You are on page 1of 124

Operating instructions Maintenance instructions

BW 211 / 212 / 213 D-40 BW 211 / 212 / 213 PD-40


S/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

Catalogue number

008 158 81

08/2006

Foreword

BOMAG machines are products from the wide range of BOMAG compaction equipment.
F oreword

BOMAGs vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your machine. This manual comprises:
l l l l

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 Engineering Liability Association Safety Rules for the Operation of Road Rollers and Soil Compactors and all relevant accident prevention regulations. For your own personal safety you should only use original spare parts from BOMAG. In the course of technical development we reserve 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 available from your BOMAG dealer against the serial number of your machine. Your BOMAG dealer will also supply you with information 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

Safety regulations Operating instructions Maintenance instructions Trouble shooting

Using these instructions will


l l

help you to become familiar with the machine. avoid malfunctions caused by unprofessional operation.

Compliance with the maintenance instructions will


l

enhance the reliability of the machine on construction sites, prolong the lifetime of the machine, reduce repair costs and downtimes.

l l

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, if it is used for purposes other than those mentioned in these instructions.

No warranty claims can be lodged in case of damage resulting from


l l l

operating errors, insufficient maintenance and wrong fuels and lubricants.

Please note! This manual was written for operators and maintenance 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 maintenance instructions are part of the machine.

BW 211/212/213 D-40

BOMAG

Foreword

Please fill in ............................ Machine type (Fig. 1) ............................ Serial No. (Fig. 1 and 2) ............................ Engine type (Fig. 3) ............................ Engine No. (Fig. 3)

Note

Fig. 1

Fill in the above listed data when receiving the machine. Upon receipt of the machine our organization will instruct you about correct operation and maintenance. Please observe strictly all safety regulations and notes on potential dangers!

Fig. 2

Fig. 3

BOMAG

BW 211/212/213 D-40

Table of Contents

Technical Data Safety regulations Indicators and Controls 3.1 General notes 3.2 Description of indicators and control elements 3.3 Display and control elements BTM 3.4 Description of indicating and control elements BTM 3.5 Line diagram (EVIB) 3.6 Description of line diagram (EVIB) 3.7 Bar diagram (EVIB) Operation 4.1 General notes 4.2 Tests before starting to operate 4.3 Disarming the anti-theft protection 4.4 Starting the engine 4.5 Starting with jump wires 4.6 Driving the machine 4.7 Switching the vibration on and off 4.8 Operating the parking brake, stopping the machine 4.9 Shutting the engine down 4.10 Emergency exit 4.11 Adjusting the steering wheel 4.12 Adjusting the seat 4.13 Operating the hood 4.14 Towing in case of an engine failure 4.15 Transport 4.16 Measuring pass with BTM 4.17 Finishing compaction of a track 4.18 Printing measuring data after completing compaction 4.19 Changing the paper roll in the measuring value printer 4.20 Changing the printer ribbon in the measuring value printer Maintenance 5.1 General notes on maintenance 5.2 Fuels and lubricants 5.3 Table of fuels and lubricants 5.4 Running-in instructions 5.5 Maintenance chart 5.6 Check the engine oil level 5.7 Check, clean the water separator 5.8 Checking the fuel level

7 15 23 26 26 36 38 40 42 43 45 46 46 47 48 50 50 52 53 54 55 55 56 56 57 59 61 64 65 66 67 69 70 71 74 75 76 79 79 80

BW 211/212/213 D-40

BOMAG

Table of Contents

5.9 Checking the hydraulic oil level 5.10 Checking the coolant level 5.11 Checking the dust separator on the oil bath air filter 5.12 Checking the tire pressure 5.13 Clean the cooling fins on engine and hydraulic oil cooler 5.14 Check the oil level in the drive axle 5.15 Checking the oil level in left/right wheel hubs 5.16 Checking the oil level in the vibration bearing housings 5.17 Changing engine oil and oil filter cartridges 5.18 Draining the fuel tank sludge 5.19 Service the battery

81 81 82 83 83 84 85 85 86 87 88

5.20 Check condition and tension of refrigerant compressor V-belt, replace the Vbelt 89 5.21 Servicing the air conditioning 5.22 Check, adjust the valve clearance 5.23 Checking / replacing the ribbed V-belt 5.24 Change the fuel filter cartridge 5.25 Change the fuel pre-filter cartridge 5.26 Check the engine mounts 5.27 Change the oil in the drive axle 5.28 Changing the oil in the wheel hubs 5.29 Changing the oil for the vibration bearings 5.30 Retighten the fastening of the axle on the frame 5.31 Tightening the wheel nuts 5.32 Checking the ROPS 5.33 Cleaning the oil bath air filter 5.34 Changing the hydraulic oil and the breather filter 5.35 Changing the hydraulic oil filter 5.36 Changing the coolant 5.37 Checking the injection valves 5.38 Cleaning, changing the dry air filter cartridge 5.39 Adjusting the scrapers 5.40 Adjusting the parking brake 5.41 Changing the tires 5.42 Changing the fresh air filter in the cabin 5.43 Tightening torques 5.44 Engine conservation Trouble shooting 6.1 General notes 6.2 Engine 90 93 95 96 97 98 99 100 101 102 102 103 103 104 105 106 108 109 111 112 113 114 114 115 117 118 119

BOMAG

BW 211/212/213 D-40

1 Technical Data

BW 211/212/213 D-40

BOMAG

Technical Data

Fig. 4

Dimensions in mm BW 211 D-40 BW 211 PD-40

A 2960 2960

B 2250 2250

D 1500 1480

H 2268 2268

H2 2972 2972

K 490 490

L 5840 5840

O1 60 60

O2 60 60

S 25 25

W 2130 2130

BW 211 D-40

BW 211 PD-40

Weights Operating weight (CECE) with ROPS and cabin Axle load, drum (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Max. gradability (depending on soil) Engine Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 3046 Rated speed Fuel

kg kg kg kg/cm

9500 5750 3750 27

10500 6750 3750 -

km/h km/h %

0 ... 6 0 ... 10 45

0 ... 6 0 ... 10 49

kW 1 rpm

Deutz BF4M 2012C Water 4 98 2300 Diesel

Deutz BF4M 2012C Water 4 98 2300 Diesel

BOMAG

BW 211/212/213 D-40

Technical Data

Electrical equipment Drive system Driven axles Brakes Service brake Parking brake Steering Type of steering Steering operation Vibration Vibrating drum Drive system Frequency Amplitude Tires Tire size Air pressure Filling capacities Engine Fuel Hydraulic oil Coolant
*

BW 211 D-40 12 hydrostatic 2

BW 211 PD-40 12 hydrostatic 2

hydrostatic hydr.-mech.

hydrostatic hydr.-mech.

articulated hydrostatic

articulated hydrostatic

Hz mm

1 hydrostatic 30/36 1,8/0,9

1 hydrostatic 30/36 1,64/0,82

bar

23.1-26/12 PR TL C7 1,4

23.1-26/12TL R1 1,4

Litres Litres Litres Litres

10 250 60 16

10 250 60 16

The right for technical modifications remains reserved

BW 211/212/213 D-40

BOMAG

Technical Data

Fig. 5

Dimensions in mm BW 212 D-40 BW 212 PD-40

A 2960 2960

B 2250 2250

D 1500 1480

H 2268 2268

H2 2972 2972

K 490 490

L 5840 5840

O1 60 60

O2 60 60

S 25 25

W 2130 2130

BW 212 D-40

BW 212 PD-40

Weights Operating weight (CECE) with ROPS and cabin Axle load, drum (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Max. gradability (depending on soil) Engine Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 3046 Rated speed Fuel

kg kg kg kg/cm

10900 7150 3750 33,6

11350 7600 3750 -

km/h km/h %

0 ... 6 0 ... 10 45

0 ... 6 0 ... 10 49

kW 1 rpm

Deutz BF4M 2012C Water 4 98 2300 Diesel

Deutz BF4M 2012C Water 4 98 2300 Diesel

10

BOMAG

BW 211/212/213 D-40

Technical Data

Electrical equipment Drive system Driven axles Brakes Service brake Parking brake Steering Type of steering Steering operation Vibration Vibrating drum Drive system Frequency Amplitude Tires Tire size Air pressure Filling capacities Engine Fuel Hydraulic oil Coolant
*

BW 212 D-40 12 hydrostatic 2

BW 212 PD-40 12 hydrostatic 2

hydrostatic hydr.-mech.

hydrostatic hydr.-mech.

articulated hydrostatic

articulated hydrostatic

Hz mm

1 hydrostatic 30/36 1,8/0,9

1 hydrostatic 30/36 1,64/0,82

bar

23.1-26/12 PR TL C7 1,4

23.1-26/12TL R1 1,4

Litres Litres Litres Litres

10 250 60 16

10 250 60 16

The right for technical modifications remains reserved

BW 211/212/213 D-40

BOMAG

11

Technical Data

Fig. 6

Dimensions in mm BW 213 D-40 BW 213 PD-40

A 2960 2960

B 2250 2250

D 1500 1480

H 2268 2268

H2 2972 2972

K 490 490

L 5840 5840

O1 60 60

O2 60 60

S 35 25

W 2130 2130

BW 213 D-40

BW 213 PD-40

Weights Operating weight (CECE) with ROPS and cabin Axle load, drum (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Max. gradability (depending on soil) Engine Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 3046 Rated speed Fuel

kg kg kg kg/cm

12420 7820 4600 36,7

12870 8270 4600 -

km/h km/h %

0 ... 6 0 ... 10 45

0 ... 6 0 ... 10 49

kW 1 rpm

Deutz BF4M 2012C Water 4 98 2300 Diesel

Deutz BF4M 2012C Water 4 98 2300 Diesel

12

BOMAG

BW 211/212/213 D-40

Technical Data

Electrical equipment Drive system Driven axles Brakes Service brake Parking brake Steering Type of steering Steering operation Vibration Vibrating drum Drive system Frequency Amplitude Tires Tire size Air pressure Filling capacities Engine Fuel Hydraulic oil Coolant
*

BW 213 D-40 12 hydrostatic 2

BW 213 PD-40 12 hydrostatic 2

hydrostatic hydr.-mech.

hydrostatic hydr.-mech.

articulated hydrostatic

articulated hydrostatic

Hz mm

1 hydrostatic 30/36 1,8/0,9

1 hydrostatic 30/36 1,64/0,82

bar

23.1-26/12 PR TL C7 23.1-26/12TL R1 1,4

1,4

Litres Litres Litres Litres

10 250 60 16

10 250 60 16

The right for technical modifications remains reserved

BW 211/212/213 D-40

BOMAG

13

Technical Data

14

BOMAG

BW 211/212/213 D-40

2 Safety regulations

BW 211/212/213 D-40

BOMAG

15

Safety regulations

General
This BOMAG machine is built in accordance with the latest technical standard and the valid technical rules and regulations. There is, however, a risk of danger for persons and property if:
l

Unintended use
Dangers may, however, arise from the machine if it is used by untrained personnel in an unprofessional way or if it is used for purposes other than those 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 explosive environment is prohibited.

the machine is used for purposes other than those it is intended for the machine is operated by untrained personnel the machine is modified or converted in an unprofessional way the applicable safety regulations are not observed.

