BOMAG BW 211 D-40 BW 212 D-40 BW 213 D-40 Single Drum Roller Repair Instructions PDF
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Complete BOMAG repair instructions for BW 211 D-40, BW 212 D-40 and BW 213 D-40 single drum rollers. 834 pages covering hydraulic travel and vibration circuits, drum overhaul, articulated joint, Deutz BF4M 2012 C engine, air conditioning, electrics and full circuit diagrams. Document 008 910 32.
Description
BOMAG BW 211 D-40 / BW 212 D-40 / BW 213 D-40 Repair Instructions
This is the full BOMAG repair instructions document (publication 008 910 32) for the BW 211 D-40, BW 212 D-40 and BW 213 D-40 single drum rollers. It is a workshop-level service manual written for the technician who has to take the machine apart, measure it, adjust it and put it back together correctly β not a quick-reference booklet. Across 834 pages it covers the Deutz BF4M 2012 C diesel engine, the hydrostatic travel circuit, the two-frequency vibration system, the drum assembly, the oscillating articulated joint, the air conditioning system and the complete machine electrics, plus full wiring and hydraulic circuit diagrams.
The BOMAG BW 211 D-40, BW 212 D-40 and BW 213 D-40 share the same repair instructions document because they share the same drive and vibration architecture. That makes this manual useful for the whole D-40 family, whether you are working on a 9.5 t BW 211, a 10.9 t BW 212 or a 12.4 t BW 213.
File Details
- Manual type: Repair Instructions (workshop service manual)
- Brand: BOMAG
- Models covered: BW 211 D-40, BW 212 D-40, BW 213 D-40
- Document number: 008 910 32
- Language: English (with German section headers preserved, e.g. Technische Daten, Stromlaufplan)
- File format: PDF
- Page count: 834 pages
Chapters Covered
- 1 General β Foreword, safety regulations, general repair instructions, tightening torques (metric coarse and fine thread), connection overview, technical data, table of fuels and lubricants
- 2 Tests and adjustments β Special tools, solenoid adjustment for engine speed control, checking rotation speeds, neutral position of the travel pump, pressure tests in the travel circuit, vibrator shaft speeds, pressure measurements in the vibration circuit, leakage rate of the vibration motor, pressure test in the steering circuit
- 3 Flushing and bleeding β Special tools for flushing, general flushing, flushing schematics and procedures for the travel circuit (travel pump and axle motor distribution) and the vibration drive, bleeding the travel circuit, bleeding the vibration circuit
- 4 Technical Manual β Basic electrics (voltage, current, resistance, CAN, metrology, diodes, relays, fuses, battery, three-phase generator, starter, plugs, terminals), Service Training (Deutz engine, travel system, vibration, steering, electrics), Speedometer Module, Vibration module
- 5 Air conditioning system β Safety notes, physical basics, refrigerant R134a, compressor oil, refrigeration diagram, component descriptions, compressor oil level, magnetic clutch, refrigerant circuit pressures, V-belt, servicing, drying and evacuation, leak test, filling instructions, heating and air conditioning control
- 6 Replacing the cab window panes β Assembly of window panes, special tools, auxiliary materials, removing and installing the window pane
- 7 Drum β Special tools, repair overview, removing and installing the drum, repairing the drum, disassembling and assembling the change-over weight, changing the rubber buffers and adjusting the pretension
- 8 Oscillating articulated joint β Special tools, repair overview, removing and installing, dismantling, assembling
- 9 Suppliers documentation β Travel pump series 90R, travel drive series 51, vibration pump 42R 041, vibration motor A10FM, MS/MSE 02 to 18, axle DANA 192
- 10 Circuit diagrams β Wiring diagram (BW 177..219 D-4/D-40) and hydraulic diagram
What this document actually gives a technician is the full teardown and rebuild logic of the machine. Travel pump neutral is set with pressure gauges on ports MA and MB; charge pressure is checked on the same ports; the multi-function valves, high pressure relief valves and charge pressure relief valve are all identified by location and function. Vibration is handled in the same way β the vibration pump, high pressure relief valves, charge pump, vibration motor and drum are pulled apart in order, with tightening torques, clearances and adjustment values printed inline. The drum chapter walks through both exciter units (travel motor side and vibration motor side), the change-over weight, the rubber buffers and pretension setting. The articulated joint chapter includes shim thickness calculations and rocker bearing pressing procedures. Electrics runs from basic Ohm’s law and CAN through the wiring diagram, sensor testing, relay references and terminal block numbering. The final section reproduces the original equipment manufacturer documentation for the Sauer-Danfoss / Brueninghaus Hydromatik travel pump 90R075, travel drive 51D110, vibration pump 42R041, vibration motor A10FM45, Poclain MS/MSE motors and the DANA 192 axle.
