BOMAG BW 211 212 213 D-40 Single Drum Roller Service Training Manual & Circuit Diagrams

Description

BOMAG BW 211 / 212 / 213 D-40 Single Drum Roller – Service Training Manual & Circuit Diagrams

This is the complete BOMAG service training and circuit diagram documentation set for the BW 211, BW 212 and BW 213 D-40 / PD-40 single drum rollers, together with the wider BW 177 through BW 219 D-4 / D-40 wiring documentation. It combines in-depth service training material, exploded views, pressure and torque tables, and the full set of hydraulic and electrical schematics used by BOMAG service personnel. If you maintain, diagnose or repair one of these Deutz-powered single drum rollers, this is the reference set that the workshop uses.

File Details

• Manual type: Service Training Manual + Circuit Diagrams + Repair Instructions
• Brand: BOMAG
• Series: BW 211 / 212 / 213 D-40 and PD-40 (also covering BW 177 – BW 219 D-4 / D-40 wiring)
• Engine covered: Deutz BF4M 2012 C (4-cylinder, water-cooled diesel)
• Language: English (with original German technical terms retained in the circuit diagrams)
• Page count: 1364 pages
• File format: PDF
• Wiring diagram document numbers: 582 702 09, 582 702 29, 582 702 41
• Hydraulic diagram document numbers: 581 202 10, 581 202 11
• Serial number coverage: 101 582 42 / 43 / 44 / 47 / 48 / 49, 861 583 00, 101 583 02 / 03 / 55

Chapters Covered

• Technical Data – dimensions, weights, travel characteristics, engine data, filling capacities for BW 211, 212 and 213 D-40 / PD-40
• Safety Regulations – general safety, intended use, ROPS, hydraulic, electrical and battery safety
• Indicators and Controls – ignition switch, instrument cluster, travel lever, vibration selector, fuses, air filter and hydraulic service indicators
• BTM Display & Control Elements – BTM plus / prof, EVIB line diagram, bar diagram, printer options
• Operation – start-up tests, anti-theft, starting, jump-starting, driving, vibration on/off, parking brake, towing, transport, BTM measuring passes, printer paper and ribbon changes
• Maintenance – fuel and lubricant table, running-in, maintenance chart, engine oil, water separator, hydraulic oil, coolant, battery, V-belts, valve clearance, air conditioning service, coolant change, engine conservation
• Trouble Shooting – engine fault tables
• Repair Instructions – general repair, tightening torques, gaskets, seals, bearings, screws and nuts
• Tests and Adjustments – rotation speeds, travel pump neutral, travel circuit pressure tests, vibrator shaft speed, vibration circuit pressure, vibration motor leakage, steering circuit pressure
• Flushing and Bleeding – travel circuit flushing (both distribution layouts), vibration circuit flushing, bleeding travel and vibration circuits
• Fundamental Electrics – circuit diagram reading, terminal designations, CAN-Bus, resistance, series/parallel, Ohm’s law, metrology, diodes, relays, fuses, batteries, three-phase generator, starter, Telemecanique, inductive proximity switches, angle sensors, Deutsch DT/DTM plugs, spring clamp terminals
• Electronic Modules – BEM (BOMAG Evib-meter), MESX service training, electric module K04, heating/air conditioning control
• Speedometer Module – description, teach mode, pin assignment
• Engine (Deutz BFM 2012) – service side, starter side, lubrication oil circuit, coolant circuit, fuel supply, injection system, injection pump replacement, injection valve service, fuel filter, compression check, valve clearance, boost fuel solenoid, shut-down solenoid, air filter, heating flange, throttle control, engine monitoring
• Air Conditioning System – physical basics, R134a, compressor oil, working principle, components, compressor oil level, magnetic clutch, V-belt, service, drying and evacuation, leak test, filling instructions, refrigerant circuit trouble shooting, R134a steam tables
• Cab Window Panes – assembly, special tools, removal and installation
• Drum – special tools, repair overview, removal and installation, drum repair, change-over weight, rubber buffers and pretension
• Oscillating Articulated Joint – special tools, repair overview, removal and installation, dismantling and assembly
• Suppliers Documentation – Sauer-Danfoss Series 90 travel pump, Sauer-Danfoss Series 42 vibration pump, Poclain MS/MSE drum drive motor, Brueninghaus Hydromatik A10FM/A10FE vibration motor, Sauer-Danfoss Series 51 axle drive motor, Dana axle
• Circuit Diagrams – hydraulic diagram 581 202 10, hydraulic diagram 581 202 11, wiring diagram 582 702 09, wiring diagram 582 702 29, wiring diagram 582 702 41
• WAGO Terminal Designers – X1 backup protection rail, X1 cable trees, X2 measurement technology, option E2 StvZO lighting
• Component Listing / Bauteilliste – full component list with blade/sheet/position references