Who is allowed to work with the machine?


The machine must only be operated by trained and authorized persons which are at least 18 years of age. The responsibilities for the operation of the machine must be clearly specified and complied with. Persons under the influence of alcohol, medication 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.

Each person involved in operation, maintenance and repair of the machine must therefore read and apply these safety regulations. This should be confirmed by obtaining the signatures of the customer, if necessary. Furthermore the following regulations and instructions are obviously also valid:
l l

applicable accident prevention instructions generally acknowledged safety and road traffic regulations 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.

Conversions and alterations to the machine


Unauthorized conversions to the machine are prohibited for safety reasons. Original parts and accessories have been specially designed for this machine. We wish to make expressly clear that we have not tested or authorized any original parts or special equipment not supplied by us. The installation and/or use of such products can impair the active and/or passive driving safety. The manufacturer expressly excludes any liability for damage resulting from the use of non-original parts or accessories.

Intended use
This machine must only be used for:
l

compaction of bituminous materials, e.g. road surface layers. (AC and AD machines only) medium and heavy compaction tasks in earth work (road sub-bases) This machine must only be operated with fully functional safety equipment. The machine should be checked by an expert once every year.

Safety notes in the operating and maintenance instructions:


Danger Sections marked like this point out possible dangers for persons.
!

16

BOMAG

BW 211/212/213 D-40

Safety regulations

Caution Sections marked like this point out possible dangers for the machine or for parts of the machine.
!

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.

Note

Sections marked like this provide technical information concerning the optimal economical use of the machine.
Environment Sections marked like this highlight activities for the safe and environmental disposal of fuels and lubricants as well as replaced parts. Observe all environment protection regulations.

Checking the Roll Over Protection Structure (ROPS)

Note

On machines with cabin the ROPS is an integral part of the cabin.


The machine frame must not be distorted, bent or cracked 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 tightened (observe the tightening torque values). Screws and nuts must not be damaged, bent or deformed. With the cabin installed check also the condition of the cabin mounts (rubber elements and screws). Neither must any additional parts be welded or bolted on, nor must any holes be drilled without the permission of the manufacturer, since this may impair the strength of the structure.

Information and safety stickers/decals on the machine


Keep stickers/decals complete (see spare parts catalogue) and fully legible and observe their meaning. Replace damaged or illegible stickers/decals immediately.

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 slipping off. Secure the machine on the transport vehicle against rolling off, slipping and turning over. Persons are highly endangered if
l l

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 control elements, the working mode of the machine and the area you will be working in. Use your personal protective outfit (hard hat, safety boots etc.). Check before mounting the machine if:
l

they step or stand under loads being lifted 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.

there are persons or obstructions beside or under the machine

BW 211/212/213 D-40

BOMAG

17

Safety regulations

the machine is free of any oily and combustible material all handrails, steps and platforms are free of grease, oils, fuels, dirt, snow and ice the engine compartment hood is closed and locked

Driving the machine


Persons in the endangered area If the machine has turned over and the cabin door is 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 immediately if persons remain in the danger area despite 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 emergency 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-voltage power lines:
l l

To climb onto the machine use steps and handrails. Check before starting, whether:
l l

the machine shows any obvious defects all protective devices are properly secured in their place steering, brakes, control elements, lighting and warning horn are in order the seat is correctly adjusted the mirrors (if available) are clean and correctly adjusted.

l l

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 operator's seat For starting set all control levers to "neutral position". 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 cable last 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 adequate supply of fresh air when starting in closed rooms!

do not leave the operator's stand warn others from coming too close to the machine or touching it if possible drive the machine out of the danger zone 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 embankments and make sure that you work does not impair the stability of the machine.

18

BOMAG

BW 211/212/213 D-40

Safety regulations

Do not work with vibration on hard concrete, on a cured concrete layer or heavily frozen ground. 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 considerably. Higher risk of accident! Behaviour in traffic Match 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 underground supply lines (gas, water, sewage, electric power supply), stop vibratory compaction if necessary. Do not work with vibration on hard (frozen, concrete) ground. Risk of bearing damage!

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 auxiliary 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 water. Leaking fuel tanks can cause explosions. Ensure tight fit of the fuel tank filling cover, replace it if necessary. Fire protection measures Make yourself acquainted with the location and the operation of fire extinguishers. Observe fire warning 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 compartment 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 machine. Do not perform maintenance work with the machine 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.

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. return the travel lever to neutral position apply the parking brake shut the engine down and pull the ignition key out. lock the cabin secure the machine against unauthorized use.

l l l

l l

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.

BW 211/212/213 D-40

BOMAG

19

Safety regulations

Working on hydraulic lines Always relieve the pressure in the hydraulic circuit before working on hydraulic lines. Hydraulic oil escaping under pressure may penetrate through the skin and cause severe injury. In case of being injured by hydraulic oil you should immediately seek medical advice, as otherwise this may lead to serious 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 - danger of scalding! Catch running out hydraulic oil and dispose of environmentally. Always catch and dispose of biological hydraulic oils separately. Do not start the engine after draining off the hydraulic oil. Once all work is completed (with the system depressurized!) 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

l l

Do not mix up hoses by mistake. damage or deformation of the fitting, which impairs 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 dispose of environmentally. Store used filters and other oily materials in a separate, 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 materials away 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 engine is cold. Catch running out coolant and dispose of environmentally. 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.

the outer layer is worn down to the metal lining (e.g. chafing, cuts, cracks) embrittlement of the outer layer (development of cracks in the hose material) deformation under pressurized and depressurized condition, which are not in accordance with the normal shape of the hydraulic hose deformation in bends, e.g, squeezes, kinks, layer separation, formation of blisters leakages. non-observance of the installation requirements separation of the hydraulic hose from the fitting corrosion of the fitting, which impairs the function and the strength.

l l

20

BOMAG

BW 211/212/213 D-40

Safety regulations

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 remove the plugs to avoid the accumulation of explosive gases. When using an external battery to start the machine 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 system Do 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 knowledge and tools. If necessary have the tires assembled 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 according 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 running. Do not use gasoline or other combustible substances 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 beforehand.


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 persons who have been instructed for this purpose. Use our repair instructions. Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms! Test Depending on the type of application and the operating conditions vibratory equipment has to be examined by a specialist whenever required, but at least once every year.

BW 211/212/213 D-40

BOMAG

21

Safety regulations

22

BOMAG

BW 211/212/213 D-40

3 Indicators and Controls

BW 211/212/213 D-40

BOMAG

23

Indicators and Controls

Fig. 7

24

BOMAG

BW 211/212/213 D-40

Indicators and Controls

1 2 3 4 5 6 7 8 9

Ignition switch Instrument cluster Vent for heating and ventilation, driver Vent for heating and ventilation, footwell Push button vibration Travel lever Rotary switch vibration, high/low frequency Rotary switch for speed range selection 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

BW 211/212/213 D-40

BOMAG

25

Indicators and Controls

3.1

General notes

3.2

Description of indicators and control elements

Please read this section thoroughly before operating 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 descriptions of the individual operating steps.

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.

Note

The engine can only be started when the travel lever is in braking position. The ignition switch is provided with a lock against repetitive starting. To repeat the starting procedure you must first turn the ignition switch back to "0"-position.
Position "II" = turn further against spring pressure, the engine starts, return 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.

26

BOMAG

BW 211/212/213 D-40

Indicators and Controls

j red l red m

= not used = Hazard light*, flashes when the hazard light is activated = Operating hour meter, counts the operating hours while the engine is running. All maintenance work must be performed according to the indicated operating hours. = not used

k yellow = not used

No. 3 = Vents for air conditioning, heating and ventilation, driver


Fig. 9

No. 2 = Instrument cluster

No. 4 = Vents for air conditioning, heating and ventilation, footwell**

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 engine 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 engine. = flashes if engine oil pressure too low, engine is shut down after 10 seconds. Check engine oil level, repair the engine if necessary.
Fig. 10

b red

No. 5 = Push button for vibration


l

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 used g red = Parking brake, with lever shifted to parking brake position, with drivers seat unoccupied.
l

Select or actuate the frequencies with the vibration selector switch. Switch the vibration on or off by pressing the push button.

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 filter reaches the contacts.
* Optional equipment ** Optional equipment

BW 211/212/213 D-40

BOMAG

27

Indicators and Controls

Fig. 11

Fig. 13

No. 6 = Travel lever Position "middle" = Braking position service brake Position "middle, right" = Parking brake, to start the engine Position "I" Position "II" = Forward travel = Backwards travel

No. 8 = Rotary switch for speed range selection Position "turtle" = Working speed Position "rabbit" = Transport speed

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. 14

No. 9 = Emergency stop switch The engine will be shut down and the brake will close. Danger Danger of accident!
!