Covered Machines and Serial Ranges
The BW 211 D-40 is listed with an operating weight of 9500 kg (CECE) and a static linear load of 27 kg/cm. The BW 212 D-40 raises that to 10900 kg / 11350 kg with ROPS and cabin, and 33.6 kg/cm static linear load. The BW 213 D-40 tops the range at 12420 kg / 12870 kg with ROPS and cabin, 36.7 kg/cm static linear load. All three share the same 98 kW Deutz BF4M 2012 C, a 2300 rpm rated speed, 60 litre hydraulic oil capacity, and the same 90R075 travel pump with a 51D110 axle motor and MSE 18 drum drive.
Serial numbers listed in the document are 101 582 42…, 101 582 43… and 101 582 44…, plus the corresponding 1001 series.
What Makes This Manual Different from a Generic Service Book
The material here is written around measurements and pressure readings, not around descriptions. Travel pump neutral is not “adjust until it feels right” β it is “connect 600 bar gauges to MA and MB, both must read charge pressure, if pressure builds on one side adjust the mechanical neutral until they match”. Vibration motor leakage is not described in vague terms β you disconnect the leak oil hose, hold a measuring hose in a beaker, run the vibration for one timed minute, and the permissible leak oil rate is 1.5 litre/min. The flushing procedures are split into two flow patterns because the flushing filter must sit on the low-pressure return side; the manual makes it clear that on a travel pump distribution setup the travel lever must be shifted forward only, otherwise the filter is fed from the wrong direction.
The drum chapter includes the change-over weight oil fill (2.5 litres of silicone oil 47 V 1000 cst up to the upper edge of the change-over weight), the Loctite grades used on specific fasteners, and the axial clearance check on the shaft after assembly. The articulated joint chapter includes the friction bearing assembly, the rocker bearing races, the V-ring and seal ring placement, and the shim thickness calculation that depends on an axial preload measurement.
The technical data chapter gives you the numbers you actually need for the machine: valve clearance 0.3 mm inlet / 0.5 mm outlet, injection valve opening pressure 220 bar, travel pump max displacement 75 cmΒ³/U with a 400 +26 bar high pressure limitation, charge pressure 26 bar at high idle, vibration pump 41 cmΒ³/U with a 345 +26 bar starting pressure, vibration motor 45 cmΒ³/U at 30/35 Hz and 2/1 mm amplitude, steering pressure 175 +26 bar, engine coolant 16 litres, engine oil 10 litres, hydraulic oil 60 litres, rear axle 11 litres, wheel hubs 2.9 litres per side, AC refrigerant 1300 g R134a and 100 ml PAG oil. Being able to read those values out of the same document that tells you how to pull the component apart is what separates a repair from an experiment.
Who This Is For
Heavy equipment mechanics, BOMAG service technicians, dealer workshops, rental fleet maintenance crews and owner-operators who do their own major repairs on the D-40 single drum rollers. The electrical and hydraulic diagrams are complete enough to be used as a fault-finding tool on their own, even if you are not pulling a component.
Get Instant Access to the Full BOMAG BW 211 / 212 / 213 D-40 Repair Instructions
With this BOMAG BW 211 D-40 BW 212 D-40 BW 213 D-40 repair instructions PDF on hand you can diagnose charge pressure drops, chase travel pump neutral faults, measure vibration motor leakage, rebuild the drum exciter units, replace the oscillating articulated joint bearings, service the air conditioning system and trace electrical faults against the original wiring diagram. Every procedure gives you the correct sequence, the correct tightening torque, the correct pressure or clearance to aim for, and the correct way to bleed and flush the circuit afterwards β which is exactly what prevents the second failure that comes from skipping a step.
