This is the factory service manual for the Bomag BW 211 D-40, BW 212 D-40, BW 213 D-40 and their padfoot PD-40 versions, all built around the Deutz BF4M 2012C intercooled diesel. It goes far past the operator book: pressure tests in the travel and vibration circuits, vibrator shaft speed checks, flushing and bleeding the hydraulics after a component failure, drum removal and repair, and the oscillating articulated joint teardown. You get Caddy and E-Plan wiring diagrams with a section that teaches you how to actually read them, coverage of the BEM and Evib-meter electronic modules, plus bound-in supplier documentation for the travel pump, vibration pump, drum drive, vibration motor and axle. Roughly 1300 pages.
What's Inside This Bomag BW 211–213 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 1-30 | Machine Overview, Safety Regulations, Important Notes, Transport |
| Technical Data | 31-40 | Dimensions, Weights, Travel Speeds, Vibration Frequency and Amplitude, Engine Data, Filling Capacities |
| Maintenance | 41-54 | General Notes on Maintenance, Fuels and Lubricants, Engine Oil, Fuels, Coolant, Hydraulic Oil, Oil for Drive Axle |
| Tests and Adjustments | 55-70 | Checking the Rotation Speeds, Special Tools, Pressure Tests in the Travel Circuit, Checking / Adjusting the Vibrator Shaft Speeds, Pressure Measurements in the Vibration Circuit, Nominal Value |
| Flushing and Bleeding | 71-106 | Special Tools for Flushing, Flushing - General, Changing a Component, Chips (Abrasion) in the Oil, Before Flushing, Servicing the Flushing Filter Kit, Flushing the Drum Drive |
| Caddy and E-Plan Wiring Diagrams | 107-128 | Caddy Wiring Diagrams, Understanding Circuit Diagrams, Structure, Potential Cross References, Relay Cross Reference, Current Paths, Component Cross References |
| Electrics | 129-214 | Designation of Components in the Wiring Diagram, Terminal Designations in Wiring Diagram, Battery Maintenance, Battery Ground and Analog Ground, Gnd, Battery Ground, Agnd |
| Dust Protection and Gasket Kits | 215-220 | 582 502 15 Dust Protection / 582 502 16 Gasket, Assembling the Dust Protection |
| Electronic Modules | 221-308 | Bem, BOMAG Evib-Meter, Electrics Module A68, Electric Module K04, Electric Module A72, Electric Module A108 |
| Speedometer Module | 309-312 | Description of Function, Teaching the Module |
| Service Training | 313-378 | - |
| Engine | 379-456 | Check the Engine Oil Level, Diesel Engine, General, Service Side, Starter Side, Lubrication Oil Circuit, Danger of Injury! |
| Air Conditioning System | 457-502 | Physical Basics, A - Heat Absorption, Refrigerant R134a, Compressor Oil / Refrigeration Oil, Working Principle of the Air Conditioning System, Monitoring Devices, Description of Components |
| Cabin Assembly and Window Panes | 503-522 | General Safety Regulations for Assembly, Applicable Accident Prevention Instructions, Changes and Conversions to the Cabin/ Machine, Notes on Safety in the Assembly Instructions, Replace Damaged Stickers/Decals, Work on Heating Lines, Working on Electric Parts of the Machine |
| Drum | 523-576 | Special Tools, Single Drum Rollers, Removing and Installing the Drum, Removing the Drum, Repairing the Drum, Removing the Travel Motor |
| Oscillating Articulated Joint | 577-600 | Dismantling the Oscillating Articulated Joint, Assembling the Oscillating Articulated Joint |
| Suppliers Documentation - Travel Pump | 601-756 | - |
| Suppliers Documentation - Vibration Pump | 757-826 | - |
| Suppliers Documentation - Drum Drive | 827-902 | - |
| Suppliers Documentation - Vibration Motor | 903-926 | - |
| Suppliers Documentation - Axle | 927-1164 | Axle Drive Motor, Steering Valve |
| Circuit Diagrams | 1165-1332 | Hydraulic Diagram 581 202 10, Hydraulic Diagram 581 202 11, Wiring Diagram 582 702 09, Wiring Diagram 582 702 29, Wiring Diagram 582 702 41 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Deutz BF4M 2012C | p. 32 |
| Operating weight (CECE), BW 211 D-40 | 9500 kg | p. 32 |
| Operating weight (CECE), BW 212 D-40 | 10900 kg | p. 34 |
| Operating weight (CECE), BW 213 D-40 | 12420 kg | p. 36 |
| Travel speed (range 1 / range 2) | 0-6 km/h / 0-10 km/h | p. 32 |
| Engine oil capacity | 10 litres (8.5 litres without filter) | p. 33 |
| Fuel tank capacity | 250 litres | p. 33 |
| Hydraulic oil capacity | 60 litres, HV 46 (ISO) | p. 33 |
| Coolant capacity | 16 litres | p. 33 |
| Valve clearance (intake / exhaust) | 0,3 mm / 0,5 mm | p. 427 |
| Steering pressure | approx. 200 bar | p. 368 |
Bomag BW 211–213 Series Common Problems This Manual Covers
Machine will not travel, or travel is weak and jerky after warm-up
Run the pressure tests in the travel circuit per section 5.4 in Tests and Adjustments, comparing charge and high pressure against the nominal values. Low readings point you to the travel pump or internal leakage; the bound-in travel pump supplier documentation covers repair.
