).

! Caution

Before reaching mark 1 the nominal exciter

shaft speed must have been reached and a val-

id Evib-value should be displayed.

Fig. 82

l When mark 1 is reached, press button F5

“START” (Fig. 82).Control field to the left of F5 lights green.

The EVIB- display shows the present value.

Fig. 83

l When the end of the track, mark 2, is reached,

press the button F6 “STOP” (Fig. 83).

l Stop the machine.

i Note

The first forward pass is finished.

Control field F5 lights green. This means, that the

compaction is not yet completed. One or several

passes are still required.

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Operation

BOMAG64 BW 211/212/213 D-40

4.17 Finishing compaction of a

track

Fig. 84

l Drive forward and reverse passes on a track

until the green control field tothe left of F5 (Fig.

84) goes out and the red control field F6 below

lights up after pressing the stop button F6.

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 wasless 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).

Fig. 85

l Repeat the complete compaction process on

the next track (Fig. 85) to record measuring

values.

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Operation

BOMAG 65BW 211/212/213 D-40

4.18 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. 86l At the end of the measurement press push

button F7 "PRINT" (Fig. 86).

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).

Fig. 87

l If no further printouts of this track are needed,

press the button F8 “DELETE” (Fig. 87) whenthe 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.

* only BTM prof

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Operation

BOMAG66 BW 211/212/213 D-40

4.19 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. 88

l Unscrew the star handles (Fig. 88) and re-

move the cover.

Fig. 89

l Remove shaft 1 (Fig. 89) with the rest of the

paper roll (2).

Fig. 90

l Insert a new paper roll (Fig. 90).

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.

* only BTM prof

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Operation

BOMAG 67BW 211/212/213 D-40

4.20 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. 91

l Unscrew the star handles (Fig. 91) and re-

move the cover.

Fig. 92

l Lift the tongue at point 1 (Fig. 92) 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

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Operation

BOMAG68 BW 211/212/213 D-40

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BOMAG 69BW 211/212/213 D-40

5 Maintenance

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Maintenance

BOMAG70 BW 211/212/213 D-40

5.1 General notes on mainte-

nance

When servicing the machine pay careful attention

to all applicable safety instructions.

Thorough maintenance of the machine ensures

maximum reliability and prolongs the lifetime of im-

portant components. The necessary effort can by

no means be compared with the problems and

malfunctions that could occur if this is not ob-

served.

The terms left/right are always related to travel di-

rection forward.

l Clean machine and engine thoroughly beforestarting maintenance work.

l For maintenance work park the machine on

level ground.

l Maintenance work must generally be carried

out with the engine shut down.

l Depressurize hydraulic lines before working

on them.

l Disconnect the battery and cover it with insu-

lation material before starting to work on elec-

trical components.

l Always attach the articulation lock (transport

lock) before starting to work in the articulation

area of the machine.

Environment

Catch running out oils, coolant and fuel and do

not let them seep into the ground or into the

sewage system. Dispose of oils, coolant and

fuels environmentally.

Notes on the fuel system

The lifetime of the diesel engine is decisively de-

pending on the cleanliness of the fuel.

l Keep the engine free of dirt and water as this

could damage the injection elements of the en-

gine.

l Zinc lined drums are not suitable for storing fu-

el.

l The fuel drum should rest for a longer period

of time before drawing off fuel.

l Do not let the suction hose disturb the sludge

on the bottom of the drum.

l Do not draw off fuel from near the bottom of

the fuel drum.

l Fuel left in the fuel drum is not suitable for the

engine and should only be used for cleaning

purposes.

Notes on the engine performance

Combustion air and fuel injection rates of the die-

sel engine have been carefully adjusted and deter-

mine the engine's performance and temperature

level as well as the quality of the exhaust gas.

If your machine has to operate permanently in

"thin air" (at high altitudes) and with full power, youshould consult the after sales service of BOMAG

or the service department of the engine manufac-

turer.

Notes on the hydraulic system

During maintenance work in the hydraulic system

cleanliness is of utmost importance. Make sure

that no dirt or other impurities can enter into the

system. Small particles can flute valves, cause

pumps to seize and block restrictors and pilot

bores, thereby causing costly repairs.

l If during the daily oil level check the oil level is

found to have dropped, check all lines, hoses

and components for leakages.

l Seal external leaks immediately. If necessary

inform the responsible service department.

l Do not store drums with hydraulic oil outside,

or at least keep them under a cover. During

weather changes water may penetrate

through the bunghole.

l Always fill the hydraulic system using the filling

and filtering unit (BOMAG part-no.007 610 01). This unit is equipped with a fine

filter, which filters the hydraulic oil and pro-

longs the lifetime of the system filter.

l Clean fittings, filler caps and their immediate

surrounding area before removing them, so

that no dirt can fall in.

l Do not leave the tank opening unnecessarily

open, cover it so that no dirt can fall in.

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Maintenance

BOMAG 71BW 211/212/213 D-40

Notes on the cooling system

On water cooled engines the preparation and

monitoring of the coolant is of utmost importance,

as otherwise engine failures caused by corrosion,caviation and freezing may occur.

The coolant is a mixture of water and a cooling

system protection agent.

The cooling system must be permanently moni-

tored. Apart from the coolant level inspection this

includes also the inspection of the concentration of

cooling system protection agent.

The concentration of the cooling system protection

agent can be checked with commercially available

test instruments (glycomat).

! Danger

Health hazard!

The mixing of nitride based cooling system

protection agents with amine based agents will

cause the generation of highly toxic nitro-

samines.