Complete Bookmarks
The complete bookmarks in the βBOMAG BW 211 D-40 BW 212 D-40 BW 213 D-40 Single Drum Roller Repair Instructions PDFβ are as follows:
+BW 213 D-40p. 1
+Single drum rollerp. 1
+Forewordp. 6
+Safety regulationsp. 7
+General repair instructionsp. 10
+Tightening torquesp. 13
+Connection overview
+Technische Daten
+Filling capacitiesp. 21
+Filling capacitiesp. 23
+1.7 Table of fuels and lubricantsp. 26
+Winterp. 26
+2.1 Special tools, tests and adjustmentsp. 28
+2.2 Adjusting the solenoid for engine speed controlp. 31
+2.3 Checking the rotation speedsp. 32
+Check the engine speedp. 32
+Checking the exciter shaft speedp. 33
+2.4 Checking / adjusting the neutral positions of the travel pumpp. 34
+2.5 Pressure tests in the travel circuitp. 36
+2.6 Checking / adjusting the vibrator shaft speedsp. 38
+2.7 Pressure measurements in the vibration circuitp. 39
+2.8 Check the leakage rate of the vibration motorp. 40
+2.9 Pressure test in steering circuitp. 41
+Fig. 5p. 42
+3.1 Special tools for flushingp. 44
+3.2 Flushing – generalp. 48
+Before flushingp. 48
+Bleedingp. 49
+Servicing the flushing filter kitp. 49
+3.4 Flushing the travel circuit (travel pump distribution)p. 52
+Flushing the drum drivep. 52
+Flushing the axle drivep. 55
+3.6 Flushing the travel circuit (axle motor distribution)p. 63
+Flushing the drum drivep. 63
+Flushing the axle motorp. 66
+3.8 Flushing the vibration circuitp. 70
+3.9 Bleeding the travel circuitp. 74
+3.10 Bleeding the vibration circuitp. 76
+Fig. 5p. 77
+4.4 Vibration modulep. 253
+5.1 Notes on safety for the air conditioning systemp. 258
+5.2 Notes on repair of the air conditioning systemp. 259
+Physical basicsp. 261
+Physical basicsp. 261
+Pressure and boiling pointp. 262
+5.4 Refrigerant R134ap. 263
+5.6 Working principle of the air conditioning systemp. 265
+5.7 Refrigeration diagramp. 266
+5.8 Description of componentsp. 267
+Compressorp. 267
+Condenserp. 268
+Dryer / filter / fluid container / inspection glassp. 268
+Expansion valvep. 270
+Evaporatorp. 270
+Defroster thermostatp. 271
+Pressure switchp. 271
+Checking the compressor oil levelp. 273
+Checking the compressor oil level / refrigeration oil levelp. 273
+5.10 Checking the magnetic clutchp. 274
+5.12 Measuring the pressure in the refrigerant circuitp. 275
+5.13 Checking, replacing the refrigerant compressor V-beltp. 276
+Check the V-beltp. 276
+Tighten the V-belt.p. 276
+5.14 Servicing the air conditioningp. 277
+Cleaning the condenserp. 277
+Checking the refrigerant levelp. 277
+Checking the moisture level of the drying agentp. 278
+Checking the condition of the drier/collector unitp. 279
+5.18 Filling instructionsp. 281
+5.19 Heating control / air conditioning controlp. 285
+Assembly of window panes
+6.2 Special toolsp. 293
+6.3 Auxiliary materialsp. 294
+6.4 Removing and installing the window panep. 296
+Fig. 14p. 299
+7.1 Special toolsp. 302
+7.3 Removing and installing the drump. 312
+Removing the drump. 312
+Installing the drump. 315
+7.4 Repairing the drump. 317
+Removing the travel motorp. 317
+Disassembling the exciter unit (travel motor side)p. 318
+Disassembling the exciter unit (travel motor side)p. 319
+Disassembling the exciter unit (vibration motor side)p. 323
+Removing, dismantling the side platep. 325
+Dismantling the exciter unit (vibration motor side)p. 327
+Assembling the exciter unit (vibration motor side)p. 330
+Assembling and installing the side platep. 336
+Assembling the exciter unit (travel motor side)p. 339
+Assembling the exciter unit (travel motor side)p. 344
+Installing the travel motorp. 345
+Installing the exciter unit (vibration motor side)p. 346
+7.5 Disassembling and assembling the change-over weightp. 350
+Dismantling the change-over weightp. 350
+Assembling the change-over weightp. 351
+7.6 Changing the rubber buffers and adjusting the pretensionp. 353
+Fig. 10p. 355
+8.1 Special toolsp. 358
+8.3 Removing and installing the oscillating articulated jointp. 363
+8.4 Dismantling the oscillating articulated jointp. 365
+8.5 Assembling the oscillating articulated jointp. 370
+Fig. 33p. 379
+9.6 Axle DANA 192p. 667
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