Operating instructions

Maintenance instructions

BW 211 D-4 / BW 211 PD-4

S/N 101 582 41 . . . .

Single drum roller

Catalogue number
008 119 31 06/2004

BOMAG machines are products from the wide
F oreword
range of BOMAG compaction equipment.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your ma-
chine.
This manual comprises:
l Safety regulations
l Operating instructions
l Maintenance instructions
l Trouble shooting
Using these instructions will
l help you to become familiar with the machine.
l avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
l enhance the reliability of the machine on con-
struction sites,
l prolong the lifetime of the machine,
l reduce repair costs and downtimes.
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,
l if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-
age resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.
Please note!
With this machine "CE" conformity is only
achieved with the corresponding optional
equipment.
This manual was written for operators and mainte-
nance personnel on construction sites.
BW 211 D-4
Foreword
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 mainte-
nance instructions are part of the machine.
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 En-
gineering Liability Association ”Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors” and all relevant accident prevention regula-
tions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve 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 avail-
able from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation 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
BOMAG 3
Foreword

Please fill in
............................
Machine type (Fig. 1)
............................
Serial-number (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine number (Fig. 3)

i Note Fig. 1
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!

Fig. 2

Fig. 3

4 BOMAG BW 211 D-4

 Table of Contents

Technical Data 7
Safety regulations 11
Indicators and Controls 19
3.1 General notes 22
3.2 Description of indicators and control elements 22
Operation 31
4.1 General notes 32
4.2 Tests before starting to operate 32
4.3 Starting the engine 33
4.4 Starting with jump wires 35
4.5 Driving the machine 35
4.6 Switching the vibration on and off 37
4.7 Operating the parking brake, stopping the machine 38
4.8 Shutting the engine down 39
4.9 Emergency exit 40
4.10 Adjusting the steering wheel 40
4.11 Adjusting the seat 41
4.12 Operating the hood 41
4.13 Towing in case of an engine failure 43
4.14 Transport 45
Maintenance 47
5.1 General notes on maintenance 48
5.2 Fuels and lubricants 49
5.3 Table of fuels and lubricants 52
5.4 Running-in instructions 53
5.5 Maintenance chart 54
5.6 Check the engine oil level 57
5.7 Check, clean the water separator 57
5.8 Check the fuel level 58
5.9 Checking the hydraulic oil level 59
5.10 Check the coolant level 59
5.11 Checking the dust separator on the oil bath air filter 60
5.12 Checking the tire pressure 61
5.13 Clean the cooling fins on engine and hydraulic oil cooler 61
5.14 Check the oil level in the drive axle 62
5.15 Checking the oil level in left/right wheel hubs 63
5.16 Check the oil level in the vibration bearings 63
5.17 Changing engine oil and oil filter cartridges 64
5.18 Change the fuel filter cartridge 65
5.19 Draining the sludge from the fuel tank 66
5.20 Service the battery 67

BW 211 D-4 BOMAG 5

Table of Contents

5.21 Change the fuel pre-filter cartridge 68

5.22 Checking, replacing the refrigerant compressor V-belt 69
5.23 Service the air conditioning 70
5.24 Check, adjust the valve clearance 73
5.25 Checking / replacing the ribbed V-belt 75
5.26 Check the engine mounts 76
5.27 Change the oil in the drive axle 76
5.28 Changing the oil in the wheel hubs 77
5.29 Change the oil in the vibration bearings 78
5.30 Retighten the fastening of the axle on the frame 79
5.31 Tightening the wheel nuts 80
5.32 Check the ROPS 80
5.33 Cleaning the oil bath air filter 81
5.34 Changing hydraulic oil and breather filter 82
5.35 Changing the hydraulic oil filter 83
5.36 Changing the coolant 84
5.37 Checking the injection valves 86
5.38 Service the combustion air filter 87
5.39 Adjust the scrapers 90
5.40 Adjust the parking brake 91
5.41 Changing the tires 92
5.42 Change the fresh air filter in the cabin 93
5.43 Tightening torques 93
5.44 Engine conservation 94
Trouble shooting 95
6.1 General notes 96
6.2 Engine 97

6 BOMAG BW 211 D-4

 1 Technical Data

BW 211 D-4 BOMAG 7

 Technical Data

Fig. 4

Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 211 D-4 2960 2250 1500 2268 2972 490 5808 60 60 25 2130
BW 211 PD-4 2960 2250 1480 2268 2972 490 5808 60 60 25 2130

*
BW 211 D-4 BW 211 PD-4

Weights
Operating weight (CECE) kg 10950 11930
with ROPS and cabin
Axle load, drum (CECE) kg 6280 7260
Rear axle load (CECE) kg 4670 4670
Static linear load kg/cm 29,5 -

Travel characteristics
Travel speed (1) km/h 0 ... 5 0 ... 5
Travel speed (2) km/h 0 ... 6 0 ... 6
Travel speed (3) km/h 0 ... 9 0 ... 9
Travel speed (4) km/h 0 ... 13,5 0 ... 13,5
Max. gradability (depend- % 47 47
ing on soil)

Engine
Engine manufacturer Deutz Deutz
Type BF4M 2012C BF4M 2012C
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO kW 98 98
3046

8 BOMAG BW 211 D-4

 Technical Data

* BW 211 D-4 BW 211 PD-4

Rated speed rpm 2300 2300
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2

Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.

Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic

Vibration
Vibrating drum 1 1
Drive system hydrostatic hydrostatic
Frequency Hz 30/36 30/36
Amplitude mm 1,8/0,9 1,64/0,82

Tires
Tire size 23.1/18-26/TL-8PR AWT 23.1-26/12TL R1
Air pressure bar 1,1 1,4

Filling capacities
Engine Litres 10 10
Fuel Litres 340 340
Hydraulic oil Litres 60 60
Coolant Litres 16 16
* The right for technical modifications remains reserved

BW 211 D-4 BOMAG 9

Technical Data

The following noise and vibration data acc. to

- EC Machine Regulation edition (98/37/EC) and

- Noise Emission Regulation 2000/14/EC

were determined at nominal speed of the drive engine and with vibration running. The machine was
standing on an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is

sound pressure level at the work place of the operator (with cabin):
LpA = 77.0 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is

guaranteed sound capacity level of the machine:

LwA = 109 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO
11204 for sound pressure level (LpA) at the place of the operator.

Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:

Vibration of the entire boy (driver’s seat)

The weighted effective acceleration value determined in accordance with ISO 7096 is γ ≤0.5 m/sec2.

Hand-arm vibration values

The weighted effective acceleration value determined in accordance with EN 500/ISO 5349 is γ ≤2.5 m/sec2.

10 BOMAG BW 211 D-4

 2 Safety regulations

BW 211 D-4 BOMAG 11

Safety regulations
General
This BOMAG machine is built in accordance
with the latest technical standard and the valid
technical rules and regulations. There is, how-
ever, a risk of danger for persons and property
if:
l the machine is used for purposes other than
those it is intended for
l the machine is operated by untrained person-
nel
l the machine is modified or converted in an un-
professional way
l the applicable safety regulations are not ob-
served.
Each person involved in operation, mainte-
nance and repair of the machine must there-
fore read and apply these safety regulations.
This should be confirmed by obtaining the sig-
natures of the customer, if necessary.
Furthermore the following regulations and instruc-
tions are obviously also valid:
l applicable accident prevention instructions
l generally acknowledged safety and road traffic
regulations
l 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.
Intended use
This machine must only be used for:
l compaction of bituminous materials, e.g. road
surface layers. (AC and AD machines only)
l medium and heavy compaction tasks in earth
work (road sub-bases)
l This machine must only be operated with fully
functional safety equipment.
l The machine should be checked by an expert
once every year.
12
Unintended use
Dangers may, however, arise from the machine if
it is used by untrained personnel in an unprofes-
sional 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 explo-
sive environment is prohibited.
Who is allowed to work with the ma-
chine?
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 com-
plied with.
Persons under the influence of alcohol, medica-
tion 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.
Conversions and alterations to the ma-
chine
Unauthorized conversions to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
pressly clear that we have not tested or authorized
any original parts or special equipment not sup-
plied by us. The installation and/or use of such
products can impair the active and/or passive driv-
ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
Safety notes in the operating and main-
tenance instructions:
Danger
!
Sections marked like this point out possible
dangers for persons.
BOMAG BW 211 D-4

Caution
!
Sections marked like this point out possible
dangers for the machine or for parts of the ma-
chine.
i Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
Observe all environment protection regula-
tions.
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 im-
mediately.
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 slip-
ping off.
Secure the machine on the transport vehicle
against rolling off, slipping and turning over.
Persons are highly endangered if
l they step or stand under loads being lifted
l 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.
BW 211 D-4
Safety regulations
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.
Checking the Roll Over Protection
Structure (ROPS)
i 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 tight-
ened (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 im-
pair the strength of the structure.
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 con-
trol elements, the working mode of the machine
and the area you will be working in.
Use your personal protective outfit (hard hat, safe-
ty boots etc.).
Check before mounting the machine if:
l there are persons or obstructions beside or
under the machine
BOMAG 13
Safety regulations
l the machine is free of any oily and combustible
material
l all handrails, steps and platforms are free of
grease, oils, fuels, dirt, snow and ice
l the engine compartment hood is closed and
locked
To climb onto the machine use steps and hand-
rails.
Check before starting, whether:
l the machine shows any obvious defects
l all protective devices are properly secured in
their place
l steering, brakes, control elements, lighting
and warning horn are in order
l the seat is correctly adjusted
l the mirrors (if available) are clean and correct-
ly adjusted.
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 oper-
ator's seat
For starting set all control levers to "neutral posi-
tion".
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 ade-
quate supply of fresh air when starting in closed
rooms!
14
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 im-
mediately if persons remain in the danger area de-
spite 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 emergen-
cy 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-volt-
age power lines:
l do not leave the operator's stand
l warn others from coming too close to the ma-
chine or touching it
l if possible drive the machine out of the danger
zone
l 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 em-
bankments and make sure that you work does not
impair the stability of the machine.
BOMAG BW 211 D-4