What This Manual Gives You

The BOMAG BW 211 / 212 / 213 D-40 service training manual is not a general compaction guide – it is a machine-specific technical training file written by BOMAG for the workshops and technicians who service the D-40 and D-4 generation single drum rollers. The training text is laid out the way the factory course is taught: travel system, vibration system, steering, then engine, then electrics, with each chapter ending in a trouble shooting table that ranks likely causes by field probability. That structure alone saves hours of diagnosis on a machine that will not drive, will only vibrate on one amplitude, or reaches no steering end stop.

The suppliers’ documentation section is the part most owners never see. It reproduces the factory repair manuals for the Sauer-Danfoss Series 90 travel pump, the Series 42 vibration pump, the Sauer-Danfoss Series 51 axle drive motor, the Poclain MSE 18 drum drive motor and the Brueninghaus Hydromatik A10FM/A10FE vibration motor – each with its own adjustment values, torque tables, exploded views and parts lists. When the pump or motor needs opening, this is the document you want on the bench next to it.

The three wiring diagrams (582 702 09, 582 702 29, 582 702 41) cover three successive design statuses of the D-4 / D-40 electrical system, so you are not stuck with a single diagram that does not match the harness in the machine. Each one is supported by a Bauteilliste that lists every relay, fuse, sensor, switch, solenoid, connector and terminal with its sheet and position reference. The WAGO terminal strip layouts are also reproduced – the X1 backup protection rail, the X1 cable trees and the X2 measurement technology rail – so a rewiring job can be planned against the actual terminal positions.

The service training chapters on the Deutz BF4M 2012 C engine are written around the real service jobs: valve clearance checking and adjustment with the crankshaft position diagrams, plug-in injection pump replacement with the corrected injection pump measurement (EK) calculation and the compensation shim selection table, injection valve testing and repair, compression testing, coolant and lubrication circuit analysis, and engine monitoring with the warning and shut-down times for water separator, oil pressure and coolant temperature faults.

Who This Manual Is For

• Owners of BW 211, BW 212 or BW 213 D-40 / PD-40 rollers doing their own maintenance and repairs
• Workshop technicians who need the factory adjustment values, torque tables and trouble shooting charts
• Fleet maintenance planners building a maintenance schedule against BOMAG’s own intervals
• Electricians tracing a fault through the D-4 / D-40 harness against the correct wiring diagram for the machine’s build status
• Hydraulic technicians rebuilding the Sauer-Danfoss, Poclain or Brueninghaus Hydromatik components

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The BOMAG BW 211 212 213 D-40 service training manual and circuit diagram set is delivered as an instant PDF download – no shipping, no waiting on a paper copy, no library hunting. Open it on a laptop in the workshop, on a tablet next to the machine, or print the pages you need for the job at hand. Every torque value, adjustment screw, pressure test port, wiring pin and exploded view is exactly where the factory put it, so the next repair on your single drum roller is done to the correct procedure the first time.