Fig. 12

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.

No. 7 = Rotary switch for vibration Position "Middle" = Vibration off Position "Right" = low amplitude, high frequency Position "Left" = high amplitude, low frequency

28

BOMAG

BW 211/212/213 D-40

Indicators and Controls

unlock to drive

= turn the button clockwise and release it. = move the travel lever first to braking position, then start the engine and choose the travel direction.

Caution Always drive and vibrate with max. engine speed! Control the travel speed with the travel lever.
!

For safety reasons the travel system of the machine will only be enabled after the travel lever has been shifted back to braking position.

Fig. 17

No. 12 = Rotary switch for direction indicators left / right* Position "middle" = Direction indicators disabled Position "left or right" = Front and rear direction indicators for the corresponding side of the machine light up, the control light in the instrument cluster flashes.

Fig. 15

No. 10 = Push button for warning horn

Fig. 16

No. 11 = Rotary momentary contact switch for engine speed Electric engine speed adjustment Position left = Idle speed position
Fig. 18

No. 13 = Rotary switch for hazard light system


**

Note Position "left" = Hazard light switched off, control lights off. = Full throttle position, operating position for driving and vibration

Normal position for engine start.


Position right

* **

Optional equipment Optional equipment

BW 211/212/213 D-40

BOMAG

29

Indicators and Controls

Position "right" = Hazard light switched on, control light 1 in instrument cluster lights up.

Fig. 21

No. 16 = Lever, steering wheel adjustment


Fig. 19

No. 14 = Rotary switch for light system (StVZO)* Position "left" = Light off Position "middle" = Sidelights on, with ignition switch in position "I" or "P" Position "right" = Travel light on, with ignition switch in position "I".

Danger Danger of accident!


!

Do not adjust the steering wheel while driving. pull up press down = adjust height of steering wheel = adjust inclination of steering wheel

Fig. 22

No. 17 = 2-pole socket


Fig. 20

No. 15 = Rotary switch for working Position "left" = Light off

lights**

Current only with the ignition switch in position "I" or when the engine is running.

Position "right" = Working lights on, with ignition switch in position "I".

* **

Optional equipment Optional equipment

30

BOMAG

BW 211/212/213 D-40

Indicators and Controls

Fig. 23

Fig. 24

No. 18 = Fuses in electric installation box F03, 15A F05, 15A F07, 15A F09, 10A F10, 10A F11, 15A F13, 30A F14, 15A F18, 10A F19, 15A F22, 15A F23, 10A F24, 10A F25, 10A F39, 15A F70, 15A F105, 20A
!

a = toggle switch for flashing beacon b = toggle switch for front windscreen wiper/ washer up down Push button = windscreen wiper moves to end position and stops. = Switches on wiping of front windscreen. = Front windscreen is sprayed during wiping.

= Vibration = Socket = Hazard light* = Parking tail light, left* = Parking tail light, right* = Head lights, StVZO* = Starting = Engine solenoid = Working head lights, relay* = Working head lights, front, left* = Working head lights, rear* = Warning horn = Monitoring, gauges = Solenoid valve brake/travel = Cab* = Indicator* = Engine speed control

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

d = toggle switch for rear windscreen heating

Danger

Fire hazard! Do not use fuses with higher ampere ratings and do not bridge fuses.

Fig. 25 * Optional equipment

No. 19 = Fuse box, cabin

BW 211/212/213 D-40

BOMAG

31

Indicators and Controls

Danger Fire hazard!


!

Note

The light goes out.


g = Rotary switch for cabin heater (temperature selector switch) Position Off Position blue range Position red range = cabin heater switched off. = temperature selection for air conditioning. = Temperature selection for cabin heater.

Do not use fuses with higher ampere ratings and 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. 27

No. 21 = Cabin light


Fig. 26

No. 20 = Control panel for ventilator, air conditioning, 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 = air conditioning switched on.

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.

Optional equipment

32

BOMAG

BW 211/212/213 D-40

Indicators and Controls

i = reading and dashboard light j = toggle switch for reading and dashboard light k = toggle switch for cabin light l = cabin light

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 temperature and with the engine running. If necessary press the pin in. = hydraulic oil filter element o.k. = replace the hydraulic oil filter element

Fig. 28

No. 22 = Main fuse for battery 80A = (F00)

Pin remains pressed in Pin pops out

Note

The main fuse is located in the battery compartment

Fig. 31

No. 25 = Fuel gauge


Fig. 29

shows the fuel level in the fuel tank.

No. 23 = Air filter service indicator With the service indicator the real degree of filter contamination can even be checked when the engine is stopped. The filter must be service when the yellow piston reaches the inscription "Service" in front of the red background.

BW 211/212/213 D-40

BOMAG

33

Indicators and Controls

Fig. 32

Fig. 33

No. 26 = Anti-theft

protection*

No. 27 = EVIBdisplay** is a compaction measuring unit for continuous display of the load bearing characteristics (MN/m2) during the compacting pass. EVIB value

prevents unauthorized starting of the engine. Keypad = Input of user and service code (maintenance).

Note

Increase Constant

= higher load bearing capacity = end of compaction

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 protection remains switched off.
red LED display flashes slowly = anti-theft protection active. LED display lights green = every time a digit of the user or service code is entered.

Note

Modular upgrading to BTM plus / BTM prof and/or BCM 05 possible.

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.

Optional equipment

**

Optional equipment

34

BOMAG

BW 211/212/213 D-40

Indicators and Controls

BW 211/212/213 D-40

BOMAG

35

Indicators and Controls

3.3

Display and control elements BTM*

Optional equipment

Fig. 34

36

BOMAG

BW 211/212/213 D-40

Indicators and Controls

1 2 3 4 5 6 7 8 9

EVIBdisplay Display for jump operation Push button F5 START Push button F6 STOP Push button F7 PRINT (only BTM prof) Push button F8 DELETE Vibration frequency display Rotary switch setting of nominal value Push button F14 nominal value increase

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

10 Push button F13 nominal value decrease

BW 211/212/213 D-40

BOMAG

37

Indicators and Controls

3.4

Description of indicating and control elements BTM

To print out the measuring data saved during the last pass press button F7 PRINT. 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.

Note

The BTM plus can be upgraded to BTM prof and/ or BCM 05.

Note

Surface covering dynamic compaction control (SCCC)


The BOMAG compaction measuring systems EVIB-meter (BEM) and Terrameter BTM plus/prof are integrated in the work process for continuous and 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 deformation 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 red symbol = Drum jumps = Drum jumps excessively or tumbles

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 deleted.

! 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 nominal values The desired maximum dynamic stiffness modulus EVIB [MN/m 2] 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. The selected value is shown on the screen in field P3 No. 10 = Button F13 reduction of nominal value With each actuation of the button the presetting is reduced by one stage.

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 STOP press = Stops recording of measuring values

The green control field "F7" PRINT on the screen lights up.

Note

Depending on the measuring result the green control field "F5" CONTINUE or the red control field "F6" FINISHED will light up.
No. 5 = Button F 7 Print*
* only with BTM prof

38

BOMAG

BW 211/212/213 D-40

Indicators and Controls

The selected value is shown on the screen in field P3 No. 11 = Button F11 is not used No. 12 = Button F12 is not used No. 13 = Button F11 is not used No. 14 = Rotary switch P1 is not used No. 15 = Button F10 is not used No. 16 = Button F9 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.

BW 211/212/213 D-40

BOMAG

39

Indicators and Controls

3.5
*

Line diagram* (EVIB)

only BTM prof

Fig. 35

40

BOMAG

BW 211/212/213 D-40

Indicators and Controls

1 2 3 4 5 6 7 8 9

Pass-No. Travel direction Machine equipment (BTM 05/BTM-E) Software status of the measuring equipment Machine number Machine type Amplitude Maxiumum EVIB value Miniumum 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, tumbling of the drum 17 Longitudinal raster line 18 Measuring value raster line 19 Diagram line 20 Marking (thin line) jumping of the drum

10 Mean EVIB-value

BW 211/212/213 D-40

BOMAG

41

Indicators and Controls

3.6

Description of line diagram (EVIB)

Graduation of the measuring track (track length in printout) into fixed sections. No. 16 = Marking of jump information Indicates excessive jumping/tumbling of the drum on the marked track section (thick line).

No. 1 = Pass Total number of measured passes on this track. No. 2 = Travel direction 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 machine 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 machine is currently working with on this track. No. 11 = EVIB-change EVIB-change in %. This always refers to the previous pass in the same direction of travel. No. 12 = Medium frequency No. 13 = Mean travel speed shows the mean value of speed driven during this pass.

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 a fault (over or under compaction). No. 20 = Marking of jump information Indicates jumping of the drum on the marked track section (thin line).

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 direction Is used to pinpoint individual measuring values on the measuring curve.

Note

The raster lines mark measuring track sections of 5 m length.


* only BTM prof

42

BOMAG

BW 211/212/213 D-40

Indicators and Controls

3.7

Bar diagram* (EVIB)

The bar diagram differs from the line diagram only by the graphic representation of measuring values. In the bar diagram the mean values of 5 m sections are shown as bars. In addition, the EVIB changes of the individual 5 m sections are specified in percent after the second pass in the same travel direction.

only BTM prof

BW 211/212/213 D-40

BOMAG

43

Indicators and Controls

44

BOMAG

BW 211/212/213 D-40

4 Operation

BW 211/212/213 D-40

BOMAG

45

Operation

4.1

General notes

4.2

Tests before starting to operate

Please read section 3 Indicators and Control Elements 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.

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 maintenance instructions!
l

Park the machine on level ground.

Check:
l l l l

Fuel tank and fuel lines for leaks Bolted connections for tight fit Function of the steering Check the machine for cleanliness and damage availability of the appropriate operating and maintenance instructions, check if the machine has been properly serviced.

Note

For a description of the following work refer to the section "maintenance every 10 operating hours"
l

engine oil level

Note

Hydraulic systems, which are filled with 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 department of the respective oil manufacturer.
l

Check the hydraulic oil level, top up if necessary. 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.