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 consider-
ably. 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 under-
ground supply lines (gas, water, sewage, electric
power supply), stop vibratory compaction if neces-
sary.
Do not work with vibration on hard (frozen, con-
crete) ground. Risk of bearing damage!
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.
l return the travel lever to neutral position
l apply the parking brake
l shut the engine down and pull the ignition key
out.
l lock the cabin
l secure the machine against unauthorized use.
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 D-4
Safety regulations
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 aux-
iliary 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 wa-
ter.
Leaking fuel tanks can cause explosions. Ensure
tight fit of the fuel tank filling cover, replace it if nec-
essary.
Fire protection measures
Make yourself acquainted with the location and the
operation of fire extinguishers. Observe fire warn-
ing 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 compart-
ment 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 ma-
chine.
Do not perform maintenance work with the ma-
chine 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.
BOMAG 15
Safety regulations
Working on hydraulic lines
Always relieve the pressure in the hydraulic circuit
before working on hydraulic lines. Hydraulic oil es-
caping under pressure may penetrate through the
skin and cause severe injury. In case of being in-
jured by hydraulic oil you should immediately seek
medical advice, as otherwise this may lead to se-
rious 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 - dan-
ger of scalding!
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always catch and dispose of biological hydraulic
oils separately.
Do not start the engine after draining off the hy-
draulic oil.
Once all work is completed (with the system de-
pressurized!) 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 the outer layer is worn down to the metal lining
(e.g. chafing, cuts, cracks)
l embrittlement of the outer layer (development
of cracks in the hose material)
l deformation under pressurized and depressu-
rized condition, which are not in accordance
with the normal shape of the hydraulic hose
l deformation in bends, e.g, squeezes, kinks,
layer separation, formation of blisters
l leakages.
l non-observance of the installation require-
ments
l separation of the hydraulic hose from the fit-
ting
l corrosion of the fitting, which impairs the func-
tion and the strength.
16
l Do not mix up hoses by mistake.
l damage or deformation of the fitting, which im-
pairs 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 dis-
pose of environmentally.
Store used filters and other oily materials in a sep-
arate, 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 en-
gine is cold.
Catch running out coolant and dispose of environ-
mentally.
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.
BOMAG BW 211 D-4
 Safety regulations

Metal objects (e.g. tools, rings, wrist watches) terials to the direct water jet, but cover them be-
must not contact the battery poles - danger of forehand.
short circuit and burns!
l Do not guide the water jet into the exhaust or
When recharging maintenance free batteries re- into the air filter.
move the plugs to avoid the accumulation of explo-
sive gases. After maintenance work
When using an external battery to start the ma- Reinstall all protective devices after completing
chine follow the respective instructions. the maintenance work.
Dispose of old batteries environmentally.
Repair
Switch the charging current off before removing
the charge clamps. Attach a warning tag to the steering wheel if the
machine is defective.
Ensure good ventilation, especially when charging
the battery in a closed room. Repairs must only be performed by qualified per-
sons who have been instructed for this purpose.
Working on the fuel system Use our repair instructions.
Do not inhale fuel fumes. Exhaust gases are highly dangerous! Always en-
No open fire, do not smoke, do not spill any fuel. sure an adequate supply of fresh air when starting
in closed rooms!
Catch running out fuel, do not let it seep into the
ground and dispose of environmentally. Test
Working on wheels and tires Depending on the type of application and the op-
erating conditions vibratory equipment has to be
Explosion like bursting of tires and parts of rims examined by a specialist whenever required, but
and tires can cause severe or even deadly injuries. at least once every year.
Assemble tires only with the appropriate knowl-
edge and tools. If necessary have the tires assem-
bled 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 ac-
cording 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 run-
ning.
Do not use gasoline or other combustible sub-
stances for cleaning purposes.
When using steam cleaning equipment do not
subject electrical components and insulating ma-

BW 211 D-4 BOMAG 17

Safety regulations

18 BOMAG BW 211 D-4

 3 Indicators and Controls

BW 211 D-4 BOMAG 19

 Indicators and Controls

Fig. 5

20 BOMAG BW 211 D-4


1 Ignition switch
2 Instrument cluster
3 Vent for heating and ventilation, driver
4 Vent for heating and ventilation, footwell
5 Push button vibration
6 Travel lever
7 Rotary switch vibration, high/low frequency
8 Rotary switch for speed range selection
9 Emergency stop push button
BW 211 D-4
Indicators and Controls
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
BOMAG 21
Indicators and Controls

3.1 General notes 3.2 Description of indicators

and control elements
Please read this section thoroughly before operat-
ing 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 de-
scriptions of the individual operating steps.

Fig. 6
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.

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

22 BOMAG BW 211 D-4


Fig. 7
No. 2 = Instrument cluster
i Note
With the ignition switch in position I all gauges and
instruments are switched on for 3 seconds.
a red = flashes if the engine temperature ex-
ceeds 135 °C, 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 en-
gine.
b red = flashes if engine oil pressure too low,
engine is shut down after 10 sec-
onds. Check engine oil level, repair
the engine if necessary.
c yellow = Engine air filter, lights if air filter car-
tridge is soiled, clean or replace if
necessary.
d yellow = Charge control light, lights if battery is
not being charged.
Check V-belt, if necessary repair the
generator.
e yellow = lights if the hydraulic oil filter is con-
taminated, the engine is shut down
after 2 minutes.
Check hydraulic system, replace hy-
draulic oil filter.
f yellow = The seat occupation monitoring sys-
tem lights when the seat is not occu-
pied. If the machine is travelling the
warning buzzer will sound, engine is
shut down after 4 seconds.
BW 211 D-4
Indicators and Controls
g red = Parking brake, with lever shifted to
parking brake position, with driver’s
seat unoccupied.
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 fil-
ter reaches the contacts.
j red = flashes, when the coolant provision
(filling level) is too low, the engine is
shut down after 2 minutes.
k yellow = not used
l red = Hazard light, flashes when the haz-
ard light is activated
m = Operating hour meter, counts the op-
erating hours while the engine is run-
ning. All maintenance work must be
performed according to the indicated
operating hours.
n = Fuel tank filling level
When falling below the lowest filling
level the last green LED will light and
the red LED will additionally come on.
When the fuel tank is empty only the
red LED will flash.
No. 3 = Vents for air conditioning, heating
and ventilation, driver
No. 4 = Vents for air conditioning, heating
and ventilation, footwell*
* Optional equipment
BOMAG 23
 Indicators and Controls

Fig. 8 Fig. 10
No. 5 = Push button for vibration No. 7 = Rotary switch for vibration
l Select or actuate the frequencies with the vi- Position "Mid-
bration selector switch. dle" = Vibration off
l Switch the vibration on or off by pressing the Position "Right" = low amplitude, high frequency
push button. Position "Left" = high amplitude, low frequency

Fig. 9 Fig. 11
No. 6 = Travel lever No. 8 = Rotary switch for speed range selec-
Position "mid- tion
dle" = Braking position service brake Position "turtle" = Working speed
Position "middle, Position "rab-
right" = Parking brake, to start the en- bit" = Transport speed
gine
Position "I" = Forward travel
Position "II" = Backwards travel

i 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.

24 BOMAG BW 211 D-4

 Indicators and Controls

Fig. 12 Fig. 13
No. 9 = Emergency stop switch No. 10 = Push button for warning horn
The engine will be shut down and the brake will
close.

! Danger
Danger of accident!
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. Fig. 14

unlock = turn the button clockwise and
release it.
to drive = move the travel lever first to
braking position, then start the
engine and choose the travel
direction.
For safety reasons the travel system of the ma-
chine will only be enabled after the travel lever has
been shifted back to braking position.
No. 11 = Rotary momentary contact switch for
engine speed
Electric engine speed adjustment
Position left = Idle speed position
i Note
Normal position for engine start.
Position right = Full throttle position, operating
position for driving and vibra-
tion

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

BW 211 D-4 BOMAG 25

 Indicators and Controls

Fig. 15 Fig. 17
No. 12 = Rotary switch for direction indicators No. 14 = Rotary switch for light system (StV-
left / right* ZO)***
Position "mid- Position "left" = Light off
dle" = Direction indicators disabled Position "mid-
Position "left or dle" = Sidelights on, with ignition
right" = Front and rear direction indica- switch in position "I" or "P"
tors for the corresponding side Position "right" = Travel light on, with ignition
of the machine light up, the switch in position "I".
control light in the instrument
cluster flashes.

Fig. 18
No. 15 = Rotary switch for working lights****
Fig. 16
No. 13 = Rotary switch for hazard light system Position "left" = Light off
**
Position "right" = Working lights on, with ignition
Position "left" = Hazard light switched off, con- switch in position "I".
trol lights off.
Position "right" = Hazard light switched on, con-
trol light 1 in instrument cluster
lights up.