Manual Section: Tests and Adjustments - Pressure tests in the travel circuit (5.4) p. 64Vibration missing, weak, or only working in one amplitude
Start with pressure measurements in the vibration circuit, section 5.6, then run the vibration motor leakage rate check in 5.7 to rule the motor in or out. Check and adjust vibrator shaft speeds against the 30/36 Hz nominal frequencies before condemning hydraulic parts.
Manual Section: Tests and Adjustments - Vibration circuit (5.6/5.7) p. 67Engine down on power, smoking, or rough under load
The Engine chapter covers the Deutz BF4M 2012C from both service and starter sides, including the lubrication oil circuit and the dry air filter cartridge procedure. Check intake restriction first, then set valve clearance to 0,3 mm intake and 0,5 mm exhaust before digging into fuel.
Manual Section: Engine (Deutz BF4M 2012C service procedures) p. 431Metal chips found in the hydraulic oil after a component failure
Do not just swap the failed part and drive off. The Flushing and Bleeding chapter tells you what to do about abrasion in the oil, how to set up and service the flushing filter kit, and how to flush the drum drive circuit so debris does not take out the replacement component.
Manual Section: Flushing and Bleeding - Chips (abrasion) in the oil / Flushing the drum drive p. 77Frequently Asked Questions
My roller's steering is stiff and it barely moves in one direction. Does this manual help me chase that down?
Yes, and this is exactly the kind of fault you cannot guess your way through. Section 5.4 gives the pressure tests in the travel circuit with nominal values, and the steering circuit pressure test is covered too, with steering pressure around 200 bar as the reference. If pressures come up short you work back through pump, charge circuit and servo control instead of throwing parts at it. p. 64
The vibration is weak or cuts out. What does the manual give me to diagnose it?
Section 5.6 covers pressure measurements in the vibration circuit and section 5.7 walks you through the leakage rate check of the vibration motor, which separates a worn motor from a supply or control problem. There is also a procedure for checking and adjusting the vibrator shaft speeds against the 30/36 Hz nominal frequencies. The supplier documentation for the vibration pump and motor is bound in for internal repair. p. 67
I just replaced a hydraulic pump after a failure. Is the flushing procedure in here?
Yes, there is a full Flushing and Bleeding chapter: what to do when you find chips in the oil, preparation before flushing, servicing the flushing filter kit, and flushing the drum drive circuit. Skipping this after a pump grenades is how you kill the new pump in fifty hours, so this chapter alone can pay for the manual. p. 77
Can I actually follow the wiring diagrams, or is it just schematic pages?
Both Caddy and E-Plan style diagrams are included, and there is a dedicated chapter explaining their structure: current paths, potential cross references, relay cross references and component designations. The Electrics chapter also covers terminal designations, battery ground versus analog ground, and battery maintenance. For chasing a bad ground wire or a dead push button switch, that is what you need. p. 107
What are the basic service specs so I can stock fluids and filters?
Engine oil capacity is 10 litres, fuel tank 250 litres, hydraulic system 60 litres of HV 46 hydraulic oil. Valve clearance on the Deutz is 0,3 mm intake and 0,5 mm exhaust. The maintenance chart calls for the combustion air filter at least once a year and the safety cartridge every two years, with the dry air filter cartridge procedure shown step by step. p. 33
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