The closed-loop travel circuit is the part of these single drum rollers nobody wants to troubleshoot from memory, and it takes the largest share of this Bomag BW 211 D-4, 213 D-4, 216 D-4 Service Training PDF, factory document 008 099 99, 156 pages covering all three machines. Hydraulic schematics trace the travel, vibration, charge and steering circuits down to their test and adjustment points, while wiring diagrams and module descriptions handle the electric system, seat contact switch included. Deutz diesel coverage walks you through valve clearance adjustment and assembly of the plug-in injection pump, then troubleshooting charts for travel, vibration and steering. Check the lift pump against its 10 bar fuel pre-pressure spec, and confirm the starter at 12 V and 3.1 kW before you condemn it. A roller parked beside an open lift is passes nobody is making. Bookmarks and a text layer get you to the right page fast, and the drum back to work.
What's Inside This Bomag BW 211 D-4, BW 213 D-4, BW 216 D-4 Manual
| System | Pages | Key Topics |
|---|---|---|
| Documentation | 5 | Index of Related Bomag Publications (Each Sold Separately) |
| General | 6-7 | Drive Concept, Hydrostatic Drives, Operator Cabin, Monitoring Display, ROPS/FOPS, Articulated Joint |
| New Developments | 8 | Instrument Cluster, Warnings, Control Data |
| Technical Data and Adjustment Values | 9-16 | Engine, Travel Pump, Travel Motor, Drum Drive, Vibration Pump, Steering and Charge Pump |
| Maintenance | 17-21 | Maintenance Table |
| Deutz Diesel Engine | 22-57 | Service Side, Starter Side, Lubrication Oil Circuit, Coolant Circuit, Fuel System, Checking and Adjusting the Valve Clearance, Assembly of the Plug-In Injection Pump |
| Travel System | 58-99 | Travel Pump, Control, Charge Pressure Relief Valve, High Pressure Relief Valve, Pressure Override, Axle Drive Motor, Drum Drive Motor, Test and Adjustment Points |
| Vibration | 100-114 | Vibration Pump, High Pressure Relief Valves, Control, Vibration Motor, Drum, Test and Adjustment Points, Vibration System, Trouble Shooting Vibration |
| Steering | 115-125 | Charge Pump, Steering Pump, Steering Valve, Articulated Joint, Measuring and Adjustment Points, Trouble Shooting Steering |
| Electric | 126-156 | Seat Contact Switch, Module Description |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Starter power | 3.1 kW | p. 10 |
| Starter voltage | 12 V | p. 11 |
| Fuel pre-pressure (main fuel filter) | 10 bar | p. 31 |
| Pressure retaining valve | 5 bar | p. 28 |
| Fuel pre-pressure (connecting line lift pump – main filter) | 10 bar | p. 28 |
| Intake valve clearance | 0.3 mm | p. 31 |
| Exhaust valve clearance | 0.5 mm | p. 31 |
| Tightening torque for cylinder head cover | 9 +/- 1 Nm | p. 48 |
| Multi-function valves tightening torque | 89 Nm | p. 72 |
| Pressure test port, vibration pressure low amplitude | max. 371 bar | p. 112 |
| Pressure test port, vibration pressure high amplitude | max. 371 bar | p. 112 |
| Battery capacity | 103A | p. 143 |
Bomag BW 211 D-4, BW 213 D-4, BW 216 D-4 Common Problems This Manual Covers
Bomag BW 211 D-4 travels a few feet then stops, or will not move in either direction
Check charge pressure first; a closed-loop travel pump will not stroke without it. Test high pressure at the travel pump; the high pressure limitation is 400 bar (page 10). If only one direction is dead, swap the high pressure relief valves side to side, then torque the multi-function valves to 89 Nm on reassembly (page 72).
Manual Section: Travel System p. 58Engine cranks slowly or refuses to start in cold weather, fuel filter suspected
Check the battery and terminals first; slow cranking kills cold starts. Drain the fuel filter and look for paraffin wax, since winter diesel gelling clogs the element. The lift pump feeds the main filter at roughly 10 bar pre-pressure (page 31), so strong cranking with no fire points to fuel delivery. Bleed the system and clear the cooling air intake.
Manual Section: Deutz Diesel Engine p. 31Steering very stiff or will not reach end stops in either direction
Test steering pressure at the measuring port while working the wheel against the stops; the relief valve is set at 175 bar (page 115). Low pressure means a worn steering pump or a stuck relief valve. If pressure is good, grease the articulated joint and check it for seizure before pulling the steering valve.
Manual Section: Steering p. 115Drum will not vibrate, or vibration works in only one amplitude setting
Test vibration pressure at both amplitude test ports, keeping the gauge under the 371 bar maximum listed on page 112. If only one amplitude builds pressure, suspect the high pressure relief valve or the amplitude solenoid for that circuit. Measure leak oil flow from the vibration motor; approximately 7 l/min is normal (page 113) flushing flow (page 113), and more means a worn motor.
Manual Section: Vibration p. 112Hydraulic functions weaken and machine slows down after short period of operation
Check the hydraulic oil level; the tank holds 60 l (page 11). Clean the hydraulic cooler fins and feel the lines at the pump, because overheated oil thins out and drops pressure in every circuit at once. If the oil looks contaminated, drain it, change the filters per the maintenance table on page 18, and get the machine back in the pass before condemning a pump.
Manual Section: Maintenance p. 18Frequently Asked Questions
What are the torque specifications for the multi-function valves in the travel system?
The multi-function valves in the travel system must be tightened to a torque of 89 Nm. p. 72
What is the valve clearance specification for the Deutz engine?
For the Deutz engine, the intake valve clearance is 0.3 mm and the exhaust valve clearance is 0.5 mm. These measurements must be checked and adjusted when the engine is cold. p. 31
What is the engine oil capacity for the BW 211 D-4 model?
The engine oil capacity for the BW 211 D-4 model is 10 liters, using SAE 15W-40, API CG-4 oil. p. 11
What is the hydraulic oil capacity for the BW 211 / 213 / 216 D-4 models?
The hydraulic oil capacity for these models is 60 liters, using HVLP 46 VI 150 oil. p. 11
What is the tightening torque for the cylinder head cover?
The cylinder head cover must be reinstalled with a tightening torque of 9 +/- 1 Nm. p. 48
Is this Bomag BW 211 D-4 manual a download or a disc?
This is a 156-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print specific sections of this Bomag BW 211 D-4 Service Manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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