Environment

Cooling system protection agents must be dis-

posed of environmentally.

5.2 Fuels and lubricants

Engine oil

Quality

Lubrication oils are classified according to their

performance and quality class. Oils according to

other comparable specifications may be used.

The exact assignment of the approved oil qualities

and oil change intervals can be taken from the fol-

lowing section "Lubrication oil change intervals".

Consult your local service station if in doubt.

Oil viscosity

Multi-purpose oils should be generally used.

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) .

Optimal operating conditions can be achieved by

using the opposite oil viscosity chart (Fig. 93) as a

reference.

Occasionally falling short of the temperature limits

will impair the cold starting ability, but will not

cause any engine damage. In order to keep the

occurring wear as low as possible, occassional ex-

ceeding of the limits should not happen over a

longer period of time.

Approved engine oils

Deutz DQC II DQC III

ACAE E3/96/E5-02 E4-99

API CH-4/CG-4 -

DHD DHD-1 -

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Maintenance

BOMAG72 BW 211/212/213 D-40

Fig. 93

With their b etter temperature and oxidation stabil-ity synthetic lubrication oils offer quite a few bene-

fits.

Oil change intervals

The longest permissible time a lubrication oil

should remain in an engine is 1 year. If the follow-

ing oil change intervals are not reached over a pe-

riod of 1 year, the oil change should be performed

at least once peryear, irrespective of the operating

hours reached.

ACEA*

E3-96/E5-02

E4-99 = 500 operating hours

API**

CG-4/CH-4 = 500 operating hours

! Caution

These intervals apply only when using a diesel

fuel with maximum 0.5 % sulphur by weight

and for ambient temperatures higher than -10

°C.

When using fuels with a sulphur content of

more than 0.5% to 1% or under ambient tem-peratures below -10 °C the oil change intervals

specified in the table must be halved. For fuels

with a sulphur content of more than 1% you

should consult the responsible service agen-

cy.

Fuels

Quality

You should only use commercially available brand

diesel fuel with a sulphur content below 0.5% and

ensure strict cleanliness when filling in. A highersulphur content has a negative effect on the oil

change intervals. Use only winter-grade diesel fuel

under low ambient temperatures. The fuel level

should always be topped up in due time so that the

fuel tank is never run dry, as otherwise filter and in-

jection lines need to be bled.

When using fuels with a Cetan number < 49 poor

starting and white smoke can be expected, in par-

ticular in connection with low ambient tempera-

tures.

The following fuel specifications are permitted:

DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75;

BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-

D.

l DIN/EN 590

l BS 2869

l ASTM D 975-78: 1-D and 2-D.

l Nato Codes: F-54, F-34, F44 und XF63

Winter fuel

! DangerFire hazard!

Diesel fuels must never be mixed with gaso-

line.

For winter operation use only winter diesel fuel, to

avoid clogging because of paraffin separation. At

very low temperatures disturbing paraffin separa-

tion can also be expected when using winter diesel

fuel.

* European Engine Oil Sequences

** American Petroleum Institute

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Maintenance

BOMAG 73BW 211/212/213 D-40

In most cases a sufficient cold resistance can also

be achieved by adding flow enhancing fuel addi-

tives. Consult the engine manufacturer.

Operation with rape seed oil methyl ester (RME„Bio Diesel“)

Due to the extreme quality differences of RMEW-

fuels available on the market, which are caused by

the non-existence of a standardization, BOMAG

does generally not approve any RME-fuels. If this

is neglected the warranty will become null and

void!

However, if you still intend to operate the machine

with RME-fuels you should observe the following

information:

l Reduced engine power (approx. 7%), higherfuel consumption.

l The quality of RME-fuel should be in compli-

ance with DIN draft 51606.

l Avoid longer periods of standstill (formation of

resin, corrosion in injection system)

l RME-fuel can damage the paint finish of the

machine.

l Fuel dilution of engine oil, therefore shortening

of oil change intervals to half.

l Rubber parts, such as leak fuel return lines,seats will be damaged in the long run and

need to be replaced on a regular basis or

should be replaced by parts made of fluorinat-

ed rubber. However, fluorinated rubber is not

resistant against normal diesel fuel.

l If the fuel filter is clogged the filter change in-

tervals must be shortened accordingly.

Coolant, anti-freeze agent

Use only soft tap water (drinking water) to prepare

the coolant mix.

As a protection against frost, corrosion and boiling

point anti-freeze agents must be used under any

climatic conditions.

The proportion of cooling system protection agent

must be between min. 35% and max. 45% to the

water.

! Caution

Do not mix different coolants and additives of

any other kind.

Environment

Cooling system protection agents must be dis-

posed of environmentally.

Hydraulic oil

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

On request the hydraulic system can also be filled

with ester based biodegradable hydraulic oil (Pan-

olin HLP Synth. 46). The biologically quickly de-

gradable hydraulic oil 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 manu-

facturer for details.

Check the filter more frequently after this change.

! Caution

Oil change bio-degradable hydraulic oil:

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

For the drive axle use only multi-purpose transmis-

sion oil of API-class GL5 with viscosity class SAE

90.

The additives in this oil ensure low wear lubrication

under all operating conditions.

Lubrication grease

For lubrication use only EP-high pressure grease,

lithium saponified (penetration 2).