46

BOMAG

BW 211/212/213 D-40

Operation

Check water separator in the fuel system, drain if necessary. Adjust the scrapers if necessary Tire pressure. Pressure see technical data.
!

4.3

l l

Disarming the anti-theft* protection

Caution Ensure equal pressure in both tires.

Before starting the engine the anti-theft protection must be disarmed by entering a code while the ignition 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

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.

Note

With each digit of the code the light emitting diode lights green.
l l

Press the confirmation key VAL. The anti-theft protection is now disarmed and the engine must be started within the next 30 seconds.

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 flashes at intervals of one second.
* Optional equipment

BW 211/212/213 D-40

BOMAG

47

Operation

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 engaged to the right in brake position.

Fig. 38
l

Turn the rotary vibration selector switch (Fig. 38) to position "0", vibration off.

48

BOMAG

BW 211/212/213 D-40

Operation

Fig. 39
l

Fig. 42

Check, whether the emergency stop switch (Fig. 39) is unlocked.

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. 40
l

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

Fig. 43
l

Turn the ignition key to position "II" (Fig. 43), the starter will crank the engine. As soon as the engine ignites return the ignition key to position "I".
!

Fig. 41
l

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

Caution Do not allow the engine to run longer than 10 minutes with idle speed.

BW 211/212/213 D-40

BOMAG

49

Operation

4.5

Starting with jump wires

4.6
!

Driving the machine

Danger

Danger of accident! Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes. Soil conditions and weather influences impair the gradability of the machine. Do not drive up and down inclinations exceeding the maximum gradability of the machine (see technical data). Do not drive without wearing your seat belt.
Fig. 44

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 driving with the machine. With the door opened and the machine fully articulated extreme oscillations of the machine may damage the door.

Caution A wrong connection will cause severe damage in the electric system.
!
l

Bridge the machine only with a 12 Volt auxiliary battery. When jump starting with an external battery connect both plus poles first. Then connect the ground cable first to the minus pole of the current supplying auxiliary battery and then to engine or chassis ground, as far away from the battery as possible (Fig. 44). Start as described under 'Starting the engine'. Once the engine is running switch on a powerful consumer (working light, etc.).
!

Note

l l

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 position), then operate the travel lever again to the desired travel direction.

Caution

If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components.
l

After starting disconnect the negative poles (ground cable) first and the positive poles after. Switch off the consumer.

50

BOMAG

BW 211/212/213 D-40

Operation

Fig. 45
l

Fig. 48
l

Close the cabin door (Fig. 45).

Select the desired travel speed range (Fig. 48).

Fig. 46
l

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

Fig. 49
l

Turn the rotary switch (Fig. 49) to "Max" position (full throttle).

Fig. 47
l l

Fasten your seat belt (Fig. 47). "Start engine", see previous sections.

Fig. 50
l

Push the travel lever (Fig. 50) to the left out of braking position and move it slowly to the desired travel direction.

BW 211/212/213 D-40

BOMAG

51

Operation

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!
!

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 underground 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!

When stopping on inclinations and slopes pull the travel lever to the right and lock it in braking 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 to brake the machine. If the engine speed drops when driving up extreme inclinations move the ravel lever slightly back, if necessary change to the lower speed range.

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).

52

BOMAG

BW 211/212/213 D-40

Operation

Switch the vibration on

4.8

Operating the parking brake, stopping the machine

Fig. 53
l

Turn the rotary switch (Fig. 53) to position "Max" (full throttle).
Fig. 55
l

Caution Switch the vibration on only at max. engine speed.


!

Return the travel lever (Fig. 55) slowly to "neutral"-position and engage it to the right parking brake position.

The machine is automatically braked by the hydrostatic drive and parking brake closes.

Note

The parking brake also closes automatically when shutting the engine down.

Fig. 54
l

Press the push button (Fig. 54) in the travel lever 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".

BW 211/212/213 D-40

BOMAG

53

Operation

4.9

Shutting the engine down

! Caution Straighten the articulated joint to provide easier access to the machine.

Fig. 58
l

Turn the ignition switch (Fig. 58) to position "0" or "P" and pull the ignition key out.

i
Fig. 56
l

Note

The parking brake closes automatically when shutting the engine down.
Return the travel lever (Fig. 56) slowly to "neutral"-position and engage it to the right in braking position. Danger Danger of accident!
!

Secure the machine against unauthorized use, pull the ignition key out, lock the cabin door.

Fig. 57
l

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

Note

Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization.

54

BOMAG

BW 211/212/213 D-40

Operation

4.10 Emergency exit


If the machine should turn over and the cabin door is 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 lever (Fig. 59) up and move the steering wheel to the desired height. Adjustment of steering wheel inclination, press lever down and adjust the inclination of the steering wheel.
!

Danger

Danger of accident! After the adjustment make sure that the steering wheel adjustment is securely locked in place.

Optional equipment

BW 211/212/213 D-40

BOMAG

55

Operation

4.12 Adjusting the seat


!

4.13 Operating the hood


!

Danger

Danger

Danger of accident! Do not adjust the seat while driving.

Danger of accident! If the hood needs to be opened further for maintenance or repair work, support it safely.

Bottom position

Fig. 60
l

To adjust the seat in longitudinal direction disengage the lever 1 (Fig. 60) and slide the seat forward or back. To adjust the weight actuate the lever (3). To adjust the inclination of the backrest actuate the lever (2) and tilt the backrest forward or back.

Fig. 61
l l

l l

Unlock the lock (Fig. 61). To open the hood press in the button and turn the 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.

56

BOMAG

BW 211/212/213 D-40

Operation

4.14 Towing in case of an engine failure


!

Danger

Secure the machine with wheel chocks against unintentional rolling. Danger of accident! When using towing ropes tow the machine only uphill.
Fig. 63
l l

Pull the spring pin (Fig. 63) out of the bracket. Secure the hood in the protection tube with spring plug.

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.

BW 211/212/213 D-40

BOMAG

57

Operation

After towing
Caution Before detaching the tow bar block the machine with chocks to prevent unintended rolling.
!
l

Turn the high pressure relief valve cartridges tightly back in. Turn all brake releasing screws of the axle evenly back out, until they are light moving again.

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. 67
l

Turn the brake releasing screws (Fig. 67) back in again, until they abut against the brake piston.

Fig. 66
l

To release the brake turn counter nuts 1 (Fig. 66) approx. 8 mm back. Turn the brake releasing screws (2) completely 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

Fig. 68
l

Turn the screws in alternately for turn at a time. Repeat this measure on the opposite wheel side.

Unscrew the brake releasing screws (Fig. 68) for two turns and tighten the counter nuts. Repeat this adjustment procedure on the opposite wheel side.

58

BOMAG

BW 211/212/213 D-40

Operation

Note

If necessary replace the seal ring under the counter nut if it is leaking. For this purpose completely unscrew the brake releasing 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 l

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

BW 211/212/213 D-40

BOMAG

59

Operation

Fig. 71
l

Fig. 73
l

Lash the machine on the transport vehicle (Fig. 71), use the four lashing eyes on front and rear frame for this purpose. Support the front frame to avoid overstressing of the rubber buffers.

Position of centre of gravity (Fig. 73). Machine BW 211 - 214-4 L 1150260 H 86070

Note

The tolerances account for all possible options, such as cabin, additional weight etc.
Weights: See technical data.
!

Danger

Danger of accident! The machine cannot be steered if the articulation lock is applied.
l

Fig. 72
l

After transport release the articulation lock again and store it in the receptacle.

For lifting use also the four lifting eyes (Fig. 72) and appropriate lifting gear.

60

BOMAG

BW 211/212/213 D-40

Operation

4.16 Measuring pass with BTM*


General notes

Note

The soil measuring values (EVIB) recorded during different passes can only be compared if the recording of measuring values took place in operating 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.

Fig. 75
l

Control field F5 (Fig. 75) lights green.

Measuring pass

Fig. 76
l

Turn the ignition key (Fig. 76) to position II engine start.

Fig. 74
l

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

The BTM plus/prof performs a self-test.

Optional equipment

BW 211/212/213 D-40

BOMAG

61

Operation

Fig. 78
l

Choose the maximum forward speed (Fig. 78).

The adjusted travel speed is indicated by a green ring segment in the tachometer on the LCD display * unit.
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 arrange the tracks so that track 1 is processed first, followed by further tracks offset to the left.

Note
Fig. 79
l

Maximum track length 150 m.


Forward: Mark 1 Mark 2 = Start of track = End of track

In the starting distance set the rotary switch for engine speed (Fig. 79) to "ECO" or "MAX".

Note

The operator may also remember the start and the end of the track by means of distinct points.

only DH-4 machines

62

BOMAG

BW 211/212/213 D-40

Operation

Fig. 80
l

Fig. 82
l

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

When mark 1 is reached, press button F5 START (Fig. 82).

The machine accelerates up to the preadjusted travel speed.


!

Control field to the left of F5 lights green. The EVIB- display shows the present value.

Caution

Differences in the travel speeds falsify the measuring result!

Fig. 83
l

When the end of the track, mark 2, is reached, press the button F6 STOP (Fig. 83). Stop the machine.

Fig. 81
l

Switch the vibration on (Fig. 81).


!

Note

The first forward pass is finished.


Caution Before reaching mark 1 the nominal exciter shaft speed must have been reached and a valid Evib-value should be displayed. Control field F5 lights green. This means, that the compaction is not yet completed. One or several passes are still required.

BW 211/212/213 D-40

BOMAG

63

Operation

4.17 Finishing compaction of a track

Fig. 84
l

Drive forward and reverse passes on a track until the green control field to the left of F5 (Fig. 84) goes out and the red control field F6 below lights up after pressing the stop button F6.

Fig. 85
l

Repeat the complete compaction process on the next track (Fig. 85) to record measuring values.