* Optional equipment *** Optional equipment

** Optional equipment **** Optional equipment

26 BOMAG BW 211 D-4

 Indicators and Controls

i Note
Swivelling angle max. 20° to either side.

Fig. 19
No. 16 = Lever, steering wheel adjustment

Fig. 21
!Danger
Danger of accident! No. 18 = 2-pole socket
Current only with the ignition switch in position "I"
Do not adjust the steering wheel while driving.
or when the engine is running.
pull up = adjust height of steering wheel
press down = adjust inclination of steering
wheel

Fig. 22
No. 19 = Fuses in electric installation box
F03, 15A = Vibration
Fig. 20
F05, 15A = Socket
No. 17 = Lever, swivelling of driver’s seat
F07, 15A = Hazard light *
F09, 10A = Parking tail light, left*
!Danger
Danger of accident! F10, 10A = Parking tail light, right*
F11, 15A = Head lights, StVZO*
Always lock the driver’s seat in one of the lock-
ing positions while driving. F13, 30A = Starting
Do not swivel the driver’s seat while driving. F14, 15A = Engine solenoid
swivel = Stop the machine and apply F18, 10A = Working head lights, relay*
the parking brake. Pull the le- F19, 15A = Working head lights, front, left*
ver up and swivel the driver’s
seat to the desired position.
* Optional equipment

BW 211 D-4 BOMAG 27

Indicators and Controls

F22, 15A = Working head lights, rear* d = toggle switch for rear windscreen heating
F23, 10A = Warning horn
F24, 10A = Monitoring, gauges
F25, 10A = Solenoid valve brake/travel
F39, 15A = Cab*
F70, 15A = Indicator*
F105, 20A = Engine speed control

! Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
Fig. 24
No. 20 = Fuse box, cabin

! Danger
Fire hazard!
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
Fig. 23
(5), 10A = (F41) flashing beacon
a = toggle switch for flashing beacon
(6), 15A = (F144) cab socket
b = toggle switch for front windscreen wiper/ (7), 15A = (F143) rear windscreen heating
washer
(8), 5A = (F42) potential 30, cab light
up = windscreen wiper moves to
end position and stops.
down = Switches on wiping of front
windscreen.
Push button = Front windscreen is sprayed
during wiping.

c = toggle switch for rear windscreen wiper/

washer
up = windscreen wiper moves to
end position and stops.
down = Switches on wiping of rear
windscreen.
Push button = Rear windscreen is sprayed Fig. 25
during wiping. No. 21 = Control panel for ventilator, air condi-
tioning, heating

28 BOMAG BW 211 D-4

 Indicators and Controls

e = Rotary switch for cabin ventilator i = reading and dashboard light

Position ’’Off“ = cabin ventilator switched off. j = toggle switch for reading and dashboard
Position 1, 2 and light
3 = ventilator stages of different
strengths k = toggle switch for cabin light

f = Push button for air conditioning* l = cabin light

press = air conditioning switched on.

i 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.

i Note
The light goes out.

g = Rotary switch for cabin heater (tempera-

Fig. 27
ture selector switch)
No. 23 = Main fuse for battery
Position ’’Off“ = cabin heater switched off.
125A = (F00)
Position blue
range = temperature selection for air
conditioning. i Note
Position red Battery with main fuse is located in the engine
range = Temperature selection for cab- compartment
in heater.

Fig. 28
Fig. 26 No. 24 = EVIBdisplay**
No. 22 = Cabin light is a compaction measuring unit for continuous dis-
play of the load bearing characteristics (MN/m2)
during the compacting pass.

EVIB value
Increase = higher load bearing capacity
* Optional equipment ** Optional equipment

BW 211 D-4 BOMAG 29

Indicators and Controls

Constant = end of compaction

30 BOMAG BW 211 D-4

 4 Operation

BW 211 D-4 BOMAG 31

Operation

4.1 General notes 4.2 Tests before starting to op-

erate
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
The following tests must be performed before
you are not yet fully familiar with the indicators and
each work day or before a longer work period.
control elements of the machine.
All indicators and control elements are described
in detail in this chapter. ! Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of these operating and mainte-
nance instructions!
l Park the machine on level ground.

Check:
l Fuel tank and fuel lines for leaks
l Bolted connections for tight fit
l Function of the steering
l Check the machine for cleanliness and dam-
age
l availability of the appropriate operating and
maintenance instructions,
l check if the machine has been properly serv-
iced.

i Note
For a description of the following work refer to the
section "maintenance every 10 operating hours"
l engine oil level

i Note
Hydraulic systems, which are filled with Panolin
HLP Synth. 46, the same oil must be used for fill-
ing up. In case of any other ester based oil consult
the lubrication service department of the respec-
tive oil manufacturer.
l Check the hydraulic oil level, top up if neces-
sary.
l 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.

32 BOMAG BW 211 D-4

 Operation

l Check water separator in the fuel system,

drain if necessary. 4.3 Starting the engine
l Adjust the scrapers if necessary
l Tire pressure. Pressure see technical data. ! Danger
Danger of accident!
Caution
!
Always wear your seat belt.
Ensure equal pressure in both tires.

Fig. 29

l Check, whether the travel lever (Fig. 29) is en-

gaged to the right in brake position.

Fig. 30

l Turn the rotary vibration selector switch (Fig.

30) to position "0", vibration off.

BW 211 D-4 BOMAG 33

Operation

Fig. 31 Fig. 34

l Check, whether the emergency stop switch
(Fig. 31) is unlocked.
All control and warning lights (Fig. 34) 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. 32

l Turn rotary switch (Fig. 32) to position "Min"

(idle speed).

Fig. 35

l Turn the ignition key to position "II" (Fig. 35),

the starter will crank the engine.
l As soon as the engine ignites return the igni-
tion key to position "I".
Fig. 33

l Turn the ignition key (Fig. 33) to position "I". Caution

!

Do not allow the engine to run longer than 10

minutes with idle speed.

34 BOMAG BW 211 D-4


4.4 Starting with jump wires
Fig. 36
!Caution
A wrong connection will cause severe damage
in the electric system.
l Bridge the machine only with a 12 Volt auxilia-
ry battery.
l When jump starting with an external battery
connect both plus poles first.
l Then connect the ground cable first to the mi-
nus pole of the current supplying auxiliary bat-
tery and then to engine or chassis ground, as
far away from the battery as possible (Fig. 36).
l Start as described under 'Starting the engine'.
l Once the engine is running switch on a power-
ful consumer (working light, etc.).
! Caution
If no powerful consumer is switched on volt-
age peaks may occur when separating the con-
necting cables between the batteries, which
could damage electrical components.
l After starting disconnect the negative poles
(ground cable) first and the positive poles af-
ter.
l Switch off the consumer.
BW 211 D-4
Operation
4.5 Driving the machine
! Danger
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclina-
tions and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive up and down inclinations exceed-
ing the maximum gradability of the machine
(see technical data).
Do not drive without wearing your seat belt.
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 driv-
ing with the machine. With the door opened
and the machine fully articulated extreme os-
cillations of the machine may damage the
door.
i Note
"Start engine", see previous sections.
The machine is equipped with a seat contact
switch (safety feature).
If the travel lever is actuated with the engine run-
ning, but the driver's seat is not occupied, the sig-
nal horn is triggered and the engine shut down.
If the driver gets up from his seat while driving, the
signal horn is activated and the engine shut down
after four seconds.
If the driver occupies the seat again within this pe-
riod of four seconds, the machine will continue
travelling.
BOMAG 35
Operation

Fig. 37 Fig. 40

l Close the cabin door (Fig. 37). l Select the desired travel speed range (Fig.
40).

Fig. 38
Fig. 41
l Sit down on the seat (Fig. 38).
l Turn the rotary switch (Fig. 41) to "Max" posi-
tion (full throttle).

Fig. 39

l Fasten your seat belt (Fig. 39).

Fig. 42

l Push the travel lever (Fig. 42) to the left out of

braking position and move it slowly to the de-
sired travel direction.

36 BOMAG BW 211 D-4

 Operation

i 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!
When stopping on inclinations and slopes pull
the travel lever to the right and lock it in brak-
ing position.
4.6 Switching the vibration on
and off
! Danger
Risk of damage!
When compacting with vibration you must
check the effect of nearby buildings and un-
derground 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!

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.
Fig. 43
If the engine speed drops when driving up ex-
l Switch to working speed (Fig. 43) (turtle).
treme inclinations move the ravel lever slightly
back, if necessary change to the lower speed
range. Pre-selecting the vibration

Fig. 44

l Pre-select amplitude/frequency with the rotary

switch (Fig. 44).

BW 211 D-4 BOMAG 37

Operation

Switch the vibration on

4.7 Operating the parking
brake, stopping the ma-
chine

Fig. 45

l Turn the rotary switch (Fig. 45) to position

"Max" (full throttle).

Fig. 47
Caution
!
l Return the travel lever (Fig. 47) slowly to "neu-
Switch the vibration on only at max. engine
tral"-position and engage it to the right parking
speed.
brake position.
The machine is automatically braked by the hydro-
static drive and parking brake closes.

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

Fig. 46

l Press the push button (Fig. 46) in the travel le-

ver 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".