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Maintenance

BOMAG74 BW 211/212/213 D-40

5.3 Table of fuels and lubri-

cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil ACEA: E3-96/E5-02 or approx. 8,5 litres without

oil filter

API: CG-4/CH-4

SAE 10W/40

(-20 °C to +40 °C)

SAE 15W/40

(-15 °C to +40 °C)

Fuel

Diesel Winter diesel fuel approx. 150 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres

46 mm2 /s at 40 °C

Vibration bearings Engine oil SAE 15W/40 approx. 0,8 litres

Drive axle Gear oil SAE 90, API GL5 approx. 9,5 litres

Wheel hubs Gear oil SAE 90, API GL5 approx. 1,9 per side

Air conditioning system Refrigerant R134A approx. 1400 g

Tires (only BW 213) Water approx. 295 litres

Calcium chloride (CaCl2) or magnesium chloride

(MgCl2)

approx. 100 kg

Engine co oling system Cooling system protection agent approx. 16 litres

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Maintenance

BOMAG 75BW 211/212/213 D-40

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

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Maintenance

BOMAG76 BW 211/212/213 D-40

5.5 Maintenance chart

No. Maintenance work Remark

R u n n i n g - i n

i n s t r u c t i o n s

a f t e r 2 5 0 o p e r a t i n g

h o u r s

e v e r y

1 0

o p e r a t i n g

h o u r s ,

d a i l y

e v e r y

2 5 0

o p e r a t i n g

h o u r s

e v e r y

5 0 0

o p e r a t i n g

h o u r s

e v e r y

1 0 0 0

o p e r a t i n g

h o u r s

e v e r y

2 0 0 0

o p e r a t i n g

h o u r s

e v e r y

3 0 0 0

o p e r a t i n g

h o u r s

a s r e q u i r e d

5.6 Check the engine oil level Dipstick mark X

5.7 Check the water separator X

5.8 Check the fuel level X

5.9 Check the hydraulic oil level Inspection glass X

5.10 Check the coolant level Inspection glass X

5.11 Check the dust separator X

5.12 Check the tire pressure X

5.13 Clean the cooling fins on engine and hy-draulic oil cooler

X

5.14 Check the oil level in the drive axle X

5.15 Check the oil level in the wheel hubs X

5.16 Check the oil level in the vibration bear-

ings

X

5.17 Change engine oil and oil filter car-

tridge*min. 1x per year X X

5.18 Drain the sludge from the fuel tank X

5.19 Service the battery Pole grease X

5.20 Check, replace the refrigerant compres-

sor V-belt

X

5.21 Service the air conditioning X

5.22 Check, adjust the valve clearance Intake = 0,3 mm

Exhaust = 0,5 mm

X

5.23 Check, replace the ribbed V-belt X

5.24 Change the fuel filter cartridge X

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Maintenance

BOMAG 77BW 211/212/213 D-40

5.25 Change the fuel pre-filter cartridge X

5.26 Check the engine mounts X X

5.27 Oil change in drive axle min. 1x per year X X

5.28 Oil change in wheel hubs min. 1x per year X X

5.29 Oil change vibration bearings** see foot note, min.

1 x per year

X X

5.30 Retighten the fastening of the axle on

the frame

X

5.31 Tighten the wheel nuts X X

5.32 Check the ROPS X

5.33 Clean the oil bath air filter min. 1x per year X

5.34 Change hydraulic oil and breather fil-

ter***at least every 2

years

X

5.35 Change the hydraulic oil filter*** at least every 2

years

X

5.36 Change the coolant at least every 2

years

X

5.37 Check the injection valves X

5.38 Service the combustion air filter min. 1x per year,

safety cartridge at

least every 2 years

X

5.39 Adjusting the scrapers X

5.40 Adjust the parking brake X

5.41 Change the tires X

5.42 Change the fresh air filter in the cabin X

5.43 Tightening torques X

5.44 Engine conservation X

No. Maintenance work Remark

R u n n i n g - i n

i n s t r u c t i o n s

a f t e r 2 5 0

o p e r a t i n g

h o u

r s

e v e r y 1 0 o p e r a t i n g

h o u

r s ,

d a i l y

e v e r y 2 5 0 o p e r a t i n g

h o

u r s

e v e r y 5 0 0 o p e r a t i n g

h o

u r s

e v e r y 1 0 0 0 o p e r a t i n g h

o u r s


o u r s


o u r s

a s

r e q u i r e d

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Maintenance

BOMAG78 BW 211/212/213 D-40

* Oil change intervals depend on quality of oil and fuel (sulphur content)

** Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h.

*** Also in case of repair in the hydraulic system.

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Every 10 operating hours

BOMAG 79BW 211/212/213 D-40


5.6 Check the engine oil level

! Danger

Danger of injury!

Support the engine hood for all maintenance

and repair work.

i Note

The machine must be parked horizontally with the

engine shut down.

Fig. 94l Pull the dipstick (Fig. 94) out, wipe it off with a

lint-free, clean cloth and reinsert it until it bot-

toms.

l Pull the dipstick back out again.

l If the oil level is below the "MAX" mark fill in oil.

l If the oil level is above the “Max” mark deter-

mine the cause and drain the oil off.

! Caution

Before longer work periods you should alwaystop the oil up to the "MAX"-mark.

For quality and quantity of oil refer to the table

of fuels and lubricants.

5.7 Check, clean the water sep-

arator

! Danger

Danger of injury!

Support the engine hood for all maintenance

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

Catch running out fuel and dispose of environ-

mentally.

Fig. 95

l Slacken the drain plug (Fig. 95) for a few turns

and catch running out fuel / water.

l Tighten the drain plug again and check for

leaks, if necessary replace the seal ring.

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BOMAG80 BW 211/212/213 D-40

5.8 Checking the fuel level

! Danger

Fire hazard!