The compaction process on this track is finished. Criterion for a finished track: Compared with the previous track the increase of the EVIB-value in the same travel direction was less than 10%. This criterion is also fulfiled if the EVIB decreases.

Note

Another pass on this track does not make any sense, because an increase in load bearing capacity is hardly possible with this machine.
l

If necessary print out the measuring data for this track (see following section).

64

BOMAG

BW 211/212/213 D-40

Operation

4.18 Printing measuring data after completing compaction*

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. 87
l

If no further printouts of this track are needed, press the button F8 DELETE (Fig. 87) when the red control lamp F6 FINISHED lights up.

The red control field F6 FINISHED goes out and the green control field F5 CONTINUE lights up. BTM plus/prof is ready to compact the next track.

Fig. 86
l

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.

Note

After the printing process has finished any amount of diagrams can be printed out by pressing the same button F7 (PRINT).

only BTM prof

BW 211/212/213 D-40

BOMAG

65

Operation

4.19 Changing the paper roll in the measuring value printer*

Note

Use a new paper roll if a red stripe appears on the paper.

Fig. 90
l l

Insert a new paper roll (Fig. 90). Feed the paper into the guide (1) on the printer. Actuate the toggle switch (2) in direction of arrow, until the paper comes out of the printer. Reassemble the cover.

Fig. 88
l

Unscrew the star handles (Fig. 88) and remove the cover.

Fig. 89
l

Remove shaft 1 (Fig. 89) with the rest of the paper roll (2).

only BTM prof

66

BOMAG

BW 211/212/213 D-40

Operation

4.20 Changing the printer ribbon in the measuring value printer*

Note

In case of faint or poorly legible diagrams the printer ribbon needs to be replaced.

Fig. 91
l

Unscrew the star handles (Fig. 91) and remove the cover.

Fig. 92
l

Lift the tongue at point 1 (Fig. 92) and take the printer ribbon (2) out of the printer. Insert the new printer ribbon into the printer, then press in the tongue (1) on the right. Tension the printer ribbon by turning the rotary button (3) in direction of arrow. Reassemble the cover.
only BTM prof

BW 211/212/213 D-40

BOMAG

67

Operation

68

BOMAG

BW 211/212/213 D-40

5 Maintenance

BW 211/212/213 D-40

BOMAG

69

Maintenance

5.1

General notes on maintenance

Do not let the suction hose disturb the sludge on the bottom of the drum. Do not draw off fuel from near the bottom of the fuel drum. Fuel left in the fuel drum is not suitable for the engine and should only be used for cleaning purposes.

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 important components. The necessary effort can by no means be compared with the problems and malfunctions that could occur if this is not observed. The terms left/right are always related to travel direction forward.
l

Notes on the engine performance


Combustion air and fuel injection rates of the diesel engine have been carefully adjusted and determine 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, you should consult the after sales service of BOMAG or the service department of the engine manufacturer.

Clean machine and engine thoroughly before starting maintenance work. For maintenance work park the machine on level ground. Maintenance work must generally be carried out with the engine shut down. Depressurize hydraulic lines before working on them. Disconnect the battery and cover it with insulation material before starting to work on electrical components. Always attach the articulation lock (transport lock) before starting to work in the articulation area of the machine.

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. Seal external leaks immediately. If necessary inform the responsible service department. 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. 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 prolongs the lifetime of the system filter. Clean fittings, filler caps and their immediate surrounding area before removing them, so that no dirt can fall in. Do not leave the tank opening unnecessarily open, cover it so that no dirt can fall in.

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 depending on the cleanliness of the fuel.
l

Keep the engine free of dirt and water as this could damage the injection elements of the engine. Zinc lined drums are not suitable for storing fuel. The fuel drum should rest for a longer period of time before drawing off fuel.

70

BOMAG

BW 211/212/213 D-40

Maintenance

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 monitored. 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).
!

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. Approved engine oils Deutz DQC II ACAE E3/96/E5-02 API CH-4/CG-4 DHD DHD-1

DQC III E4-99 -

Danger

Health hazard! The mixing of nitride based cooling system protection agents with amine based agents will cause the generation of highly toxic nitrosamines. Environment Cooling system protection agents must be disposed of environmentally.

The exact assignment of the approved oil qualities and oil change intervals can be taken from the following 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 operating location of the engine is of utmost importance when choosing the viscosity class (SAEclass) . 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 exceeding of the limits should not happen over a longer period of time.

BW 211/212/213 D-40

BOMAG

71

Maintenance

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 temperatures 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 agency.

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 higher sulphur 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 injection lines need to be bled. When using fuels with a Cetan number < 49 poor starting and white smoke can be expected, in particular in connection with low ambient temperatures.
Fig. 93

With their better temperature and oxidation stability synthetic lubrication oils offer quite a few benefits. Oil change intervals The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operating hours reached. ACEA* E3-96/E5-02 E4-99 API** CG-4/CH-4
!

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 2D.
l l l l

DIN/EN 590 BS 2869 ASTM D 975-78: 1-D and 2-D. Nato Codes: F-54, F-34, F44 und XF63

Winter fuel Danger Fire hazard!


!

= 500 operating hours

Diesel fuels must never be mixed with gasoline. = 500 operating hours For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.

Caution These intervals apply only when using a diesel fuel with maximum 0.5 % sulphur by weight
* ** European Engine Oil Sequences American Petroleum Institute

72

BOMAG

BW 211/212/213 D-40

Maintenance

In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel additives. Consult the engine manufacturer. Operation with rape seed oil methyl ester (RME Bio Diesel) Due to the extreme quality differences of RMEWfuels 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

Environment Cooling system protection agents must be disposed of environmentally.

Hydraulic oil
The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm 2/s at 40C. For topping up or for oil changes 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 index (VI) should be at least 150 (observe information of manufacturer). Bio-degradable hydraulic oil On request the hydraulic system can also be filled with ester based biodegradable hydraulic oil (Panolin HLP Synth. 46). The biologically quickly degradable 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 manufacturer for details. Check the filter more frequently after this change. Caution Oil change bio-degradable hydraulic oil:
!

Reduced engine power (approx. 7%), higher fuel consumption. The quality of RME-fuel should be in compliance with DIN draft 51606. Avoid longer periods of standstill (formation of resin, corrosion in injection system) RME-fuel can damage the paint finish of the machine. Fuel dilution of engine oil, therefore shortening of oil change intervals to half. 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 fluorinated rubber. However, fluorinated rubber is not resistant against normal diesel fuel. If the fuel filter is clogged the filter change intervals must be shortened accordingly.

Perform regular oil analyses for content of water and mineral oil. Replace the hydraulic oil filter element every 500 operating hours.

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.

Oil for drive axle


For the drive axle use only multi-purpose transmission 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).

BW 211/212/213 D-40

BOMAG

73

Maintenance

5.3

Table of fuels and lubricants

Assembly Summer

Fuel or lubricant Winter

Quantity approx. Attention Observe the level marks

Engine

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

approx. 150 litres approx. 60 litres

Hydraulic system

Hydraulic oil (ISO), HV46, kinem. viscosity 46 mm2/s at 40 C

Vibration bearings Drive axle Wheel hubs Air conditioning system Tires (only BW 213)

Engine oil SAE 15W/40 Gear oil SAE 90, API GL5 Gear oil SAE 90, API GL5 Refrigerant R134A Water Calcium chloride (CaCl2) or magnesium chloride (MgCl2)

approx. 0,8 litres approx. 9,5 litres approx. 1,9 per side approx. 1400 g approx. 295 litres approx. 100 kg approx. 16 litres

Engine cooling system

Cooling system protection agent

74

BOMAG

BW 211/212/213 D-40

Maintenance

5.4

Running-in instructions

The following maintenance work must be performed 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. Retighten the bolted connections on the machine. Retighten all wheel fastening screws with the specified tightening torque. Changing engine oil and oil filter 1. Oil change vibration bearings Oil change in drive axle Oil change in wheel hubs

l l l l

After 500 operating hours


l

2. Oil change vibration bearings

BW 211/212/213 D-40

BOMAG

75

Maintenance

5.5

Maintenance chart
every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

No.

Maintenance work

Remark

every 3000 operating hours

every 250 operating hours

every 500 operating hours

Running-in instructions after 250 operating hours

5.6 5.7 5.8 5.9

Check the engine oil level Check the water separator Check the fuel level Check the hydraulic oil level

Dipstick mark

X X X

Inspection glass Inspection glass

X X X X X X X X

5.10 Check the coolant level 5.11 Check the dust separator 5.12 Check the tire pressure 5.13 Clean the cooling fins on engine and hydraulic oil cooler 5.14 Check the oil level in the drive axle 5.15 Check the oil level in the wheel hubs 5.16 Check the oil level in the vibration bearings 5.17 Change engine oil and oil filter cartridge* 5.18 Drain the sludge from the fuel tank 5.19 Service the battery 5.20 Check, replace the refrigerant compressor V-belt 5.21 Service the air conditioning 5.22 Check, adjust the valve clearance 5.23 Check, replace the ribbed V-belt 5.24 Change the fuel filter cartridge

min. 1x per year

X X

Pole grease

X X X

Intake = 0,3 mm Exhaust = 0,5 mm

X X

76

BOMAG

BW 211/212/213 D-40

as required

Maintenance

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

No.

Maintenance work

Remark

every 3000 operating hours X

every 250 operating hours

every 500 operating hours

Running-in instructions after 250 operating hours

5.25 Change the fuel pre-filter cartridge 5.26 Check the engine mounts 5.27 Oil change in drive axle 5.28 Oil change in wheel hubs 5.29 Oil change vibration bearings** 5.30 Retighten the fastening of the axle on the frame 5.31 Tighten the wheel nuts 5.32 Check the ROPS 5.33 Clean the oil bath air filter 5.34 Change hydraulic oil and breather filter*** 5.35 Change the hydraulic oil filter*** 5.36 Change the coolant 5.37 Check the injection valves 5.38 Service the combustion air filter min. 1x per year, safety cartridge at least every 2 years min. 1x per year at least every 2 years at least every 2 years at least every 2 years X min. 1x per year min. 1x per year X X X

X X X X X X X X X X X X

see foot note, min. X 1 x per year

5.39 Adjusting the scrapers 5.40 Adjust the parking brake 5.41 Change the tires 5.42 Change the fresh air filter in the cabin 5.43 Tightening torques 5.44 Engine conservation

X X X X X X

BW 211/212/213 D-40

BOMAG

as required 77

Maintenance

* 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.