38 BOMAG BW 211 D-4

 Operation

4.8 Shutting the engine down

! Caution
Straighten the articulated joint to provide easi-
er access to the machine.

Fig. 50

l Turn the ignition switch (Fig. 50) to position "0"

or "P" and pull the ignition key out.

i Note
The parking brake closes automatically when
shutting the engine down.
Fig. 48

l Return the travel lever (Fig. 48) slowly to "neu- Danger

!

tral"-position and engage it to the right in brak- Danger of accident!

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

Fig. 49

l Turn rotary switch (Fig. 49) to position "Min"

(idle speed).

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

BW 211 D-4 BOMAG 39

Operation

4.9 Emergency exit 4.10 Adjusting the steering

wheel
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.

Fig. 51

l Adjustment of steering wheel in height, pull le-

ver (Fig. 51) up and move the steering wheel
to the desired height.
l 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 steer-
ing wheel adjustment is securely locked in
place.

40 BOMAG BW 211 D-4

 Operation

4.11 Adjusting the seat 4.12 Operating the hood

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

Opening the hood

Fig. 52

l To adjust the seat in longitudinal direction dis-

engage lever e (Fig. 52) upwards and push the
seat forward or back.
l To adjust the weight turn lever (d) and read the
weight in sight glass (c).
l To adjust the inclination of the backrest oper-
ate lever (a) and tilt the backrest forward or
Fig. 54
back.
l Unlock the lock (Fig. 54).
l To swivel the seat pull lever (b) up and turn the
seat to the desired direction. l To open the hood press in the button and turn
the handle.

Fig. 53
Fig. 55
l To adjust the height of the seat lift the seat up
(Fig. 53) until it engages at the desired level. l Pull the support (Fig. 55) out of the bracket.
When lifting the seat completely it will sink down to
lowest position.

BW 211 D-4 BOMAG 41

Operation

Closing the hood

Fig. 56

l Let the spring pin (Fig. 56) click into place.

l If the hood is to be raised to top position you
must also pull out and lock the bottom rod.
Fig. 58
l Pull down the hood, press in the spring pin
(Fig. 58) and push the hood together.
l Store the hood support.
l Close the hood, lock it and pull off the key.

Fig. 57

l Push up the hood and place the support rod

into its receptacle.

42 BOMAG BW 211 D-4

 Operation

4.13 Towing in case of an engine

failure

! Danger
Secure the machine with wheel chocks against
unintentional rolling.

Danger
!

Danger of accident!
When using towing ropes tow the machine Fig. 60
only uphill.
l To release the brake turn counter nuts 1 (Fig.
When towing downhill you must use a rigid 60) approx. 8 mm back.
towing device.
l Turn the brake releasing screws (2) complete-
l Secure the machine with wheel chocks ly in against the stop.
against unintentional rolling.
l Attach the towing ropes safely to the front or Caution
!
rear lifting eyes.
From this stop turn the screw in for maximum
another turn to release the brake!
! Caution
Turn the screws in evenly on both sides.
Towing speed 1 km/h, max. towing distance
500 m. l Turn the screws in alternately for ¼ turn at a
time.
l Open the tailgate.
l Repeat this measure on the opposite wheel
side.

Fig. 59

l Slacken the middle hexagon on both valves Fig. 61

(Fig. 59) for approx. 2 to 3 turns.
l Remove plug 1 (Fig. 61).
l Place an U-section (5) across the brake hous-
Caution
!
ing (2) and turn the screw (4) into the tapped
Do not turn the valves out completely. bore (3), until it bottoms.
l Turn the nut (6) down and tighten it approx.
one revolution. The drum must rotate freely.

BW 211 D-4 BOMAG 43

Operation

After towing i Note

!Caution
Before detaching the tow bar block the ma-
chine with chocks to prevent unintended roll-
ing.
l Turn the high pressure relief valve cartridges
tightly back in.
l Turn all brake releasing screws of the axle
evenly back out, until they are light moving
again.
If necessary replace the seal ring under the coun-
ter nut if it is leaking.
For this purpose completely unscrew the brake re-
leasing 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.

Fig. 62

l Turn the brake releasing screws (Fig. 62) back

in again, until they abut against the brake pis-
ton.

Fig. 63

l Unscrew the brake releasing screws (Fig. 63)

for two turns and tighten the counter nuts.
l Repeat this adjustment procedure on the op-
posite wheel side.

44 BOMAG BW 211 D-4

 Operation

4.14 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. Fig. 66
Always use shackles on the lifting points for l Lash the machine on the transport vehicle
loading, tying or lifting the machine. (Fig. 66), use the four lashing eyes on front
and rear frame for this purpose.
l Support the front frame to avoid overstressing
of the rubber buffers.

Fig. 64

l Pull the spring pin (Fig. 64) out.

l Engage the articulation lock and secure it with
the spring pin. Fig. 67

l For lifting use also the four lifting eyes (Fig. 67)
and appropriate lifting gear.

Weights: See technical data

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

Fig. 65

l Engage the articulation lock and secure it with

the spring pin (Fig. 65).

BW 211 D-4 BOMAG 45

Operation

46 BOMAG BW 211 D-4

 5 Maintenance

BW 211 D-4 BOMAG 47

Maintenance
5.1 General notes on mainte-
nance
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 im-
portant components. The necessary effort can by
no means be compared with the problems and
malfunctions that could occur if this is not ob-
served.
The terms left/right are always related to travel di-
rection forward.
l Clean machine and engine thoroughly before
starting maintenance work.
l For maintenance work park the machine on
level ground.
l Maintenance work must generally be carried
out with the engine shut down.
l Depressurize hydraulic lines before working
on them.
l Disconnect the battery and cover it with insu-
lation material before starting to work on elec-
trical components.
l Always attach the articulation lock (transport
lock) before starting to work in the articulation
area of the machine.
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 de-
pending on the cleanliness of the fuel.
l Keep the engine free of dirt and water as this
could damage the injection elements of the en-
gine.
l Zinc lined drums are not suitable for storing fu-
el.
l The fuel drum should rest for a longer period
of time before drawing off fuel.
48
l Do not let the suction hose disturb the sludge
on the bottom of the drum.
l Do not draw off fuel from near the bottom of
the fuel drum.
l Fuel left in the fuel drum is not suitable for the
engine and should only be used for cleaning
purposes.
Notes on the engine performance
Combustion air and fuel injection rates of the die-
sel engine have been carefully adjusted and deter-
mine 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 manufac-
turer.
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.
l Seal external leaks immediately. If necessary
inform the responsible service department.
l 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.
l 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 pro-
longs the lifetime of the system filter.
l Clean fittings, filler caps and their immediate
surrounding area before removing them, so
that no dirt can fall in.
l Do not leave the tank opening unnecessarily
open, cover it so that no dirt can fall in.
BOMAG BW 211 D-4
 Maintenance

Notes on the cooling system

5.2 Fuels and lubricants
On water cooled engines the preparation and
monitoring of the coolant is of utmost importance,
as otherwise engine failures caused by corrosion, Engine oil
caviation and freezing may occur.
The coolant is a mixture of water and a cooling Quality
system protection agent. Lubrication oils are classified according to their
The cooling system must be permanently moni- performance and quality class. Oils according to
tored. Apart from the coolant level inspection this other comparable specifications may be used.
includes also the inspection of the concentration of
cooling system protection agent. Approved engine oils
The concentration of the cooling system protection Deutz DQC II DQC III
agent can be checked with commercially available ACAE E3/96/E5-02 E4-99
test instruments (glycomat). API CH-4/CG-4 -
DHD DHD-1 -
! Danger The exact assignment of the approved oil qualities
Health hazard! and oil change intervals can be taken from the fol-
lowing section "Lubrication oil change intervals".
The mixing of nitride based cooling system
protection agents with amine based agents will Consult your local service station if in doubt.
cause the generation of highly toxic nitro-
Oil viscosity
samines.
Multi-purpose oils should be generally used.

Environment Since lubrication oil changes its viscosity with the

Cooling system protection agents must be dis-
posed of environmentally.
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class) .
Optimal operating conditions can be achieved by
using the opposite oil viscosity chart (Fig. 68) 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 ex-
ceeding of the limits should not happen over a
longer period of time.

BW 211 D-4 BOMAG 49

 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 tem-
peratures 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 agen-
cy.

Fig. 68
With their better temperature and oxidation stabil-
ity synthetic lubrication oils offer quite a few bene-
fits.
Oil change intervals
The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the follow-
ing oil change intervals are not reached over a pe-
riod of 1 year, the oil change should be performed
at least once per year, irrespective of the operating
hours reached.
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 in-
jection lines need to be bled.
When using fuels with a Cetan number < 49 poor
starting and white smoke can be expected, in par-
ticular in connection with low ambient tempera-
tures.
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 2-
D.
l DIN/EN 590
l BS 2869
l ASTM D 975-78: 1-D and 2-D.
l Nato Codes: F-54, F-34, F44 und XF63
Winter fuel

ACEA*
Danger
!

