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

Description

File Details

• Manual type: Service 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
• Document number: 008 911 63
• Edition / date: November 2010
• Language: English
• File format: PDF
• Page count: 1,332 pages
• Publisher: BOMAG GmbH, Printed in Germany

Chapters Covered

• 1 General — Introduction, Safety Regulations, General Repair Instructions, Tightening Torques
• 2 Technical Data
• 3 Maintenance — General Notes, Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Chart
• 4 Connection Overview
• 5 Tests and Adjustments — Special Tools, Rotation Speeds, Travel Pump Neutral Positions, Travel Circuit Pressure Tests, Vibrator Shaft Speeds, Vibration Circuit Pressure Measurements, Vibration Motor Leakage Rate, Steering Circuit Pressure Test
• 6 Flushing and Bleeding — Special Tools, General, Travel Circuit Flushing (Travel Pump and Axle Motor Distribution), Vibration Drive Flushing, Bleeding Travel Circuit, Bleeding Vibration Circuit
• 7 Caddy Wiring Diagrams — Understanding Circuit Diagrams, Circuit Symbols, Switch Block Identification
• 8 E-Plan Wiring Diagrams — Understanding Wiring Diagrams, Circuit Symbols, Switch Block Identification
• 9 Electrics — Component Designation, Terminal Designations, Battery and Analog Ground, Current and Voltage, Resistance, Series / Parallel Connection, Ohm’s Law, Electrical Energy, Formula Diagram, Metrology, Diodes, Relays, Fuses, Telemeanique Switch, Plug Connectors, Magnetic Coil Plug, Deutsch Plug (DT and DTM), Spring Clamping Terminals, Inductive Proximity Switches, Angle Sensors, Acceleration Transducer, Batteries, Battery Maintenance, Main Battery Fuse, Jump Starting, Generator, Voltage Regulator, Electric Starter, Operator’s Stand, Cabin, Fuses, Electronic Control Units, Voltage Supply Checks, Diagnostics Concept, Dust Protection
• 10 Dust Protection / Gasket Assembly
• 11 Electronic Modules — BEM (BOMAG Evib-Meter), Electrics Modules A68, K04, A72, A108, Service Training MESX
• 12 Speedometer Module
• 13 Service Training — Travel System, Vibration, Steering
• 14 Engine — Diesel Engine General, Service Side, Starter Side, Lubrication Oil Circuit, Oil Pressure Switch, Oil Level Checks, Engine Oil and Filter Changes, Coolant Circuit, Coolant Temperature Switch, Thermostat, Coolant Level, Anti-Freeze Concentration, Cooling Fin Cleaning, Three-Phase Generator, Fuel Supply, Injection System, Injection Pump Replacement, Injection Valve Replacement and Repair, Fuel Filters, Water Separator, Compression Check, Valve Clearance, Boost Fuel Solenoid, Engine Shut-Down Solenoid, Air Filter, Heating Flange, Electric Throttle Control, Engine Monitoring, Deutz Special Tools
• 15 Air Conditioning System — Physical Basics, Refrigerant R134a, Compressor Oil, Working Principle, Monitoring Devices, Components, Oil Level Measurement, Magnetic Clutch, Inspection and Maintenance, V-Belt, Service Procedures, Drying and Evacuation, Emptying, Leak Test, Filling Instructions, Troubleshooting, Steam Table
• 16 Cabin Assembly — Preparations, Assembly, Final Function Tests
• 17 Replacing the Cab Window Panes
• 18 Drum — Special Tools, Repair Overview, Removal and Installation, Repair, Change-Over Weight, Rubber Buffers
• 19 Oscillating Articulated Joint — Special Tools, Repair Overview, Removal and Installation, Dismantling, Assembly
• 20 Suppliers Documentation — Travel Pump (Sauer Series 90), Vibration Pump (Sauer Series 42), Drum Drive (Poclain MSE/MF MS2-18), Vibration Motor (A10FM/A10FE Series 5), Axle Drive Motor (Sauer Series 51), Steering Valve (Danfoss OSPB/OSPC/OSPF), Axle
• 21 Circuit Diagrams — Hydraulic Diagrams 581 202 10 / 581 202 11, Wiring Diagrams 582 702 09 / 582 702 29 / 582 702 41 and Wiring Diagram 9

This BOMAG BW 211 BW 212 BW 213 D-40 PD-40 Single Drum Roller Service Manual is the complete workshop reference for the D-40 and PD-40 generation of BOMAG single drum rollers. It takes the technician from general repair instructions and tightening torques through to the teardown and rebuild of the drum, the oscillating articulated joint, the Deutz BF4M 2012 C diesel engine and every major hydraulic assembly on the machine. Because BOMAG produced this manual as a single shop-floor document, the same volume that tells you how to check the travel pump neutral position also walks you through the disassembly of the Sauer Series 90 pump, the A10FM 45 vibration motor, the Poclain MS2-18 drum drive, the Sauer Series 51 axle motor and the Danfoss OSPC steering valve. You do not need three separate books to work on this roller.

Hydraulic and Travel System Coverage

The travel, vibration and steering circuits on the BW 211, BW 212 and BW 213 are covered in detail. Pressure tests, neutral position adjustments, high and low frequency vibrator shaft speed checks, leakage rate measurement of the vibration motor and steering circuit pressure tests all appear with their nominal values. The manual then goes further: flushing schematics for both the travel pump distribution and the axle motor distribution, plus the vibration circuit, with step-by-step flushing and bleeding procedures. The tandem pump arrangement — Sauer 90R075 travel pump feeding the drum drive and axle motor, Sauer 42R041 vibration pump driving the A10FM 45 motor — is documented component by component in the supplier section at the back.