When working on the fuel system do not use

open fire, do not smoke, do not refuel in closed

rooms, do not inhale any fuel fumes.

Fig. 96

l Check the fuel level on the fuel gauge (Fig.

96).

i Note

Never drive the fuel tank empty, because this

would required bleeding of the entire fuel system.

l Clean the area around the filler opening.

Fig. 97

l Open the fuel tank cover (Fig. 97).

! Caution

Dirty fuel can cause engine failures or even

damage to the engine.

If necessary fill in fuel through a screen filter.

l If necessary top up fuel (diesel or winter die-

sel).

For quality of fuel refer to the table of fuels and

lubricants.

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BOMAG 81BW 211/212/213 D-40

5.9 Checking the hydraulic oil

level

! Caution

In mit Panolin HLP Synth. 46, the same oil must

be used for filling up. In case of any other ester

based oil consult the lubrication service de-

partment of the respective oil manufacturer.

Fig. 98

l Check the oil level in the inspection glass (Fig.

98) on the hydraulic oil tank.

Normal level

approx. 3 cm below the upper edge of the inspec-

tion glass.

Minimum level

middle of inspection glass.

! Caution

If during the daily oil check the oil level is

found to have dropped, check all lines, hoses

and components for leakages.

l If necessary fill in hydraulic oil through the filler

neck.



5.10 Checking the coolant level

! Danger

Danger of scalding!

Top up coolant only when the engine is cold.

Fig. 99

l Check the coolant level (Fig. 99).

! Caution

If during the daily coolant level check the cool-

ant level is found to have dropped, check alllines, hoses and engine for leakages.

l To top up unscrew the lid and fill in coolant up

to the MAX-mark.

For quality of coolant refer to the table of fuels

and lubricants in chapter 5.2.

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BOMAG82 BW 211/212/213 D-40

5.11 Checking the dust separa-

tor on the oil bath air filter*

Fig. 100

l If the dust reaches the mark loosen the clamp

(Fig. 100), take the cover off and clean the

bowl.

* O pt io n

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BOMAG 83BW 211/212/213 D-40


5.12 Checking the tire pressure

! Caution

Always close the valves with the dust cap.

Fig. 101

l Check the tire pressure with a pressure gauge

and the tire inflation valve 1 (Fig. 101) in top

position.

Nominal value see "Technical Data".

i NoteEnsure even pressure in all tires.

l Screw the valve caps back on.

5.13 Clean the cooling fins on

engine and hydraulic oil

cooler

! 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

effect. Dirt deposits in these areas are substantial-

ly supported by oil and fuel on these surfaces. For

this reason you should always seal any oil or fuel

leaks in the vicinity of the cooling fan or the oil

cooler and clean the cooling surfaces after.

Cleaning with compressed air

Fig. 102

i Note

Start to blow out from the exhaust side.

l Blow the cooler (Fig. 102) out with com-

pressed air.

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BOMAG84 BW 211/212/213 D-40

Cleaning with cold cleansing agent

! Caution

Protect electrical equipment such as genera-

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.

5.14 Check the oil level in the

drive axle


Fig. 103

l Unscrew the oil level inspection plug (Fig. 103)

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.

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BOMAG 85BW 211/212/213 D-40

5.15 Checking the oil level in left/

right wheel hubs

Fig. 104

l Move the machine until the oil level inspection

plug 1 (Fig. 104) 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.

l Repeat this inspection on the other side.

5.16 Checking the oil level in the

vibration bearing housings

i Note

Check the oil level only at operating temperature

after running the vibration for about 1/2 hour.

Fig. 105

l Move the drum so that the oil level control plug

(Fig. 105) on the left hand side is in lowest po-

sition.

l Unscrew the control plug (1).

Some oil should drip out of the level bore

l If necessary unscrew the oil filler plug (2) and

fill in some oil through the filler bore (2), until it

starts to run out from the level inspection bore.


lubricants.

l Screw the oil filler (2) and control plug (1) back

in.

l Repeat this procedure on the opposite side.

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BOMAG86 BW 211/212/213 D-40


5.17 Changing engine oil and oil

filter cartridges

! Caution

The oil change at 500 operating hours refers to

the use of fuels with a sulphur content of less

than 0.5%.

When using fuels with a sulphur content high-

er than 0.5 % the oil change intervals must be

halved (see section 5.2 fuels and lubricants).

Drain the engine oil only when the engine is

warm.

! Danger

Danger of scalding!

When draining off hot oil.

Environment

Catch running out oil and dispose of environ-

mentally together with the engine oil filter car-

tridge.

Fig. 106

l Unscrew the drain plug (Fig. 106) and catch

running out oil.

l Turn the drain plug tightly back in.

Fig. 107

l Thoroughly clean the outside of both filter car-

tridges (Fig. 107).

l Unscrew both filter cartridges using an appro-

priate filter wrench.

i Note

The filter cartridges are fitted with a valve that p re-

vents engine oil from running out during removal

and installation.

l Clean the sealing face on the filter carrier from

any dirt.

l

Slightly oil the rubber seal on the new filter car-tridges.

Fig. 108

l Turn the new filter cartridges (Fig. 108) on by

hand, until the seal contacts.

l Tighten the filter cartridges for another half

turn.

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BOMAG 87BW 211/212/213 D-40

Fig. 109

l Fill in new engine oil (Fig. 109).



l Tighten the oil filler cap properly.