E3-96/E5-02
Fire hazard!
E4-99 = 500 operating hours
Diesel fuels must never be mixed with gaso-
API** line.
CG-4/CH-4 = 500 operating hours For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At
Caution
!
very low temperatures disturbing paraffin separa-
tion can also be expected when using winter diesel
These intervals apply only when using a diesel
fuel.
fuel with maximum 0.5 % sulphur by weight
* European Engine Oil Sequences
** American Petroleum Institute

50 BOMAG BW 211 D-4


In most cases a sufficient cold resistance can also
be achieved by adding flow enhancing fuel addi-
tives. Consult the engine manufacturer.
Operation with rape seed oil methyl ester (RME
„Bio Diesel“)
Due to the extreme quality differences of RMEW-
fuels 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 Reduced engine power (approx. 7%), higher
fuel consumption.
l The quality of RME-fuel should be in compli-
ance with DIN draft 51606.
l Avoid longer periods of standstill (formation of
resin, corrosion in injection system)
l RME-fuel can damage the paint finish of the
machine.
l Fuel dilution of engine oil, therefore shortening
of oil change intervals to half.
l 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 fluorinat-
ed rubber. However, fluorinated rubber is not
resistant against normal diesel fuel.
l If the fuel filter is clogged the filter change in-
tervals must be shortened accordingly.
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.
BW 211 D-4
Maintenance
Environment
Cooling system protection agents must be dis-
posed 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 40°C. For topping up or for oil chang-
es 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 in-
dex (VI) should be at least 150 (observe informa-
tion of manufacturer).
Bio-degradable hydraulic oil
On request the hydraulic system can also be filled
with ester based biodegradable hydraulic oil (Pan-
olin HLP Synth. 46). The biologically quickly de-
gradable 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 manu-
facturer for details.
Check the filter more frequently after this change.
!Caution
Oil change bio-degradable hydraulic oil:
Perform regular oil analyses for content of wa-
ter and mineral oil.
Replace the hydraulic oil filter element every
500 operating hours.
Oil for drive axle
For the drive axle use only multi-purpose transmis-
sion 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).
BOMAG 51
Maintenance

5.3 Table of fuels and lubri-

cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

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

oil filter

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. 150 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres

46 mm2/s at 40 °C

Vibration bearings Engine oil SAE 15W/40 approx. 0,8 litres

Drive axle Gear oil SAE 90, API GL5 approx. 9,5 litres

Wheel hubs Gear oil SAE 90, API GL5 approx. 1.9 l per side

Air conditioning system Refrigerant R134A approx. 1400 g

Engine cooling system Cooling system protection agent approx. 16 litres

52 BOMAG BW 211 D-4

 Maintenance

5.4 Running-in instructions

The following maintenance work must be per-

formed 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 50 operating hours

l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.
l Retighten all wheel fastening screws with the
specified tightening torque.
l Oil change vibration bearings
l Oil change in drive axle
l Oil change in wheel hubs

After 500 operating hours

l Oil change vibration bearings

BW 211 D-4 BOMAG 53

Maintenance

5.5 Maintenance chart

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 250 operating hours

every 500 operating hours

after 50 operating hours
Running-in instructions
No. Maintenance work Remark

as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Check the dust separator X
5.12 Check the tire pressure X
5.13 Clean the cooling fins on engine and X
hydraulic oil cooler
5.14 Check the oil level in the drive axle X
5.15 Check the oil level in the wheel hubs X
5.16 Check the oil level in the vibration X
bearings
5.17 Change engine oil and oil filter car- min. 1x per year X
tridge*
5.18 Change the fuel filter cartridge X
5.19 Drain the sludge from the fuel tank X
5.20 Service the battery Pole grease X
5.21 Change the fuel pre-filter cartridge X
5.22 Check, replace the refrigerant com- X
pressor V-belt
5.23 Service the air conditioning X
5.24 Check, adjust the valve clearance Intake = 0,3 mm X
Exhaust = 0,5 mm

54 BOMAG BW 211 D-4

 Maintenance

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 250 operating hours

every 500 operating hours

after 50 operating hours
Running-in instructions
No. Maintenance work Remark

as required
5.25 Check, replace the ribbed V-belt X
5.26 Check the engine mounts X X
5.27 Oil change in drive axle min. 1x per year X X
5.28 Oil change in wheel hubs min. 1x per year X X
5.29 Oil change vibration bearings** see foot note, min. 1 X X
x per year
5.30 Retighten the fastening of the axle on X
the frame
5.31 Tighten the wheel nuts X X
5.32 Check the ROPS X
5.33 Clean the oil bath air filter min. 1x per year X
5.34 Change hydraulic oil and breather fil- at least every 2 X
ter*** years
5.35 Change the hydraulic oil filter**** at least every 2 X
years
5.36 Change the coolant at least every 2 X
years
5.37 Check the injection valves X
5.38 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2 years
5.39 Adjust the scrapers X
5.40 Adjust the parking brake X
5.41 Change the tires X
5.42 Change the fresh air filter in the cabin X
5.43 Tightening torques X
5.44 Engine conservation X

BW 211 D-4 BOMAG 55

Maintenance

* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h.
*** Also in case of repair in the hydraulic system.
**** Also in case of repair in the hydraulic system.

56 BOMAG BW 211 D-4

 Every 10 operating hours

Every 10 operating hou rs

5.6 Check the engine oil level 5.7 Check, clean the water sep-
arator
! Danger
Danger of injury! ! Danger
Support the engine hood for all maintenance Danger of injury!
and repair work.
Support the engine hood for all maintenance
and repair work.
i Note
The machine must be parked horizontally with the i Note
engine shut down.
The service intervals for the water separator de-
pend 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 re-
quired", bleeding the fuel system.

Environment
Catch running out fuel and dispose of environ-
mentally.
Fig. 69

l Pull the dipstick (Fig. 69) out, wipe it off with a

lint-free, clean cloth and reinsert it until it bot-
toms.
l Pull the dipstick back out again.
l If the oil level is below the "MAX" mark fill in oil.
l If the oil level is above the “Max” mark deter-
mine the cause and drain the oil off.

Caution
!

Before longer work periods you should always

top the oil up to the "MAX"-mark. Fig. 70

For quality and quantity of oil refer to the table l Slacken the drain plug (Fig. 70) for a few turns
of fuels and lubricants. and catch running out fuel / water.
l Tighten the drain plug again and check for
leaks, if necessary replace the seal ring.

BW 211 D-4 BOMAG 57

Every 10 operating hours

Caution
5.8 Check the fuel level !

Contaminated fuel can cause malfunction or

even damage of the engine.
! Danger If necessary, fill in fuel through a funnel with
Fire hazard! screen.

When working on the fuel system do not use l If necessary top up with fuel (diesel or winter
open fire, do not smoke, do not refuel in closed diesel).
rooms, do not inhale any fuel fumes. For quality of fuel refer to the table of fuels and
lubricants.

Fig. 71

l Check the fuel level on the fuel level gauge "n"

(Fig. 71) with the ignition switched on.

i Note
Do not drive the fuel tank dry, as otherwise the fuel
system needs to be bled.
l Clean the area around the filler opening.

Fig. 72

l Open the fuel tank cover (Fig. 72).

58 BOMAG BW 211 D-4

 Every 10 operating hours

5.9 Checking the hydraulic oil 5.10 Check the coolant level
level
! Danger
! Caution Danger of scalding!
In mit Panolin HLP Synth. 46, the same oil must Fill up coolant only when the engine is cold.
be used for filling up. In case of any other ester
based oil consult the lubrication service de-
partment of the respective oil manufacturer.

Fig. 74

l Check the coolant level (Fig. 74).

Fig. 73

l Check the oil level in the inspection glass (Fig. ! Caution

73) on the hydraulic oil tank. If, during the daily inspection the coolant level
is found to have dropped, check all lines, hos-
Normal level es and engine for leaks.
approx. 3 cm below the upper edge of the inspec- l To top up unscrew the filler cap and fill in cool-
tion glass. ant up to the MAX-mark.
Minimum level For quality of coolant refer to the chapter 5.2,
middle of inspection glass. fuels and lubricants.

!Caution
If during the daily oil check the oil level is
found to have dropped, check all lines, hoses
and components for leakages.
l 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 D-4 BOMAG 59

 Every 10 operating hours

5.11 Checking the dust separa-

tor on the oil bath air filter*

Fig. 75

l If the dust reaches the mark loosen the clamp

(Fig. 75), take the cover off and clean the bowl.

* Option

60 BOMAG BW 211 D-4

 Every 250 operating hours

Every 250 oper ating hours

5.12 Checking the tire pressure 5.13 Clean the cooling fins on
engine and hydraulic oil
! Caution
cooler
Since the tires are filled with water, you should
always turn the inflation valve to top position
to check the tire pressure! Danger
!

Danger of injury!
Always close the valves with the dust cap.
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 Note
Dirt on fan blades and oil cooler reduce the cooling
effect. Dirt deposits in these areas are substantial-
ly 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
Fig. 76 cooler and clean the cooling surfaces after.
l Check the tire pressure with a pressure gauge
and the tire inflation valve 1 (Fig. 76) in top po- Cleaning with compressed air
sition.

Nominal value see "technical data".

i Note
Ensure even pressure in all tires.
l Screw the valve caps back on.

Fig. 77

i Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 77) out with compressed
air.

BW 211 D-4 BOMAG 61

Every 250 operating hours

Cleaning with cold cleansing agent

5.14 Check the oil level in the
! Caution
drive axle
Protect electrical equipment such as genera-
l Park the machine on level ground.
tor, regulator and starter against the direct wa-
ter jet.
l 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.
l Run the engine warm for a while to avoid cor-
rosion.