78

BOMAG

BW 211/212/213 D-40

Every 10 operating hours

Every 10 operating hou rs

5.6
!

Check the engine oil level

5.7

Check, clean the water separator

Danger
!

Danger of injury! Support the engine hood for all maintenance and repair work.

Danger

Danger of injury! Support the engine hood for all maintenance and repair work.

Note

The machine must be parked horizontally with the engine shut down.

Note

The service intervals for the water separator depend 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 required", bleeding the fuel system.
Environment Catch running out fuel and dispose of environmentally.

Fig. 94
l

Pull the dipstick (Fig. 94) out, wipe it off with a lint-free, clean cloth and reinsert it until it bottoms. Pull the dipstick back out again. If the oil level is below the "MAX" mark fill in oil. If the oil level is above the Max mark determine the cause and drain the oil off.
!

l l l

Caution Before longer work periods you should always top the oil up to the "MAX"-mark. For quality and quantity of oil refer to the table of fuels and lubricants.

Fig. 95
l

Slacken the drain plug (Fig. 95) for a few turns and catch running out fuel / water. Tighten the drain plug again and check for leaks, if necessary replace the seal ring.

BW 211/212/213 D-40

BOMAG

79

Every 10 operating hours

5.8
!

Checking the fuel level

Caution Dirty fuel can cause engine failures or even damage to the engine.
!

Danger

If necessary fill in fuel through a screen filter.


l

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.

If necessary top up fuel (diesel or winter diesel).

For quality of fuel refer to the table of fuels and lubricants.

Fig. 96
l

Check the fuel level on the fuel gauge (Fig. 96).

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).

80

BOMAG

BW 211/212/213 D-40

Every 10 operating hours

5.9

Checking the hydraulic oil level


Caution

5.10 Checking the coolant level


!

Danger

Danger of scalding! Top up coolant only when the engine is cold.

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 department of the respective oil manufacturer.

Fig. 99
l

Check the coolant level (Fig. 99).


!

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 inspection 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

Caution If during the daily coolant level check the coolant level is found to have dropped, check all lines, 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.

If necessary fill in hydraulic oil through the filler neck.

For quality and quantity of oil refer to the table of fuels and lubricants.

BW 211/212/213 D-40

BOMAG

81

Every 10 operating hours

5.11 Checking the dust separator 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.

Option

82

BOMAG

BW 211/212/213 D-40

Every 250 operating hours

Every 250 oper ating hours

5.12 Checking the tire pressure


! Caution Always close the valves with the dust cap.

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
Fig. 101
l

Note

Check the tire pressure with a pressure gauge and the tire inflation valve 1 (Fig. 101) in top position.

Dirt on fan blades and oil cooler reduce the cooling effect. Dirt deposits in these areas are substantially 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.

Nominal value see "Technical Data".

Cleaning with compressed air

i
l

Note Screw the valve caps back on.

Ensure even pressure in all tires.

Fig. 102

i
l

Note Blow the cooler (Fig. 102) out with compressed air.

Start to blow out from the exhaust side.

BW 211/212/213 D-40

BOMAG

83

Every 250 operating hours

Cleaning with cold cleansing agent


Caution Protect electrical equipment such as generator, regulator and starter against the direct water jet.
!
l

5.14 Check the oil level in the drive axle


l

Park the machine on level ground.

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. Run the engine warm for a while to avoid corrosion.

Fig. 103
l

Unscrew the oil level inspection plug (Fig. 103) and check the oil level.

Note

The second level inspection plug as at the back. After filling in oil wait until the oil has evenly distributed 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.

84

BOMAG

BW 211/212/213 D-40

Every 250 operating hours

5.15 Checking the oil level in left/ right wheel hubs

5.16 Checking the oil level in the vibration bearing housings

Note

Check the oil level only at operating temperature after running the vibration for about 1/2 hour.

Fig. 104
l

Move the machine until the oil level inspection plug 1 (Fig. 104) is in horizontal position. Clean and unscrew the plug.
Fig. 105
l

The oil level must reach the bottom edge of the bore.
l

Top up oil, if necessary.


l

Move the drum so that the oil level control plug (Fig. 105) on the left hand side is in lowest position. Unscrew the control plug (1).

For quality of oil refer to the table of fuels and lubricants.


l l

Some oil should drip out of the level bore


l

Screw the plug back in tightly. Repeat this inspection on the other side.

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.

For quality of oil refer to the table of fuels and lubricants.


l

Screw the oil filler (2) and control plug (1) back in. Repeat this procedure on the opposite side.

BW 211/212/213 D-40

BOMAG

85

Every 500 operating hours

Every 500 operating h ours

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 higher 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!
!

Fig. 107
l

Thoroughly clean the outside of both filter cartridges (Fig. 107). Unscrew both filter cartridges using an appropriate filter wrench.

When draining off hot oil. Environment Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.

Note

The filter cartridges are fitted with a valve that prevents engine oil from running out during removal and installation.
l

Clean the sealing face on the filter carrier from any dirt. Slightly oil the rubber seal on the new filter cartridges.

Fig. 106
l

Unscrew the drain plug (Fig. 106) and catch running out oil.
Fig. 108

Turn the drain plug tightly back in.


l

Turn the new filter cartridges (Fig. 108) on by hand, until the seal contacts. Tighten the filter cartridges for another half turn.

86

BOMAG

BW 211/212/213 D-40

Every 500 operating hours

5.18 Draining the fuel tank sludge


!

Danger

Fire hazard! When working on the fuel system do not use open fire, do not smoke. Do not spill any fuel. Catch running out fuel, do not let it seep into the ground. Do not inhale any fuel fumes.

Fig. 109
l

Fill in new engine oil (Fig. 109).

For quality and quantity of oil refer to the table of fuels and lubricants.
l

Tighten the oil filler cap properly.


!

Caution

Before starting crank the engine with the starter 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. Check filter cartridge and drain plug for leaks after a short test run. Shut the engine down and wait for about 15 minutes, so that all oil can flow back into the oil sump. Check the oil level again, if necessary fill up to the Max.-mark.
Fig. 110
l

Unscrew the drain plug (Fig. 110) from the bottom of the fuel tank and drain off approx. 5 litres of fuel. Screw the drain plug back in with a new sealing ring.

BW 211/212/213 D-40

BOMAG

87

Every 500 operating hours

5.19 Service the battery


!

Danger

Caution Exhausted batteries (batteries with formation of sulphate on the plates are not covered under warranty!
!
l

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! Environment Dispose of the old battery environmentally.

Open the engine hood and remove the covering

Note
Fig. 111
l

Maintenance free batteries also need care. Maintenance free only means that the fluid level does not need to be checked. Each battery suffers under self-discharge, which may, in not checked occasionally, even cause damage to the battery as a result of exhaustive discharge.
The following therefore applies for the service life:
l

Remove the battery (Fig. 111) and clean the battery compartment. Clean the outside of the battery. Clean battery poles and pole clamps and grease them with pole grease (Vaseline). Check the fastening of the battery. On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water.

l l

Switch off all consumers (e.g. ignition, light, inside light, radio). Check open-circuit voltage of the battery at regular intervals. At least once per month.

l l

Reference values: 12.6 V = fully charged; 12.3 V = 50% discharged.


l

Charging voltage recommendation

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 approx. 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. For resting periods of more than one month you should always disconnect the battery. Do not forget to perform regular open-circuit voltage measurements.

Fig. 112

88

BOMAG

BW 211/212/213 D-40

Every 500 operating hours

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

Tensioning the V-belt

Work on the V-belt must only be performed with the engine shut down.

Checking the V-belt


Fig. 114
l

Slightly slacken the fastening screws 1, 2 and 3 (Fig. 114). Press the compressor in direction of arrow, until the correct V-belt tension is reached. Retighten all fastening screws.

Changing the V-belt


l

Slightly slacken the fastening screws 1, 2 and 3. Press the compressor against the direction of arrow completely against the engine. Take the old V-belt off. Fit the new V-belt to the V-belt pulleys. Tension the V-belt as previously described.

Fig. 113
l

Inspect the entire circumference of the V-belt (Fig. 113) visually for damage and cracks. Replace damaged or cracked V-belts. 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.

l l l

! Caution Check the V-belt tension after a running time of 30 minutes.

BW 211/212/213 D-40

BOMAG

89

Every 500 operating hours

5.21 Servicing the air conditioning*


Cleaning the condenser
Caution A soiled condenser results in a considerable reduction of air conditioning power.
!

Checking the refrigerant level


l l

Start the engine. Switch the air conditioning on.

Under extremely dusty conditions it may be necessary to clean the condenser several times per day. If, during operation of the air conditioning system, the warning buzzer sounds switch the air conditioning off and clean the condenser. Danger Danger of accident!
!

Fig. 116
l

Turn the rotary fan switch (Fig. 116) to position "2", middle fan stage. Open the air outlet openings on both control units.

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 dismount the machine.
! Caution In case of formation of foam have the air conditioning system inspected by the service department.

Fig. 117
l

Turn the rotary switch for the air conditioning thermostat (Fig. 117) clockwise. The air flow cools down.

Note

The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.
Fig. 115
l

Clean the condenser fins (Fig. 115) with compressed air or a cold water jet.
Optional equipment

90

BOMAG

BW 211/212/213 D-40

Every 500 operating hours

Checking the moisture level of the drying agent

Fig. 118
l

Check whether the white float (Fig. 118) inside the inspection glass of the drier/collector unit floats right at the top.

Fig. 120
l

Note

The refrigerant level is correct.