! Caution

Before starting crank the engine with the start-

er motor until the oil pressure warning light

goes out.

l After a short test run check the oil level on the

dipstick, if necessary top up to the top dipstick

mark.l Check filter cartridge and drain plug for leaks

after a short test run.

l Shut the engine down and wait for about 15

minutes, so that all oil can flow back into the oil

sump.

l Check the oil level again, if necessary fill up to

the Max.-mark.

5.18 Draining the fuel tank

sludge

! Danger

Fire hazard!


open fire, do not smoke.

Do not spill any fuel.

Catch running out fuel, do not let it seep into

the ground.

Do not inhale any fuel fumes.

Fig. 110

l Unscrew the drain plug (Fig. 110) 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.

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BOMAG88 BW 211/212/213 D-40

5.19 Service the battery

! Danger

Danger of cauterisation ! Danger of explosion!

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!

EnvironmentDispose of the old battery environmentally.

i Note

Maintenance free batteries also need care. Main-

tenance free only means that the fluid level does

not need to be checked. Each battery suffers un-

der self-discharge, which may, in not checked oc-

casionally, even cause damage to the battery as a

result of exhaustive discharge.

The following therefore applies for the service

life: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 boost 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.

! Caution

Exhausted batteries (batteries with formation

of sulphate on the plates are not covered un-

der warranty!

l Open the engine hood and remove the cover-

ing

Fig. 111

l Remove the battery (Fig. 111) and clean the

battery compartment.

l Clean the outside of the battery.

l Clean battery poles and pole clamps and

grease them with pole grease (Vaseline).

l Check the fastening of the battery.

l On serviceable batteries check the acid level,

if necessary top up to the filling mark with dis-

tilled water.

Charging voltage recommendation

Fig. 112

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BOMAG 89BW 211/212/213 D-40

5.20 Check condition and ten-

sion of refrigerant compres-

sor V-belt, replace the V-belt

! Danger

Danger of injury!

Work on the V-belt must only be performed

with the engine shut down.

Checking the V-belt

Fig. 113

l Inspect the entire circumference of the V-belt

(Fig. 113) 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.

Tensioning the V-belt

Fig. 114

l Slightly slacken the fastening screws 1, 2 and

3 (Fig. 114).

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.

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BOMAG90 BW 211/212/213 D-40

5.21 Servicing the air condition-

ing*

Cleaning the condenser

! Caution

A soiled condenser results in a considerable

reduction of air conditioning power.

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.

! 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

In case of formation of foam have the air con-

ditioning system inspected by the service de-

partment.

Fig. 115

l Clean the condenser fins (Fig. 115) with com-

pressed air or a cold water jet.

Checking the refrigerant level

l Start the engine.

l

Switch the air conditioning on.

Fig. 116

l Turn the rotary fan switch (Fig. 116) to position

"2", middle fan stage.

l Open the air outlet openings on both control

units.

Fig. 117

l Turn the rotary switch for the air conditioning

thermostat (Fig. 117) clockwise. The air flow

cools down.

i Note

The adjusted temperature must be below the actu-

al temperature inside the cabin, so that the com-

pressor will be switched on.


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BOMAG 91BW 211/212/213 D-40

Fig. 118

l Check whether the white float (Fig. 118) inside

the inspection glass of the drier/collector unitfloats right at the top.

i Note

The refrigerant level is correct.

Fig. 119

l If the white float (Fig. 119) inside the inspec-

tion glass of the drier/collector unit floats at the

bottom, inform the service department.

i Note

The refrigerant level is not correct.

l Refrigerant must be filled up, if necessary the

air conditioning system must be checked for

leaks.

Checking the moisture level of the dry-ing agent

Fig. 120

l Check the moisture indication pearl (Fig. 120)

inside the inspection glass of the drier/collec-

tor unit.

blue = drying agent o.k.

purple = 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.

Checking the condition of the drier/col-lector unit

! Caution

According to the regulation for pressure reser-

voirs all pressure reservoirs must be repeated-

ly inspected by a specialist. In this sense

repeated inspections are external examina-

tions, normally on pressure reservoirs in oper-

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

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BOMAG92 BW 211/212/213 D-40

arising from the handling and operation of

pressure reservoirs.

! 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. 121

l Check the drier/collector unit (Fig. 121) for me-

chanical damage or rust.

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BOMAG 93BW 211/212/213 D-40


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. 122

Valve 1 (Fig. 122) white = not adjustable

Valve (2) black = adjustable

Fig. 123

Crankshaft position 1 (Fig. 123) (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-

ing valve is adjusted.

Fig. 124

Crankshaft position 2 (Fig. 124) (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.

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BOMAG94 BW 211/212/213 D-40

Check the valve clearance

l Loosen the crankcase ventilation valve and

swing it to the side.

Fig. 125

l Remove the valve cover (Fig. 125).

l Crankshaft position as per "valve adjustment

schematic".

Fig. 126

l Check valve clearance 2 (Fig. 126) 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.

Adjusting the valve clearance

Fig. 127

l Slightly slacken the counter nut. Adjust set-

screw 7 (Fig. 127) with a screwdriver, until the

feeler gauge (6) can be inserted and pulled out

with little resistance after retightening the

counter nut.

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.

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BOMAG 95BW 211/212/213 D-40

5.23 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. 128

l Check the distance between the tongue of the

moveable tensioner arm and the fixed tension-

er housing (Fig. 128).

l If measurement "a" is smaller than 3 mm, re-

place the ribbed V-belt.

Changing the ribbed V-belt

Fig. 129

l Unscrew the fastening screws (Fig. 129) and

slide the fan forward.

Fig. 130

l Release the idler pulley (Fig. 130) 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.