Fig. 78

l Unscrew the oil level inspection plug (Fig. 78)

and check the oil level.

i Note
The second level inspection plug as at the back.
After filling in oil wait until the oil has evenly distrib-
uted 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.

62 BOMAG BW 211 D-4


5.15 Checking the oil level in left/
right wheel hubs
Fig. 79
l Move the machine until the oil level inspection
plug 1 (Fig. 79) is in horizontal position.
l Clean and unscrew the plug.
The oil level must reach the bottom edge of the
bore.
l Top up oil, if necessary.
For quality of oil refer to the table of fuels and
lubricants.
l Screw the plug back in tightly.
l Repeat this inspection on the other side.
BW 211 D-4
Every 250 operating hours
5.16 Check the oil level in the vi-
bration bearings
i Note
Check only at operating temperature after running
the machine approx. 1/2 hour with vibration.
l Park the machine on level ground.
Fig. 80
l Move the drum, until oil level inspection plug 1
(Fig. 80) on the left hand side of the drum is in
bottom position.
l Unscrew level inspection plug (1).
Some oil should run out of the inspection bore.
l If necessary unscrew oil filler plug (2) and fill in
some oil through the oil filler bore (2), until oil
starts to drip out through the inspection bore.
For quality of oil refer to the table of fuels and
lubricants.
l Screw oil filler (2) and level inspection plug (1)
back in tightly.
l Repeat this inspection on the other side.
! Caution
If a loss of oil is found perform trouble shoot-
ing, repair the drum if necessary.
BOMAG 63
 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 oils of oil quality class API CG-4/CH-
4 or ACAE E3-96/E5-02 respectively.
Refer also to the chapter 5.2, fuels and lubri-
cants.
Drain the engine oil only when the engine is
warm. Fig. 82

l Thoroughly clean the outside of both filter car-

tridges (Fig. 82).
Danger
!

Danger of scalding! l Unscrew both filter cartridges using an appro-

priate filter wrench.
When draining off hot oil.
By hot oil when unscrewing the engine oil fil-
ter.
i Note
The filter cartridges are fitted with a valve that pre-
vents engine oil from running out during removal
Environment and installation.
Catch running out oil and dispose of environ- l Clean the sealing face on the filter carrier from
mentally together with the engine oil filter car- any dirt.
tridge.
l Slightly oil the rubber seal on the new filter car-
tridges.

Fig. 81

l Unscrew the drain plug (Fig. 81) and catch Fig. 83

running out oil.
l Turn the new filter cartridges (Fig. 83) on by
l Turn the drain plug tightly back in. hand, until the seal contacts.
l Tighten the filter cartridges for another half
turn.

64 BOMAG BW 211 D-4

 Every 500 operating hours

5.18 Change the fuel filter car-

tridge

! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.
Catch running out fuel, do not let it seep into
the ground.
Fig. 84
Do not inhale any fuel fumes.
l Fill in new engine oil (Fig. 84).

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 start-
er 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.
Fig. 85
l Check filter cartridge and drain plug for leaks
after a short test run. l Loosen and unscrew the fuel filter cartridge
l Shut the engine down and wait for about 15 (Fig. 85) using an appropriate filter wrench.
minutes, so that all oil can flow back into the oil l Clean the sealing face on the filter carrier from
sump. any dirt.
l Check the oil level again, if necessary fill up to
the Max.-mark.

Fig. 86

l Slightly oil the rubber seal (Fig. 86) on the new

filter cartridge.

BW 211 D-4 BOMAG 65

Every 500 operating hours

l Fill the filter cartridge with clean diesel fuel.

5.19 Draining the sludge from
l Turn the new filter cartridge on by hand, until
the seal contacts. the fuel tank
l Tighten the filter element for another half turn.
l Check the filter cartridge for leaks after a short ! Danger
test run.
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. 87

l Unscrew the cap (Fig. 87) and drain off ap-

prox. 5 litres of fuel.
l Turn the cap tightly back in.

66 BOMAG BW 211 D-4

 Every 500 operating hours

Caution
5.20 Service the battery !

Exhausted batteries (batteries with formation

of sulphate on thge plates are not covered un-
der warranty!
! Danger
Danger of cauterisation ! Danger of explosion! l Open the engine hood and remove the cover-
ing.
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.

i Note
Maintenance free batteries also need care. Main-
tenance free only means that the fluid level does Fig. 88
not need to be checked. Each battery suffers un- l Remove the battery (Fig. 88) and clean the
der self-discharge, which may, in not checked oc- battery compartment.
casionally, even cause damage to the battery as a
result of exhaustive discharge. l Clean the outside of the battery.
l Clean battery poles and pole clamps and
The following therefore applies for the service grease them with pole grease (Vaseline).
life:
l Check the fastening of the battery.
l Switch off all consumers (e.g. ignition, light, in-
side light, radio). l On serviceable batteries check the acid level,
if necessary top up to the filling mark with dis-
l Check open-circuit voltage of the battery at
tilled water.
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V = Charging voltage recommendation
50% discharged.
l 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 ap-
prox. 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.
l For resting periods of more than one month
you should always disconnect the battery. Do
not forget to perform regular open-circuit volt-
age measurements. Fig. 89

BW 211 D-4 BOMAG 67

Every 500 operating hours

5.21 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 fu-
el.
Catch running out fuel, do not let it seep into
the ground.
Fig. 92
Do not inhale any fuel fumes.
l Apply a thin coat of oil to the rubber seal of the
water separator 1 (Fig. 92).
l Screw the water separator on by hand (2), until
the seal contacts.
l Tighten the water separator for another half
turn (3).
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter el-
ement (5) and screw it on by hand, until the
seal contacts.
l Tighten the filter element for another half turn
(6).
Fig. 90 l Check the filter cartridge for leaks after a short
l Unscrew the fuel filter cartridge (Fig. 90) using test run.
an appropriate filter wrench.
l Clean the sealing face on the filter carrier from i Note
any dirt. Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the en-
gine and makes starting impossible.
Therefore bleed the fuel system after changing the
fuel prefilter.

Fig. 91

l Unscrew the water separator from the filter

cartridge (Fig. 91).

68 BOMAG BW 211 D-4

 Every 500 operating hours

5.22 Checking, replacing the re-

frigerant compressor V-
belt*

Danger
!

Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.

Fig. 93 Check the V-belt

l Slacken the bleeding screw (Fig. 93) on the
fuel pre-filter for 2 to 3 turns.
l Operate the hand pump manually, until fuel
flows out of the slackened bleeding screw (Fig.
93) without air bubbles.
l Then tighten the bleeding screw while pump-
ing.

Fig. 94

l Inspect the entire circumference of the V-belt

(Fig. 94) visually for damage and cracks. Re-
place damaged or cracked V-belts.
l 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.

* Optional equipment

BW 211 D-4 BOMAG 69

Every 500 operating hours
Tighten the V-belt.
Fig. 95
l Slightly slacken fastening screws 1, 2 and 3
(Fig. 95).
l Press the compressor in direction of arrow, un-
til the correct V-belt tension is reached.
l Retighten all fastening screws.
Changing the V-belt
l Slightly slacken the fastening screws 1, 2 and
3.
l Press the compressor against the direction of
arrow completely against the engine.
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
! Caution
Check the V-belt tension after a running time of
30 minutes.
70
5.23 Service the air conditioning*
Cleaning the condenser
! Caution
A soiled condenser results in a considerable
reduction of air conditioning power.
Under extremely dusty conditions it may be
necessary to clean the condenser several
times per day.
If, during operation of the air conditioning sys-
tem, the warning buzzer sounds switch the air
conditioning off and clean the condenser.
In case of formation of foam have the air con-
ditioning system inspected by the service de-
partment.
Danger
!
Danger of accident!
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 dis-
mount the machine.
Fig. 96
l Unscrew the condenser fastening screws (Fig.
96) and fold the condenser forward.
l Clean the condenser fins on front and back
with compressed air or cold water.
* Optional equipment
BOMAG BW 211 D-4

Checking the refrigerant level
l Start the engine.
Fig. 97
l Switch the air conditioning (Fig. 97) on.
Fig. 98
l Choose a cooling temperature with the rotary
switch for cabin heater (Fig. 98) in the blue
section.
l Open the air outlet nozzles.
l Check, whether the outflowing air is noticeably
cooler.
i Note
The adjusted temperature must be below the actu-
al temperature inside the cabin, so that the com-
pressor will be switched on.
l Open the hood.
BW 211 D-4
Every 500 operating hours
Fig. 99
l Check whether the white float (Fig. 99) inside
the inspection glass of the drier/collector unit
floats right at the top.
i Note
The refrigerant level is correct.
Fig. 100
l If the white float (Fig. 100) inside the inspec-
tion glass of the drier/collector unit floats at the
bottom, inform the service department.
i Note
The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary
check the air conditioning system for leaks.
BOMAG 71
Every 500 operating hours

Checking the moisture level of the dry- arising from the handling and operation of
ing agent pressure reservoirs.

! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be re-
placed, to avoid bursting and further damage.

Fig. 101

l Check the moisture indication pearl (Fig. 101)

inside the inspection glass of the drier/collec-
tor unit.
blue = drying agent o.k.
purple = moisture level of drying agent too
high. Fig. 102

l Inform the service department. Replace drier/ l Check the drier/collector unit (Fig. 102) for me-
collector unit, check air conditioning system. chanical damage or rust.

!Caution
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.