Engine and Powertrain

The engine chapter deals with the Deutz BF4M 2012 C, water-cooled, four-cylinder diesel engine fitted to all six models. Coverage includes the lubrication oil circuit, oil pressure switch, cooling circuit, thermostat, coolant temperature switch, fuel supply and injection system, single-cylinder plug-in injection pumps, injection valve removal and repair, fuel filters, water separator and compression checks. Valve clearance adjustment and the check and adjust procedure for the valve clearance are included with the intake and exhaust values. The engine monitoring system — warning lights, warning buzzer and automatic shut-down — is documented with the fault logic used on the D-40 and PD-40 operator stations. Ribbed V-belt and ribbed belt checks, three-phase generator, voltage regulator replacement, starter motor operation and starter fault diagnosis are also part of this section.

Electrical and Electronic Systems

The electrical portion of this BOMAG BW 211 BW 212 BW 213 D-40 PD-40 service manual is unusually complete for a construction machine of this class. It begins with basic electrical theory — current, voltage, resistance, series and parallel circuits, Ohm’s law, formula diagrams — and then builds up to the actual machine systems. Battery maintenance, main battery fuse, jump starting procedure, generator function and testing, voltage regulator replacement, starter function, operator station switch panels, cabin electrics and fuse box layouts (both old and new design) are included. The electronic control units chapter covers the BEM (BOMAG Evib-Meter), the electrics modules A68, K04, A72 and A108, the MESX measurement control with its fault codes and diagnostics concept, and the module voltage supply checks with test protocols and setpoints. The Caddy and E-Plan wiring diagrams with switch block identification and circuit symbol legends give the technician the reference material needed for tracing faults on the machine.

Drum, Oscillating Joint and Cabin

Repair of the single drum itself is covered in depth: special tools, repair overview, removal and installation of the drum, disassembly and assembly of the exciter unit on both the travel motor side and the vibration motor side, change-over weight disassembly and assembly, rubber buffer change and pretension adjustment. The oscillating articulated joint chapter has its own special tools, repair overview, removal, dismantling and assembly procedures including the shim thickness determination with measured values and calculation examples. The cabin assembly chapter covers preparation, mounting procedures with torque values, and final function tests. Replacing cab window panes is treated as its own chapter with bonding agent, activator and silicone sealant part references.

Air Conditioning

The air conditioning system chapter is a complete short course in itself: physical basics of refrigerant, R134a properties, compressor oil (PAG SP-20), system components, magnetic clutch check, V-belt replacement, refrigerant recovery, evacuation and drying, leak test, filling instructions and troubleshooting of the refrigerant circuit with pressure and temperature diagnosis. A steam table for R134a is included at the end of the chapter.

Suppliers Documentation

The back half of the manual contains the component manufacturers’ own service documentation, reproduced in full. This includes the Sauer Series 90 travel pump service manual and repair instructions, the Sauer Series 42 axial piston closed circuit pump service manual, the Poclain MS2-18 drum drive repair manual, the Brueninghaus Hydromatik A10FM / A10FE Series 5 vibration motor repair instructions, the Sauer Series 51 bent axis variable motor service manual, and the Danfoss OSPB / OSPC / OSPF hydrostatic steering unit service manual. This means the BOMAG BW 211 BW 212 BW 213 D-40 PD-40 workshop manual does not just tell you to send the pump away — it gives you the internal clearances, torque values and assembly sequences to service the hydraulics yourself.

Circuit Diagrams

The final chapter collects the full machine schematics: hydraulic diagrams 581 202 10 and 581 202 11, wiring diagrams 582 702 09, 582 702 29, 582 702 41 and Wiring Diagram 9. Each diagram is presented as a full-page sheet suitable for printing or viewing on a large screen.

What This Manual Enables You to Do

With this BOMAG BW 211 BW 212 BW 213 D-40 PD-40 Single Drum Roller Service Manual on hand, a qualified technician or a well-equipped owner-operator can carry out scheduled maintenance, diagnose hydraulic and electrical faults, adjust travel and vibration parameters, replace major components and rebuild assemblies that would otherwise be sent to a dealer. The values in the tests and adjustments chapter — charge pressure, high pressure, start-up pressure, vibrator shaft speed, steering pressure, leakage rates — let you verify that a repair has actually solved the problem instead of guessing. The tightening torque tables, the flushing and bleeding procedures and the wiring and hydraulic schematics all support the same goal: bringing the machine back to specification without a second trip to the workshop.

Why the Correct Procedures and Specifications Matter

Single drum rollers of this size work hard and their hydraulic systems run at high pressure. Getting the charge pressure wrong, reusing a high pressure line, skipping the flushing step after a component change or setting the wrong vibrator shaft speed does not just cause poor compaction — it leads to pump failure, motor failure, drum bearing damage or premature drum drive failure. This manual spells out the sequence, the torque values, the pressure setpoints, the tolerances and the leak oil limits that BOMAG published for the BW 211, BW 212 and BW 213 D-40 and PD-40. It also carries the safety information — hydraulic oil injection, high pressure lines, hot oil, articulated joint crushing hazards, battery acid, refrigerant handling — that a shop needs to have on record.

Instant Delivery, Any Device, Printable

The BOMAG BW 211 BW 212 BW 213 D-40 PD-40 Single Drum Roller Service Manual 008 911 63 is delivered as an instant PDF download after payment. There is no shipping, no waiting and no physical book to lose in the workshop. Open it on a laptop in the service bay, on a tablet next to the machine or on a phone for a quick reference. Print the pages you actually need — a wiring diagram, a torque table, a flushing schematic — and keep them with the machine. The PDF is ready to use the moment the download completes.