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BOMAG96 BW 211/212/213 D-40

5.24 Change the fuel filter car-

tridge

! Danger

Fire hazard!


open fire, do not smoke and do not spill any fu-

el.


the ground.


Fig. 131

l Loosen and unscrew the fuel filter cartridge

(Fig. 131) using an appropriate filter wrench.


any dirt.

Fig. 132

l Slightly oil the rubber seal (Fig. 132) on the

new filter cartridge.

l Fill the filter cartridge with clean diesel fuel.

l Turn the new filter cartridge on by hand, until

the seal contacts.

l Tighten the filter element for another half turn.

l Check the filter cartridge for leaks after a short

test run.

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BOMAG 97BW 211/212/213 D-40

5.25 Change the fuel pre-filter

cartridge

! Danger

Fire hazard!


open fire, do not smoke and do not spill any fu-

el.


the ground.


Fig. 133

l Unscrew the fuel filter cartridge (Fig. 133) us-

ing an appropriate filter wrench.


any dirt.

Fig. 134

l Unscrew the water separator from the filter

cartridge (Fig. 134).

Fig. 135

l Apply a thin coat of oil to the rubber seal of the

water separator 1 (Fig. 135).

l Screw the water separatoron by hand (2), until

the seal contacts.

l Tighten the water separator for another half

turn (3).

l Fill the filter cartridge with clean diesel fuel (4).

l Apply some oil to the rubber seal of the filter el-

ement (5) and screw it on by hand, until the

seal contacts.

l Tighten the filter element for another half turn

(6).l Check the filter cartridge for leaks after a short

test run.

i Note

Air in the fuel system causes irregular running of

the engine, a drop in engine power, stalls the en-

gine and makes starting impossible.

Therefore bleed the fuel system after changing the

fuel prefilter.

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BOMAG98 BW 211/212/213 D-40

Fig. 136

l Slacken the bleeding screw (Fig. 136) 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 (Fig.

136) without air bubbles.

l Then tighten the b leeding screw while pump-

ing.

5.26 Check the engine mounts

Fig. 137

l Tighten fastenings of intake and exhaust man-

ifolds (Fig. 137) on the cylinder heads.

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.

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BOMAG 99BW 211/212/213 D-40

5.27 Change the oil in the drive

axle

i Note

On other axle versions drain and filler plugs are of

slightly different design. Perform the oil change ac-

cordingly.

! Caution

Drain oil only at operating temperature.

Environment

Catch old oil and dispose of environmentally.


Fig. 138

l Clean and unscrew all level inspection and

drain plugs (Fig. 138).

l Drain and catch all oil.

l Clean the drain plug and turn it back in with a

new seal ring.

Fig. 139

l Fill in oil through the oil level inspection bores

(Fig. 139), until it has reached the bottom edgeof the bore.

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.



l Retighten the filler and level inspection plug.

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BOMAG100 BW 211/212/213 D-40

5.28 Changing the oil in the

wheel hubs

! Caution

Drain oil only at operating temperature.

Change the oil on both sides of the axle.

Environment

Catch old oil and dispose of environmentally.

Fig. 140

l Move the drive wheel, until the plug (Fig. 140)

is in bottom position.

l Clean and unscrew the plug.

l Drain and catch all oil.

Fig. 141

l Move the drive wheel, until the plug (Fig. 141)

is in horizontal position on the housing.

l Fill in oil, until it reaches the bottom edge of the

bore.



l Turn the plug tightly back in.

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BOMAG 101BW 211/212/213 D-40

5.29 Changing the oil for the vi-

bration bearings

! Caution

Change the oil at operating temperature. For

this purpose run the machine approx. half an

hour with vibration.

Environment


mentally.

Fig. 142

l Move the drum until the drain plug 1 (Fig. 142)

is in lowest position.

l Unscrew the drain plug, drain all oil off and

catch it.

l Once the oil has run out clean the drain plug

and screw it tightly back in.

Fig. 143

l Unscrew the level plug 1 (Fig. 143) at the bot-

tom of the drum and fill in oil through the fillerbore (2), until it starts to run out through the

level bore.



l Screw the oil filler (2) and control plug (1) back

in.

l Repeat the oil change on the opposite side.

l Check the oil level again at operating temper-

ature (after running the vibration for approx.

0.5 hours).

! Caution

Overfilling causes overheating of the vibration

bearings!

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BOMAG102 BW 211/212/213 D-40

5.30 Retighten the fastening of

the axle on the frame

Fig. 144

l Check all fastening nuts on axle mounting

bolts (Fig. 144) for tight fit.

5.31 Tightening the wheel nuts

Fig. 145

l Tighten the wheel nuts (Fig. 145) in a cross-

type pattern.

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BOMAG 103BW 211/212/213 D-40

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. 146

l Check the cabin, especially the ROPS (Fig.

146) 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 theseat belt.

5.33 Cleaning the oil bath air fil-

ter *

Fig. 147

l Loosen the quick locks (Fig. 147), take the fil-

ter bowl off and empty it.

l Clean the filter mesh by repetitive dipping into

diesel fuel.

l Clean the filter bowl with diesel fuel and fill in

engine oil up to the level mark.

l reinstall the filter bowl.

* Option

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BOMAG104 BW 211/212/213 D-40


5.34 Changing the hydraulic oil

and the breather filter

i Note

See also section 5.1 "Notes on the Hydraulic Sys-

tem".

! Caution

Apart from the normal oil change intervals the

hydraulic oil must also be changed after major

repairs in the hydraulic system.

Change the hydraulic oil only at operating tem-

perature.