Checking the condition of the drier/col-

lector unit

!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeated-
ly inspected by a specialist. In this sense
repeated inspections are external examina-
tions, normally on pressure reservoirs in oper-
ation. 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 op-
erators and third parties against any danger

72 BOMAG BW 211 D-4

 Every 1000 operating hours

Every 1000 operating hours

5.24 Check, adjust the valve

clearance

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

Valve adjustment schematic Fig. 104

Crankshaft position 1 (Fig. 104) (4 cylinder en-

gine)
l Crank the engine with the starter or a spanner
by the V-belt pulley until both valves on cylin-
der 1 are “overlapping”.
Overlapping means: Exhaust valve not yet closed,
intake valve starts to open.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram "crankshaft posi-
tion 1", black mark.
l For control purposes mark the respective rock-
er arm with while chalk once the correspond-
Fig. 103 ing valve is adjusted.
Valve 1 (Fig. 103) white = not adjustable
Valve (2) black = adjustable

Fig. 105

Crankshaft position 2 (Fig. 105) (4 cylinder en-

gine)
l Turn the crankshaft one revolution (360°) fur-
ther.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram "crankshaft posi-
tion 2", black mark.

BW 211 D-4 BOMAG 73

Every 1000 operating hours

Check the valve clearance Adjusting the valve clearance

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

Fig. 108

l Slightly slacken the counter nut. Adjust set-

Fig. 106 screw 7 (Fig. 108) with a screwdriver, until the
l Remove the valve cover (Fig. 106). feeler gauge (6) can be inserted and pulled out
with little resistance after retightening the
l Crankshaft position as per "valve adjustment counter nut.
schematic".
l Perform tests and adjustments on all other ad-
justable valves.
l Check the gasket of the valve cover, replace it
if necessary.
l Reassemble the cylinder head cover.
l Swivel the ventilation valve back to correct po-
sition and fasten it.
l Fasten the air filter again and ensure correct fit
of combustion air hoses and clamps.

Fig. 107

l Check valve clearance 2 (Fig. 107) between

rocker arm (1) and valve (3) with a feeler
gauge.
Intake valve = 0,3 mm
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 feel-
er gauge, the valve must be adjusted.

74 BOMAG BW 211 D-4

 Every 1000 operating hours

Changing the ribbed V-belt

5.25 Checking / replacing 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 V-

belt

Fig. 110

l Unscrew the fastening screws (Fig. 110) and

slide the fan forward.

Fig. 109

l Check the distance between the tongue of the

moveable tensioner arm and the fixed tension-
er housing (Fig. 109).
l If measurement "a" is smaller than 3 mm, re-
place the ribbed V-belt.
Fig. 111
l Release the idler pulley (Fig. 111) in direction
of arrow until the ribbed V-belt is free.
l Pull the ribbed V-belt first to the smallest pul-
ley.
l Install the new ribbed V-belt.
l Release the idler pulley against the direction
of arrow until the V-belt is tensioned.
l Measure the V-belt tension, tighten if neces-
sary.

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

BW 211 D-4 BOMAG 75

Every 1000 operating hours

5.26 Check the engine mounts 5.27 Change the oil in the drive
axle

i Note
On other axle versions drain and filler plugs are of
slightly different design. Perform the oil change ac-
cordingly.

Caution
!

Drain oil only at operating temperature.

Environment
Catch old oil and dispose of environmentally.
Fig. 112

l Tighten fastenings of intake and exhaust man- l Park the machine on level ground.
ifolds (Fig. 112) on the cylinder heads.
l 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.
l Retighten the fastening screws for oil sump
and engine mounts.

Fig. 113

l Clean and unscrew all level inspection and

drain plugs (Fig. 113).
l Drain and catch all oil.
l Clean the drain plug and turn it back in with a
new seal ring.

76 BOMAG BW 211 D-4

 Every 1000 operating hours

5.28 Changing the oil in the

wheel hubs

! 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. 114

l Fill in oil through the oil level inspection bores

(Fig. 114), until it has reached the bottom edge
of the bore.

i Note
The second level inspection plug as at the back.
After filling in oil wait until the oil has evenly distrib-
uted 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. 115

l Move the drive wheel, until the plug (Fig. 115)

is in bottom position.
l Clean and unscrew the plug.
l Drain and catch all oil.

Fig. 116

l Move the drive wheel, until the plug (Fig. 116)

is in horizontal position on the housing.
l Fill in oil, until it reaches the bottom edge of the
bore.

BW 211 D-4 BOMAG 77

Every 1000 operating hours

For quality and quantity of oil refer to the table

of fuels and lubricants. 5.29 Change the oil in the vibra-
l Turn the plug tightly back in. tion 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 environ-
mentally.
l Park the machine on level ground.

Fig. 117

l Move the drum, until the drain plug 1 (Fig. 117)

is in bottom position.
l Unscrew the drain plug, let the oil run out and
catch it.
l Turn the oil drain plug back in tightly after all oil
has run out.

78 BOMAG BW 211 D-4

 Every 1000 operating hours

5.30 Retighten the fastening of

the axle on the frame

Fig. 118

l Unscrew oil level inspection plug 1 (Fig. 118)

on the drum and fill in oil through the filler
opening (2), until it starts to drip out from the
level inspection bore.
Fig. 119
For quality and quantity of oil refer to the table l Check all fastening nuts on axle mounting
of fuels and lubricants. bolts (Fig. 119) for tight fit.
l Screw oil filler (2) and level inspection plug (1)
back in tightly.
l Repeat the oil change on the opposite side.
l Check the oil level once again at operating
temperature (after running the machine for
about half an hour with vibration).

! Caution
Overfilling causes overheating and destruc-
tion of the vibration bearings!

BW 211 D-4 BOMAG 79

Every 1000 operating hours

5.31 Tightening the wheel nuts 5.32 Check the ROPS

i Note
On machines with cabin the ROPS (roll over pro-
tection structure) is an integral part of the cabin.
Please observe also the corresponding section in
the safety regulations in this manual.

Fig. 120

l Tighten the wheel nuts (Fig. 120) in a cross-

type pattern.

Fig. 121

l Inspect the cabin, especially the ROPS (Fig.

121), for cracks, corrosion, damage and miss-
ing fastening parts.

i Note
Unusual movements and noises (vibrations) dur-
ing operation are signs for damage or loosened
fastening elements.
l Check the fastening screws for the cabin
(ROPS) to the operator’s stand for tight fit.
l Check the rubber buffers of the operator’s plat-
form suspension for condition and tight fit.
l Check the condition and fastening of the seat
belts.

80 BOMAG BW 211 D-4

 Every 1000 operating hours

5.33 Cleaning the oil bath air fil-

ter *

Fig. 122

l Loosen the quick locks (Fig. 122), take the fil-

ter bowl off and empty it.
l Clean the filter mesh by repetitive dipping into
diesel fuel.
l Clean the filter bowl with diesel fuel and fill in
engine oil up to the level mark.
l reinstall the filter bowl.

* Option

BW 211 D-4 BOMAG 81

 Every 2000 operating hours

Every 2000 operating hour s

5.34 Changing hydraulic oil and

breather filter

i Note
See also chapter 5.1 "Notes on the hydraulic sys-
tem".

Caution
!

Apart from the normal oil change intervals, the

hydraulic oil must also be changed after major
repairs in the hydraulic system. Fig. 123

Perform the oil change when the hydraulic oil l Unscrew the plug (Fig. 123) and drain off all
is warm. hydraulic oil.

Clean the area round hydraulic oil tank, filler l Check seal ring (1), replace if necessary and
opening and breather filter. turn the plug tightly back in.
Do not use any detergents to clean the system.
Do not start the engine after draining the hy-
draulic oil.
Replace the hydraulic oil filter element with
every hydraulic oil change.

! Danger
Danger of scalding!
Danger of scalding by hot oil.

Environment
Catch running out oil and dispose of environ- Fig. 124
mentally. l Remove the filler cap (Fig. 124).
l Fill in new hydraulic oil through the screen.
i Note
Generally replace the hydraulic oil filter element
after the test run.
i Note
We recommend to use the filling and filtering unit
(BOMAG part-no. 079 930 35) with fine filter to fill
the hydraulic system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the hy-
draulic 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 inspec-
tion glass

82 BOMAG BW 211 D-4

 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
i Note
The breather filter for the hydraulic oil tank is inte-
grated in the filler cap, you must therefore replace ! Danger
the complete filler cap. Danger of scalding!
l Close the tank with a new filler cap. 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.
Do not use the oil in the filter bowl.

Environment
Catch running out oil, dispose of oil and filter
element environmentally.

i Note
The filter element must be changed with every hy-
draulic oil change and after major repairs in the hy-
draulic system.

Fig. 125

l Unscrew the cap nut 4 (Fig. 125) and take the

filter bowl (5) with the filter element (3) off.
l Examine the sealing face on the filter element
thoroughly for any visible dirt.

! Caution
Visible impurities may be an early indicator for
a failure of system components and predict the

BW 211 D-4 BOMAG 83

Every 2000 operating hours

possible malfunction of important parts. In

such a case you should perform trouble shoot- 5.36 Changing the coolant
ing and replace or repair the defective compo-
nents. Nonobservance may lead to total
damage of the hydraulic system. ! Danger
Do not clean or reuse the filter element. Danger of scalding!
l Take the old filter element (3) out and clean Change the coolant only when the engine is
the filter bowl and the thread. cold.
l Reinstall the filter bowl with the new filter ele-
ment, check the condition of the O-rings (1) Environment
and (2), replace if necessary. Catch running out coolant and dispose of envi-
l After a test run check the filter for leaks. ronmentally.