Check the moisture indication pearl (Fig. 120) inside the inspection glass of the drier/collector unit. = drying agent o.k. = moisture level of drying agent too high.

blue purple
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 operating season.

Fig. 119
l

Checking the condition of the drier/collector unit


Caution According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. 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 operators and third parties against any danger
!

If the white float (Fig. 119) inside the inspection glass of the drier/collector unit floats at the bottom, inform the service department.

i
l

Note Refrigerant must be filled up, if necessary the air conditioning system must be checked for leaks.

The refrigerant level is not correct.

BW 211/212/213 D-40

BOMAG

91

Every 500 operating hours

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 replaced, to avoid bursting and further damage.

Fig. 121
l

Check the drier/collector unit (Fig. 121) for mechanical damage or rust.

92

BOMAG

BW 211/212/213 D-40

Every 1000 operating hours

Every 1000 operating hours

5.22 Check, adjust the valve clearance


!

Caution

Before checking the valve clearance let the engine cool down for at least 30 minutes. The engine oil temperature must be less than 80 C. After a short test run check the engine for leaks.

Valve adjustment schematic

Fig. 123

Crankshaft position 1 (Fig. 123) (4 cylinder engine)


l

Crank the engine with the starter or a spanner by the V-belt pulley until both valves on cylinder 1 are overlapping.

Overlapping means: Exhaust valve not yet closed, intake valve starts to open.
l

Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 1", black mark. For control purposes mark the respective rocker arm with while chalk once the corresponding valve is adjusted.

Fig. 122

Valve 1 (Fig. 122) white = not adjustable Valve (2) black = adjustable

Fig. 124

Crankshaft position 2 (Fig. 124) (4 cylinder engine)


l

Turn the crankshaft one revolution (360) further. Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 2", black mark.

BW 211/212/213 D-40

BOMAG

93

Every 1000 operating hours

Check the valve clearance


l

Adjusting the valve clearance

Loosen the crankcase ventilation valve and swing it to the side.

Fig. 127
l

Fig. 125
l l

Remove the valve cover (Fig. 125). Crankshaft position as per "valve adjustment schematic".
l

Slightly slacken the counter nut. Adjust setscrew 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. Perform tests and adjustments on all other adjustable valves. Check the gasket of the valve cover, replace it if necessary. Reassemble the cylinder head cover. Swivel the ventilation valve back to correct position and fasten it. Fasten the air filter again and ensure correct fit of combustion air hoses and clamps.

l l

Fig. 126
l

Check valve clearance 2 (Fig. 126) between rocker arm (1) and valve (3) with a feeler gauge. = 0,3 mm

Intake valve

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 feeler gauge, the valve must be adjusted.

94

BOMAG

BW 211/212/213 D-40

Every 1000 operating hours

5.23 Checking / replacing the ribbed V-belt


!

Changing 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 Vbelt


Fig. 129
l

Unscrew the fastening screws (Fig. 129) and slide the fan forward.

Fig. 128
l

Check the distance between the tongue of the moveable tensioner arm and the fixed tensioner housing (Fig. 128). If measurement "a" is smaller than 3 mm, replace the ribbed V-belt.
Fig. 130
l

Release the idler pulley (Fig. 130) in direction of arrow until the ribbed V-belt is free. Pull the ribbed V-belt first to the smallest pulley. Install the new ribbed V-belt. Release the idler pulley against the direction of arrow until the V-belt is tensioned. Measure the V-belt tension, tighten if necessary.

l l

Note

Retighten the new fan V-belt after a running time of 20 minutes.

BW 211/212/213 D-40

BOMAG

95

Every 1000 operating hours

5.24 Change the fuel filter cartridge


!

l l

Fill the filter cartridge with clean diesel fuel. Turn the new filter cartridge on by hand, until the seal contacts. Tighten the filter element for another half turn. Check the filter cartridge for leaks after a short test run.

Danger

Fire hazard! When working on the fuel system do not use open fire, do not smoke and do not spill any fuel. Catch running out fuel, do not let it seep into the ground. Do not inhale any fuel fumes.

Fig. 131
l

Loosen and unscrew the fuel filter cartridge (Fig. 131) using an appropriate filter wrench. Clean the sealing face on the filter carrier from any dirt.

Fig. 132
l

Slightly oil the rubber seal (Fig. 132) on the new filter cartridge.

96

BOMAG

BW 211/212/213 D-40

Every 1000 operating hours

5.25 Change the fuel pre-filter cartridge


!

Danger

Fire hazard! When working on the fuel system do not use open fire, do not smoke and do not spill any fuel. Catch running out fuel, do not let it seep into the ground. Do not inhale any fuel fumes.
Fig. 135
l

Apply a thin coat of oil to the rubber seal of the water separator 1 (Fig. 135). Screw the water separator on by hand (2), until the seal contacts. Tighten the water separator for another half turn (3). Fill the filter cartridge with clean diesel fuel (4). Apply some oil to the rubber seal of the filter element (5) and screw it on by hand, until the seal contacts. Tighten the filter element for another half turn (6). Check the filter cartridge for leaks after a short test run.

l l

Fig. 133
l

Unscrew the fuel filter cartridge (Fig. 133) using an appropriate filter wrench. Clean the sealing face on the filter carrier from any dirt.

Note

Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible. Therefore bleed the fuel system after changing the fuel prefilter.

Fig. 134
l

Unscrew the water separator from the filter cartridge (Fig. 134).

BW 211/212/213 D-40

BOMAG

97

Every 1000 operating hours

5.26 Check the engine mounts

Fig. 136
l

Slacken the bleeding screw (Fig. 136) on the fuel pre-filter for 2 to 3 turns. Operate the hand pump manually, until fuel flows out of the slackened bleeding screw (Fig. 136) without air bubbles. Then tighten the bleeding screw while pumping.
Fig. 137
l

Tighten fastenings of intake and exhaust manifolds (Fig. 137) on the cylinder heads. 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. Retighten the fastening screws for oil sump and engine mounts.

98

BOMAG

BW 211/212/213 D-40

Every 1000 operating hours

5.27 Change the oil in the drive axle

Note

On other axle versions drain and filler plugs are of slightly different design. Perform the oil change accordingly.
Caution Drain oil only at operating temperature.
!

Fig. 139

Environment Catch old oil and dispose of environmentally.


l

Fill in oil through the oil level inspection bores (Fig. 139), until it has reached the bottom edge of the bore.

Park the machine on level ground.

Note

The second level inspection plug as at the back. After filling in oil wait until the oil has evenly distributed inside the axle.
For quality and quantity of oil refer to the table of fuels and lubricants.
l

Retighten the filler and level inspection plug.

Fig. 138
l

Clean and unscrew all level inspection and drain plugs (Fig. 138). Drain and catch all oil. Clean the drain plug and turn it back in with a new seal ring.

l l

BW 211/212/213 D-40

BOMAG

99

Every 1000 operating hours

5.28 Changing the oil in the wheel hubs


!

For quality and quantity of oil refer to the table of fuels and lubricants.
l

Turn the plug tightly back in.

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. Clean and unscrew the plug. Drain and catch all oil.

l l

Fig. 141
l

Move the drive wheel, until the plug (Fig. 141) is in horizontal position on the housing. Fill in oil, until it reaches the bottom edge of the bore. BOMAG BW 211/212/213 D-40

100

Every 1000 operating hours

5.29 Changing the oil for the vibration bearings


!

Caution

Change the oil at operating temperature. For this purpose run the machine approx. half an hour with vibration. Environment Catch running out oil and dispose of environmentally.

Fig. 143
l

Unscrew the level plug 1 (Fig. 143) at the bottom of the drum and fill in oil through the filler bore (2), until it starts to run out through the level bore.

For quality and quantity of oil refer to the table of fuels and lubricants.
l

Screw the oil filler (2) and control plug (1) back in. Repeat the oil change on the opposite side. Check the oil level again at operating temperature (after running the vibration for approx. 0.5 hours).

l l

Fig. 142
l

Move the drum until the drain plug 1 (Fig. 142) is in lowest position. Unscrew the drain plug, drain all oil off and catch it. Once the oil has run out clean the drain plug and screw it tightly back in.

! Caution Overfilling causes overheating of the vibration bearings!

BW 211/212/213 D-40

BOMAG

101

Every 1000 operating hours

5.30 Retighten the fastening of the axle on the frame

5.31 Tightening the wheel nuts

Fig. 145 Fig. 144


l l

Check all fastening nuts on axle mounting bolts (Fig. 144) for tight fit.

Tighten the wheel nuts (Fig. 145) in a crosstype pattern.

102

BOMAG

BW 211/212/213 D-40

Every 1000 operating hours

5.32 Checking the ROPS

5.33 Cleaning the oil bath air filter *

Note

On machines with a fitted cabin the ROPS (roll over protection structure) is integrated in the cabin. Please observe also the respective section in the safety regulations in this manual.

Fig. 147
l

Loosen the quick locks (Fig. 147), take the filter bowl off and empty it. Clean the filter mesh by repetitive dipping into diesel fuel. Clean the filter bowl with diesel fuel and fill in engine oil up to the level mark. reinstall the filter bowl.

Fig. 146
l

Check the cabin, especially the ROPS (Fig. 146) for cracks, corrosion, damage and missing fastening elements.

Note

Unusual movements and noises (vibrations) during operation indicate damage or loose fastening elements.
l

Check the fastening screws for the cabin (ROPS) to the operator's platform for tight fit. Check the suspension buffers for the operator's stand for tight fit. Check the condition and the fastening of the seat belt.

Option

BW 211/212/213 D-40

BOMAG

103

Every 2000 operating hours

Every 2000 operating hour s

5.34 Changing the hydraulic oil and the breather filter

Note

See also section 5.1 "Notes on the Hydraulic System".


Caution Apart from the normal oil change intervals the hydraulic oil must also be changed after major repairs in the hydraulic system.
!

Fig. 148
l

Change the hydraulic oil only at operating temperature. 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 hydraulic oil. Change the hydraulic oil filter element with every hydraulic oil change.
!