Clean the area around the hydraulic oil tank,

the filler opening and the breather filter.

Do not use any detergents to clean the system.

Do not start the engine after draining the hy-

draulic oil.

Change the hydraulic oil filter element with

every hydraulic oil change.

! Danger

Danger of scalding!

Danger of scalding by hot oil.

Environment


mentally.

i Note

The hydraulic oil filter element should only be

changed after the test run.

Fig. 148

l Unscrew the plug (Fig. 148) and drain the hy-

draulic oil off.

l Check the sealing ring (1), replace if neces-

sary and screw the plug tightly back in.

Fig. 149

l Take the filler cap (Fig. 149) off.

l Fill in hydraulic oil through the screen.

i Note

We recommend to use the filling and filtering unit

(part-no. 079 930 35) with fine filter to fill the hydraulic system. This filters the hydraulic oil, pro-

longs the service life of the hydraulic oil filter and

protects 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

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BOMAG 105BW 211/212/213 D-40



i Note

The breather filter for the hydraulic tank is located

in the filler cap and must therefore be replaced

with the filler cap.

l Close the tank with the new filler cap.

5.35 Changing the hydraulic oil

filter

! 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. 150

l Unscrew the cap nut 4 (Fig. 150) 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 can be an early indicator for

a premature failure of system components and

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BOMAG106 BW 211/212/213 D-40

a possible malfunction of parts. In such a case

perform trouble shooting and, if necessary, re-

place or repair defective components. Negli-

gance may damage the complete hydraulicsystem.

Do not clean or reuse the filter element.

l Take the old filter element (3) out and clean

the filter bowl and the thread.

l Reinstall the filter bowl with the new filter ele-

ment, check the condition of the O-rings (1)

and (2), replace if necessary.

l After a test run check the filter for leaks.

5.36 Changing the coolant

! Danger

Danger of scalding!

Change the coolant only when the engine is

cold.

Environment

Catch running out coolant and dispose of envi-

ronmentally.

Fig. 151l Switch the shut-off valve for the cabin heater

to "warm".

Fig. 152

l Unscrew the drain plug, drain all coolant off

and catch it.

l Screw the plug back in after all coolant has

been drained off.

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BOMAG 107BW 211/212/213 D-40

Fig. 153

l Screw the lid off and fill in coolant up to the

MAX-mark.

For quality of coolant refer to section 5.2, fuels

and lubricants.

l Start the engine and run it up to operating tem-

perature.

l Allow the engine to cool down and check the

coolant level again, top up if necessary.

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BOMAG108 BW 211/212/213 D-40


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.

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As required

BOMAG 109BW 211/212/213 D-40

As required

5.38 Cleaning, changing the dry

air filter cartridge

! Caution

Perform cleaning, maintenance and repair

work only with the engine shut down. Do not

start the engine after removing the filter ele-

ment.

Fig. 154

Servicing of the dry air filter is necessary when the

yellow piston (Fig. 154) has reached the inscrip-

tion "Service" in front of a red background, but atthe latest after 2 years.

After completion of the filter service reset the indi-

cator back to "Zero" by pressing the button.

Removing the main filter element

l Fully open the engine hood.

Fig. 155

l Unclip three clamps on the housing cover and

take off the cover (Fig. 155).

Fig. 156

l Pull the main filter element (Fig. 156) with light

turning movements.

Cleaning the main filter element

! Caution

If necessary, the main filter element may be

cleaned up to five times. It must be renewed atthe latest after a maximum utilization period of

two years.

The number of cleaning intervals of the main

filter element can be marked on the safety ele-

ment with a ball pen or a felt pen.

Cleaning does not make sense if the main filter

element is covered with a sooty deposit. Use a

new filter cartridge.

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As required

BOMAG110 BW 211/212/213 D-40

Incorrectly handled inserts may be ineffective

because of damage (e.g. cracks) and cause

damage to the engine.

Replace the safety cartridge if the main filter el-ement is defective!

Additional cleaning intervals between two fil-

ter services signalized by the fault monitoring

board are not necessary.

Fig. 157

i Note

Forcleaning purposes fit a tube to the compressed

air gun (Fig. 157), the end of which should be bent

for approx. 90°.

The length should reach down to the bottom of the

cartridge.

l Blow the cartridge out with compressed air

(max. 5 bar) from inside to outside by moving

the tube up and down inside the cartridge, until

it if free of dust.

l Examine the filter cartridge with a torch for

cracks and holes in the paper bellows.

! CautionDo not continue to run the machine with a

damaged main filter element. If in doubt use a

new main filter element.

Cleaning the dust bowl

Fig. 158

l Pull the internal part (Fig. 158) out and remove

the dust from the cover.

l Reinsert the inner part.

! Caution

When assembling the inner part make sure

that the notch in the cover engages in the

opening of the inner part.

Installing the main filter element

l Slide the main filter element carefully into the

housing.

When closing the housing cover the main filter el-

ement is automatically forced in the correct posi-

tion.

l Reinstall the service covers.

Changing the safety filter element

! Caution

The safety filter element must not be cleanedand should not be used again after it has been

removed.

Break the seal only to replace the safety filter

element.

The safety filter element must be replaced:

if the main filter element is defective,

after five service intervals of the filter car-

tridge,

at the latest after 2 years,

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As required

BOMAG 111BW 211/212/213 D-40

if the warning light comes on again after serv-

icing the main filter cartridge.

l Remove the housing cover and pull the main

filter element off.