Fig. 126

l Set the cock valve for the cabin heater to posi-

tion "warm".

Fig. 127

l Unscrew the plug, let the coolant run out and

catch it.
l Screw the plug back in once all coolant has run
out.

84 BOMAG BW 211 D-4

 Every 2000 operating hours

Fig. 128

l Unscrew the cap and fill in coolant up to the

MAX-mark.

For quality of coolant refer to the chapter 5.2,

fuels and lubricants.
l Start the diesel engine and run it warm to op-
erating temperature.
l Let the engine cool down and check the cool-
ant level again, top up if necessary.

BW 211 D-4 BOMAG 85

 Every 3000 operating hours

Every 3000 operating hour s

5.37 Checking the injection

valves

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

86 BOMAG BW 211 D-4

 As required

As r equired

5.38 Service the combustion air i Note

Once the air filter service indicator lights up, work
filter may be continued until the end of the day.

! Caution
Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter ele-
ment.
Do not use gasoline or hot fluids to clean the
filter element.
After cleaning the filter element must be in-
spected for damage using a torch.
Air filter elements with damaged paper bellows
or seal lips must be replaced in any case.
Fig. 130
The main filter element must be replaced after
3 times cleaning, but at the latest after one l Open the engine hood (Fig. 130) completely
year, irrespective of the operating hours. and secure it.
Each cleaning interval must be marked with a
cross on the cover of the filter element.
Cleaning does not make sense if the air filter
element is covered with a sooty deposit. Use a
new filter element.
Incorrectly handled filter elements may be-
come ineffective because of damage (e.g.:
cracks) and cause engine damage.

Fig. 131

l Release the locking hook (Fig. 131) and take

the filter hood off.
l Clean filter hood and dust discharge valve.

Fig. 129
Maintenance of the dry air filter is due when con-
trol light “c” (Fig. 129) in the instrument cluster
lights permanently when the engine is running, but
at the latest after one year.

BW 211 D-4 BOMAG 87

As required

Fig. 132 Fig. 134

l Carefully loosen the main filter element (Fig.
132).
The main filter element is located directly on the air
intake tube, thereby providing a seal on the inside
of the filter cover. Carefully remove the main filter
element, in order to reduce the released amount of
dust. To release the seal pull the main filter ele-
ment carefully up, down and sideways or turn it
(Fig. 132).
Caution
!
Avoid contact between main filter element and
housing.
l Clean the sealing face on the outlet tube (Fig.
134).
Dust on the outer diameter of the outlet tube can
impair effective sealing.
l Check the old main filter element.
The old main filter element can be of help to dis-
cover foreign particles on the sealing face, which
could lead to leaks. A line of dust on the clean air
side of the filter may be a sign for such a leak.
Eliminate this problem before installing a new
main filter element.
l If the main filter element is damaged, the safe-
ty element must be replaced as well.
l Clean or replace the main filter element.

i Note
We generally recommend to change the filter. A
new filter element is far less expensive than a pos-
sible engine damage.
l Examine the main filter element thoroughly for
damage.
Before installing the new main filter element check
it for possible damage from transport, cleaning or
incorrect handling. Especially on the inside of the
open end (sealing area). Do not install damaged
Fig. 133
filter elements.
l Pull the main filter element (Fig. 133) carefully
l If necessary use safety elements.
out of the housing.

88 BOMAG BW 211 D-4


Fig. 135
l Insert the main filter element (Fig. 135).
The radial sealing area is located at the inside of
the open filter edge. This critical sealing area must
be under slight tension after the filter has been in-
stalled. In order to achieve a tight seal apply pres-
sure to the outer edge of the filter and not to the
moveable centre.
l Reinstall the filter hood with the dust discharge
valve.
Caution
! ement, until it if free of dust.
The dust discharge valve must point vertically
downwards.
Dry cleaning of the main filter element
! Danger
Eye injury!
Wear protective clothing (goggles, gloves).
BW 211 D-4
As required
Fig. 136
i Note
For cleaning purposes fit a tube to the compressed
air gun (Fig. 136), the end of which should be bent
for approx. 90°.
The length should reach down to the bottom of the
element.
l Blow the main filter element out with com-
pressed air (max. 5 bar) from inside to outside
by moving the tube up and down inside the el-
l Examine the main filter element with a torch
for cracks and holes in the paper bellows.
Caution
!
Do not continue to use a damaged main filter
element. If in doubt use a new main filter ele-
ment.
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.
The safety filter element must be replaced:
if the main filter element is defective,
after three times cleaning of the main filter ele-
ment,
at the latest after 2 years,
BOMAG 89
As required
if the warning light comes on again after serv-
icing the main filter cartridge.
l Remove the housing cover and pull the main
filter element off.
Fig. 137
l Pull the safety element (Fig. 137) out by turn-
ing it lightly.
l Push in a new safety filter element.
l Reassemble main filter element and cover.
90 BOMAG
5.39 Adjust the scrapers
Smooth drum
l Check adjustment and condition of front and
rear scrapers, if necessary adjust or replace
the scraper rubber.
Fig. 138
l In order to adjust the scrapers 2 (Fig. 138),
slacken the fastening screws (1) in the slots
and push the scraper towards the drum to con-
tact.
l Retighten the fastening screws.
Padfoot drum
l Check adjustment and condition of front and
rear scrapers, if necessary adjust or replace
the scraper rubber.
BW 211 D-4
 As required

5.40 Adjust the parking brake

! Caution
Have adjustment work on the brakes only car-
ried out by a specialist! Always adjust both
sides.
l Secure the machine with wheel chocks
against rolling.
l Start the diesel engine to relieve the brake.

Fig. 139

l Check adjustment and condition of scrapers

(Fig. 139), adjust or replace the teeth if neces-
sary.
l To adjust the scrapers slacken the clamping
screws and push the scrapers towards the
drum, leaving a gap of about 25 mm.
l Retighten the clamping screws.

Fig. 140

l Disengage the travel lever (Fig. 140) to the

left, but do not move to position "I" or "II".
The parking brake is released

Fig. 141

l Unscrew locking plate 2 (Fig. 141).

l Turn the square (1) in anti-clockwise direction
against the stop.

BW 211 D-4 BOMAG 91

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.
l Unscrew the wheel nuts and take the wheel
off.
Fig. 142

l In order to adjust the brake clearance turn the

square 1 (Fig. 142) three turns back in clock-
wise direction.
l Fasten the locking plate again.
l Pull the plug off the brake solenoid valve and
perform the drive test.
The machine must be braked.

Fig. 143

l Attach the wheel (Fig. 143) and tighten the

wheel nuts crosswise with 550 Nm (405 ft. lb.).
l Check the tire pressure, see technical data.

92 BOMAG BW 211 D-4

 As required

5.42 Change the fresh air filter in 5.43 Tightening torques

the cabin

Fig. 145
* Strength classes for screws with untreated, non-
lubricated surface. Screw quality designations are
Fig. 144 stamped on the screw heads.
l Unscrew fastening screws for the ventilation 8.8 = 8G
grid (Fig. 144) and remove the filter. 10.9 = 10K
l Insert a new filter and reassemble the ventila- 12.9 = 12K
tion grid.
l Axle - frame
M 22x1.5 = 710 Nm
l Wheel nuts
M 22x1.5 = 550 Nm
The values result in a 90% utilization of the screw
yield point at a coefficient of friction µ total = 0,14.
When using lubricant MOS2 the specified tighten-
ing torques do not apply.

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

BW 211 D-4 BOMAG 93

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 serv-
ice department of the engine manufacturer for fur-
ther details.

94 BOMAG BW 211 D-4

 6 Trouble shooting

BW 211 D-4 BOMAG 95

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 mainte-
nance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serv-
iced. 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.

96 BOMAG BW 211 D-4

 Trouble shooting

6.2 Engine

Faults Possible cause Remedy

The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank

Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.

Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.

Fuel lines leaking Check all line connections for leakages

and tighten the fittings.

Battery discharged or not connected Tighten the pole clamps, check the cable
connections

Injection valves or injection pump defec- Have examined by a specialist

tive

The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature

Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

Injection lines leaking Check the lines for leakages

Turbo charger defective Have examined by a specialist

Dry air filter dirty clean, replace if necessary

Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary

BW 211 D-4 BOMAG 97

Trouble shooting

Faults Possible cause Remedy

Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary

Exhaust gas turbo-charger defective Have examined by a specialist

Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance

Incorrect valve clearance Adjust the valve clearance

Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Injection valve defective Have examined by a specialist

Engine oil level too low Top up engine oil to the upper dipstick
mark

Filling capacity of the injection pump not Have adjusted by a specialist

correctly adjusted

Cooling air flow restricted Clean the cooling air duct

V-belt loos or broken Tension or replace the V-belt

Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark

Dry air filter dirty clean, change if necessary

Exhaust gas turbo-charger defective Have examined by a specialist

Charge air hose leaking Check fastening and connections

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine 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.

The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective

98 BOMAG BW 211 D-4

 Trouble shooting

BW 211 D-4 BOMAG 99

Trouble shooting

100 BOMAG BW 211 D-4