Unscrew the plug (Fig. 148) and drain the hydraulic oil off. Check the sealing ring (1), replace if necessary and screw the plug tightly back in.

Danger

Danger of scalding! Danger of scalding by hot oil. Environment Catch running out oil and dispose of environmentally.
Fig. 149
l l

Take the filler cap (Fig. 149) off. Fill in hydraulic oil through the screen.

Note

The hydraulic oil filter element should only be changed after the test run.

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, prolongs 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 inspection glass

104

BOMAG

BW 211/212/213 D-40

Every 2000 operating hours

For quality and quantity of oil refer to the table of fuels and lubricants.

5.35 Changing the hydraulic oil filter


!

Note Danger

The breather filter for the hydraulic tank is located in the filler cap and must therefore be replaced with the filler cap.
l

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.
!

Close the tank with the new filler cap.

Do not use the oil in the filter bowl. Environment Catch running out oil, dispose of oil and filter element environmentally.

Note

The filter element must be changed with every hydraulic oil change and after major repairs in the hydraulic system.

Fig. 150
l

Unscrew the cap nut 4 (Fig. 150) and take the filter bowl (5) with the filter element (3) off. 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

BW 211/212/213 D-40

BOMAG

105

Every 2000 operating hours

a possible malfunction of parts. In such a case perform trouble shooting and, if necessary, replace or repair defective components. Negligance may damage the complete hydraulic system. Do not clean or reuse the filter element.
l

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 environmentally.

Take the old filter element (3) out and clean the filter bowl and the thread. Reinstall the filter bowl with the new filter element, check the condition of the O-rings (1) and (2), replace if necessary. After a test run check the filter for leaks.

Fig. 151
l

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. Screw the plug back in after all coolant has been drained off.

106

BOMAG

BW 211/212/213 D-40

Every 2000 operating hours

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 temperature. Allow the engine to cool down and check the coolant level again, top up if necessary.

BW 211/212/213 D-40

BOMAG

107

Every 3000 operating hours

Every 3000 operating hour s

5.37 Checking the injection valves

Note

This work must only be performed by authorized service personnel. The injection valves must be replaced every 12000 operating hours.

108

BOMAG

BW 211/212/213 D-40

As required

As r equired

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 element.

Fig. 155
l

Unclip three clamps on the housing cover and take off the cover (Fig. 155).

Fig. 154

Servicing of the dry air filter is necessary when the yellow piston (Fig. 154) has reached the inscription "Service" in front of a red background, but at the latest after 2 years. After completion of the filter service reset the indicator back to "Zero" by pressing the button.
Fig. 156
l

Removing the main filter element


l

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

Fully open the engine hood.

Cleaning the main filter element


!

Caution

If necessary, the main filter element may be cleaned up to five times. It must be renewed at the 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 element 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.

BW 211/212/213 D-40

BOMAG

109

As required

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 element is defective! Additional cleaning intervals between two filter services signalized by the fault monitoring board are not necessary.

Cleaning the dust bowl

Fig. 158
l

Pull the internal part (Fig. 158) out and remove the dust from the cover. Reinsert the inner part.
!

Fig. 157

Note

Caution When assembling the inner part make sure that the notch in the cover engages in the opening of the inner part.

For cleaning 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

Installing the main filter element


l

Slide the main filter element carefully into the housing.

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. Examine the filter cartridge with a torch for cracks and holes in the paper bellows.
!

When closing the housing cover the main filter element is automatically forced in the correct position.
l

Reinstall the service covers.

Changing the safety filter element


Caution The safety filter element must not be cleaned and should not be used again after it has been removed.
!

Caution Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element.

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 cartridge, at the latest after 2 years,

110

BOMAG

BW 211/212/213 D-40

As required

if the warning light comes on again after servicing the main filter cartridge.
l

5.39 Adjusting the scrapers


smooth drum only

Remove the housing cover and pull the main filter element off.

Fig. 159
l

Fig. 160
l

Perforate the seal of the safety filter element from inside to outside using a suitable tool (Fig. 159) and pull both latches up. Grip the safety element by both latches and pull it out with slight turning movements. Push in a new safety filter element. Reassemble main filter element and cover.

Check the condition and adjustment of the front and rear scrapers, adjust or replace the scraper rubber if necessary. 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. Retighten the fastening screws.

l l

Caution Make sure that the cover locks engage correctly.


!

padfoot drum only

Fig. 161
l

Check condition and adjustment of scrapers 2 (Fig. 161), adjust or replace the teeth if necessary. To adjust the scrapers (2) slacken the fastening screws (1) in the slots and move the scrap-

BW 211/212/213 D-40

BOMAG

111

As required

er towards the drum, leaving a gap of approx. 25 mm.


l

5.40 Adjusting the parking brake


! Caution Have adjustment work on the brake performed by a specialist! Always adjust both sides.
l

Retighten the fastening screws.

Secure the machine with chocks against unintentional rolling. 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 l

Unscrew the locking plate 2 (Fig. 163). Turn the square (1) in anti-clockwise direction against the end stop.

112

BOMAG

BW 211/212/213 D-40

As required

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. Unscrew the wheel nuts and take the wheel off.

Fig. 164
l

To adjust the clearance turn the square 1 (Fig. 164) three revolutions back in clockwise direction. Screw the locking plate back on. Pull the plug off the brake valve and try to drive.

l l

The machine must be braked.

Fig. 165
l

Attach the wheel (Fig. 165) and tighten the wheel nuts crosswise with 550 Nm (405 ft. lb.). Check the tire pressure, see technical data.

BW 211/212/213 D-40

BOMAG

113

As required

5.42 Changing the fresh air filter in the cabin

5.43 Tightening torques

Fig. 167

Fig. 166
l

* Strength classes for screws with untreated, nonlubricated surface. Screw quality designations are stamped on the screw heads. 8.8 = 8G 10.9 = 10K 12.9 = 12K
l

Unscrew the fastening screws for the filter bracket (Fig. 166) and take the filter out. Insert the new filter and reassemble the filter bracket.

Axle - frame = 710 Nm

M 22x1.5
l

Wheel nuts = 550 Nm

M 22x1.5

The values result in a 90% utilization of the screw yield point at a coefficient of friction total = 0,14. When using lubricant MOS2 the specified tightening torques do not apply.

Note

Self-locking nuts must always be replaced once they have been unscrewed.

114

BOMAG

BW 211/212/213 D-40

As required

5.44 Engine conservation


If the engine is to be shut down for a longer period of time (e.g. over winter), please consult the service department of the engine manufacturer for further details.

BW 211/212/213 D-40

BOMAG

115

As required

116

BOMAG

BW 211/212/213 D-40

6 Trouble shooting

BW 211/212/213 D-40

BOMAG

117

Trouble shooting

6.1

General notes

The following work must only be carried out by qualified and trained personnel or by the sales service. Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions. Faults occur frequently due to the fact, that the machine has not been properly operated or serviced. 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.

118

BOMAG

BW 211/212/213 D-40

Trouble shooting

6.2

Engine
Possible cause Starter defective or pinion not engaging Fuel tank empty Temperature below starting limit Fuel filter clogged, in winter due to paraffin separation. Fuel lines leaking Battery discharged or not connected Injection valves or injection pump defective Remedy Have examined by a specialist Fill and bleed the tank Use winter fuel and engine oil acc. to the ambient temperature. Change the filter. use winter fuel Check all line connections for leakages and tighten the fittings. Tighten the pole clamps, check the cable connections Have examined by a specialist Have the battery checked, clean the terminal clamps, tighten them and cover them with acid free grease Use engine oil suitable for the ambient temperature Change the fuel filter. Check the line connections for leaks and tighten the fittings. Use winter fuel in the cold season. Adjust the valve clearance Have examined by a specialist Check the lines for leakages Have examined by a specialist clean, replace if necessary Adjust the throttle cable, change it if necessary

Faults The engine does not start

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 Especially during winter: the use of too viscous engine oil Fuel supply restricted, in winter fuel system clogged due to paraffin separation Incorrect valve clearance Injection valve defective Injection lines leaking Turbo charger defective Dry air filter dirty Excessive play in the throttle cable

BW 211/212/213 D-40

BOMAG

119

Trouble shooting

Faults Excessive exhaust smoke

Possible cause Engine oil level too high Dry air filter dirty Exhaust gas turbo-charger defective Poor compression due to burned or broken compression rings or incorrect valve clearance Incorrect valve clearance

Remedy Drain the oil to the upper dipstick mark clean, replace if necessary Have examined by a specialist Have compression rings and pistons examined by a specialist, adjust the valve clearance Adjust the valve clearance Clean the cooling fins

Engine overheats, shut down immediately!

Cooling fins on radiator extremely soiled (the warning light "engine oil temperature" lights) Injection valve defective Engine oil level too low Filling capacity of the injection pump not correctly adjusted Cooling air flow restricted V-belt loos or broken

Have examined by a specialist Top up engine oil to the upper dipstick mark Have adjusted by a specialist Clean the cooling air duct Tension or replace the V-belt Drain the engine oil down to the upper dipstick mark clean, change if necessary Have examined by a specialist Check fastening and connections Adjust the valve clearance Have examined by a specialist Top up oil

Poor engine power

Engine oil level too high Dry air filter dirty Exhaust gas turbo-charger defective Charge air hose leaking Incorrect valve clearance Injection valve defective

Engine oil pressure too low

Engine oil level too low (control light "engine oil pressure" lights, the warning buzzer sounds) Leakages in the lubrication system

Shut the engine down immediately, check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten the fittings. Check the V-belt tension, replace the Vbelt if necessary Have examined by a specialis

The charge control light lights during operation, the warning buzzer sounds

Generator speed too low The generator does not charge the battery, because generator or regulator is defective

120

BOMAG

BW 211/212/213 D-40

Trouble shooting

BW 211/212/213 D-40

BOMAG

121

Trouble shooting

122

BOMAG

BW 211/212/213 D-40