Fig. 159

l Perforate the seal of the safety filter element

from inside to outside using a suitable tool

(Fig. 159) and pull both latches up.

l Grip the safety element by both latches and

pull it out with slight turning movements.

l Push in a new safety filter element.

l Reassemble main filter element and cover.

! Caution

Make sure that the cover locks engage correct-

ly.

5.39 Adjusting the scrapers

smooth drum only

Fig. 160

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. 160) loosen the

fastening screws (2) in the slots and push the

scraper bracket towards the drum until the

scraper touches.

l Retighten the fastening screws.

padfoot drum only

Fig. 161

l Check condition and adjustment of scrapers 2

(Fig. 161), 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-

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As required

BOMAG112 BW 211/212/213 D-40

er towards the drum, leaving a gap of approx.

25 mm.

l Retighten the fastening screws.

5.40 Adjusting the parking brake

! Caution

Have adjustment work on the brake performed

by a specialist! Always adjust both sides.

l Secure the machine with chocks against unin-

tentional rolling.

l Start the diesel engine to release the brake.

Fig. 162

l Unlock the travel lever (Fig. 162) by pushing it

to the left, but do not actuate it to position "I" or"II".

The parking brake is released

Fig. 163

l Unscrew the locking plate 2 (Fig. 163).

l Turn the square (1) in anti-clockwise direction

against the end stop.

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As required

BOMAG 113BW 211/212/213 D-40

Fig. 164

l To adjust the clearance turn the square 1 (Fig.

164) three revolutions back in clockwise direc-tion.

l Screw the locking plate back on.

l Pull the plug off the brake valve and try to

drive.

The machine must be braked.

5.41 Changing the tires

! 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. 165

l Attach the wheel (Fig. 165) and tighten the

wheel nuts crosswise with 550 Nm (405 ft. lb.).

l Check the tire pressure, see technical data.

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As required

BOMAG114 BW 211/212/213 D-40

5.42 Changing the fresh air filter

in the cabin

Fig. 166

l Unscrew the fastening screws for the filter

bracket (Fig. 166) and take the filter out.

l Insert the new filter and reassemble the filter

bracket.

5.43 Tightening torques

Fig. 167

* Strength classes for screws with untreated, non-lubricated surface. Screw quality designations are

stamped on the screw heads.

8.8 = 8G

10.9 = 10K

12.9 = 12K

l Axle - frame

M 22x1.5 = 710 Nm

l Wheel nuts

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.

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As required

BOMAG 115BW 211/212/213 D-40

5.44 Engine conservation

If the engine is to be shut down for a longer periodof time (e.g. over winter), please consult the serv-

ice department of the engine manufacturer for fur-

ther details.

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As required

BOMAG116 BW 211/212/213 D-40

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BOMAG 117BW 211/212/213 D-40

6 Trouble shooting

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Trouble shooting

BOMAG118 BW 211/212/213 D-40

6.1 General notes

The following work must only be carried out byqualified 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.

! Danger

Danger of injury!

Keep away from rotating parts of the engine.

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Trouble shooting

BOMAG 119BW 211/212/213 D-40

6.2 Engine

Faults Possible cause Remedy

The engine

does not start

Starter defective or pinion not engaging Have examined by a specialist

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-

fin separation.

Change the filter. use winter fuel

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-

tive

Have examined by a specialist

The engine

starts poorly and

works irregularly

with poor power

Battery power too low, battery clamps

loose or oxidized, causing the starter to

turn too slowly

Have the battery checked, clean the ter-

minal clamps, tighten them and cover

them with acid free grease

Especially during winter: the use of too

viscous engine oil

Use engine oil suitable for the ambient

temperature

Fuel supply restricted, in winter fuel sys-

tem clogged due to paraffin separation

Change the fuel filter. Check the line con-

nections for leaks and tighten the fittings.

Use winter fuel in the cold season.

Incorrect valve clearan ce Adjust the va lve cle arance

Injecti on 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

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Trouble shooting

BOMAG120 BW 211/212/213 D-40

Excessive ex-

haust smoke

Engine oil level too high Dra in the oil to the uppe r dipstick mark

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-

ken compression rings or incorrect valve

clearance

Have compression rings and pistons ex-

amined by a specialist, adjust the valve

clearance

Incorrect valve cl earance Adjust the valve clearance

Engine over-

heats, shut

down immedi-

ately!

Cooling fins on radiator extremely soiled

(the warning light "engine oil temperature"

lights)

Clean the cooling fins

Injection valve defective Ha ve examined by a sp ecialist

Engine oil level too low Top up engine oil to the upper dipstick

mark

Filling capacity of the injection pump not

correctly adjusted

Have adjusted by a specialist

Co oling air fl ow restricte d Clean the cooling air duct

V-belt loos or broken Tension or replace the V-belt

Poor engine

power

Engi ne oil level too high Dra in the en gine oil d own to the uppe rd ip-

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

Incorrect valve clearance Adj ust the valve clearan ce

Injection valve defective Ha ve examined by a sp ecialist

Engine oil pres-

sure too low

Engine oil level too low (control light "en-

gine oil pressure" lights, the warning

buzzer sounds)

Top up oil

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-

trol light lights

during opera-

tion, the warning

buzzer sounds

Generator spee d too low Ch eck the V-belt tension, repl ace the V-

belt if necessary

The generator does not charge the bat-

tery, because generator or regulator is de-

fective

Have examined by a specialis

Faults Possible cause Remedy

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Trouble shooting

BOMAG 121BW 211/212/213 D-40

7/23/2019 O&M BW211 BW212


Trouble shooting

BOMAG122 BW 211/212/213 D-40

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7/23/2019 O&M BW211 BW212


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