BOMAG BW 211 / 212 / 213 D-40 PD-40 Single Drum Roller Service Manual

Description

BOMAG BW 211 / 212 / 213 D-40 PD-40 — Complete Workshop Service Manual

This is the full BOMAG service manual for the BW 211, BW 212 and BW 213 single drum rollers in D-40 and PD-40 configuration, catalogue number 008 911 63, dated March 2008. It is the same document BOMAG service technicians use in the workshop: 1,040 pages covering the diesel engine, hydrostatic travel and vibration circuits, steering, drum assembly, oscillating articulated joint, electrical system, air conditioning and every maintenance, test and adjustment value needed to keep the machine in specification. German-built Deutz-powered rollers are engineered to tight tolerances, and this manual gives you the exact procedures and numbers to work on them correctly.

File Details

• Manual type: Service / Workshop Manual
• Brand: BOMAG
• Models covered: BW 211 D-40, BW 211 PD-40, BW 212 D-40, BW 212 PD-40, BW 213 D-40, BW 213 PD-40
• Catalogue number: 008 911 63
• Edition / date: 03/2008
• Language: English (supplier documentation sections include German/English side-by-side)
• Page count: 1,040
• File format: PDF
• Engine: Deutz BF4M 2012 C / BF4M 2012 CC, water-cooled, 4-cylinder

Chapters Covered

• 1 General — introduction, safety regulations, general repair instructions, tightening torques
• 2 Maintenance — general notes, fuels and lubricants table, running-in instructions, maintenance chart
• 3 Technical data — dimensions, weights, travel characteristics, engine, steering, vibration, tyres, filling capacities
• 4 Connection overview — travel pump, ports, gauge points
• 5 Tests and adjustments — rotation speeds, neutral positions of travel pump, pressure tests in travel and vibration circuits, leakage rate, steering circuit pressures
• 6 Flushing and bleeding — special tools, travel circuit flushing (pump and axle-motor distribution), vibration circuit flushing, bleeding procedures
• 7 Fundamental electrics — circuit diagrams, terminal designations, current/voltage, CAN-Bus, resistance, Ohm’s law, metrology, diodes, relays, fuses, batteries, three-phase generator, starter, sensors, plug connectors, electric modules
• 8 Special tools, electrics
• 9 Electronic modules — BEM / BOMAG Evib-meter, MESX / BOP diagnostics, fault codes, input codes, electric module K04, heating/air-conditioning control
• 10 Speedometer module
• 11 Service training — travel system, vibration system, steering system overview
• 12 Engine — diesel engine general, service side, starter side, lubrication circuit, oil pressure switch, oil change, coolant circuit, thermostat, fuel supply, injection system, injection pump replacement, injection valve replacement, compression check, valve clearance, boost fuel solenoid, shut-down solenoid, air filter, heating flange, throttle control, engine monitoring
• 13 Air conditioning system — physical basics, refrigerant R134a, compressor oil, working principle, monitoring devices, components, compressor oil level, magnetic clutch, V-belt, service, drying and evacuation, leak test, filling, troubleshooting, steam table
• 14 Replacing the cab window panes — assembly, special tools, auxiliary materials, removal and installation
• 15 Drum — special tools, repair overview, removal and installation, repairing the drum, change-over weight, rubber buffers and pretension
• 16 Oscillating articulated joint — special tools, repair overview, removal and installation, dismantling and assembly
• 17 Suppliers documentation — travel pump (Sauer-Danfoss Series 90), vibration pump (Series 42), drum drive (Poclain MS/MSE), vibration motor (A10FM/A10FE), axle drive motor (Series 51), axle (Spicer/Dana)
• 18 Circuit diagrams — hydraulic diagrams 581 202 10 and 581 202 11, wiring diagrams 582 702 09, 582 702 29 and 582 702 41

IMAGES PREVIEW

What makes this manual worth having is the depth of the hydraulic and electrical content. The travel circuit chapter alone walks through the Sauer-Danfoss Series 90 travel pump with its servo control, multi-function valves, pressure override, charge relief valve and flushing valve — then does the same for the Series 42 vibration pump, the Poclain MS/MSE drum drive motor, the A10FM/A10FE vibration motor and the Series 51 axle drive motor. Every pump and motor has its own adjustment and troubleshooting section with pressure gauge port locations, torque values and acceptable operating ranges. Because BOMAG built the D-40 and PD-40 variants around the same Deutz BF4M 2012 platform, this single document covers six machine configurations with only minor differences in drum type, axle load and vibration system setup.

Engine, Hydraulics and Electrics in One Volume

The Deutz BF4M 2012 C section covers everything from the low-pressure fuel system through the plug-in injection pumps to valve clearance and compression testing. There are full step-by-step procedures for injection pump replacement with the injection pump code tables, injection valve testing and adjustment with shim selection, coolant circuit and thermostat service, boost fuel solenoid valve, engine shut-down solenoid and air filter service. If you are rebuilding or diagnosing a no-start, low-power or overheating condition on a D-40 roller, the engine chapter gives you the diagnostic path and the values to check.

The electrical section starts from first principles — Ohm’s law, series and parallel circuits, diode and relay function — then moves into the specific machine circuits: CAN-Bus communication, the BEM / BOMAG Evib-meter display module, MESX and BOP diagnostic menus, fault codes, input codes and the K04 electric module. The wiring diagram chapters at the end include the complete hydraulic and electrical schematics for the D-40 and PD-40 families, with terminal designations, plug connector pinouts and component cross-references. This is the material you need when a fault code points to a sensor, a CAN line or a proportional valve and you have to trace it through the harness.

Drum, Axle and Articulated Joint

The drum chapter covers the complete rebuild: removing and installing the drum, disassembling the exciter unit on both the travel motor side and the vibration motor side, replacing the cylinder roller bearings and radial seals, changing the rubber buffers and adjusting their pretension, and disassembling and assembling the change-over weight. The oscillating articulated joint chapter covers removal, dismantling and assembly with the shim thickness calculation for the correct bearing preload. The rear axle chapter covers the Spicer/Dana axle with its No-Spin differential, and the Poclain MS/MSE drum drive motor chapter includes brake piston seal replacement, brake shoe replacement and cam ring service.

Why This Manual Matters

Single drum rollers are expensive capital equipment, and a bearing failure in the exciter unit or a misadjusted travel pump can take a machine out of service for weeks. This manual gives you the procedures, the torque values, the pressure settings and the adjustment steps to do the job correctly the first time. Whether you are servicing the charge pressure relief valve, setting the neutral position on the travel pump, flushing the hydraulic circuit after a component change, replacing a drum bearing or diagnosing a fault code in the electrical system, the answer is in these pages. The diagnostic trouble-shooting charts at the end of the travel, vibration and steering sections are especially useful because they list the most probable causes in order of likelihood based on BOMAG’s field experience.

Instant PDF Download

This BOMAG service manual is delivered as a PDF that you can open on any computer, tablet or phone and print the pages you need for the workshop. There is no shipping, no waiting and no separate software required. Search for the model, section or value you need and get straight to work — the same reference material a BOMAG dealer workshop would use for BW 211, BW 212 and BW 213 D-40 and PD-40 single drum rollers.