Operating instructionsMaintenance instructions

Catalogue number008 119 31 06/2004

BW 211 D-4 / BW 211 PD-4S/N 101 582 41 . . . .

Single drum roller

ForewordF orewordBOMAG machines are products from the widerange of BOMAG compaction equipment.

BOMAGs vast experience in connection withstate-of-the-art production and testing meth-ods, such as lifetime tests of all importantcomponents and highest quality demandsguarantee maximum reliability of your ma-chine.

This manual comprises:l Safety regulationsl Operating instructionsl Maintenance instructionsl Trouble shooting

Using these instructions willl help you to become familiar with the machine.l avoid malfunctions caused by unprofessional

operation.

Compliance with the maintenance instructions willl 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 thefunction of the machinel 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 froml operating errors,l insufficient maintenance andl wrong fuels and lubricants.

Please note!

With this machine "CE" conformity is onlyachieved with the corresponding optionalequipment.This manual was written for operators and mainte-nance personnel on construction sites.

Always keep this manual close at hand, e.g. in thetool compartment of the machine or in a speciallyprovided container. These operating and mainte-nance instructions are part of the machine.You should only operate the machine after youhave been instructed and in compliance with theseinstructions.Strictly observe the safety regulations.Please observe also the guidelines of the Civil En-gineering Liability Association Safety Rules forthe Operation of Road Rollers and Soil Compac-tors and all relevant accident prevention regula-tions.

For your own personal safety you should onlyuse original spare parts from BOMAG.

In the course of technical development we re-serve the right for technical modificationswithout prior notification.These operating and maintenance instructions arealso available in other languages.Apart from that, the spare parts catalogue is avail-able from your BOMAG dealer against the serialnumber of your machine.Your BOMAG dealer will also supply you with in-formation about the correct use of our machines insoil and asphalt construction.The above notes do not constitute an extension ofthe warranty and liability conditions specified in thegeneral terms of business of BOMAG GmbH.We wish you successful work with your BOMAGmachine.BOMAG GmbHPrinted in GermanyCopyright by BOMAGBOMAG 3BW 211 D-4

ForewordPlease fill in. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine type (Fig. 1). . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial-number (Fig. 1 and 2). . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine type (Fig. 3). . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine number (Fig. 3)

i NoteSupplement the above data together with the com-missioning protocol.During commissioning our organisation will in-struct you in the operation and maintenance of themachine.Please observe strictly the safety regulations andall notes on risks and dangers!

Fig. 1

Fig. 2

Fig. 3BOMAG4 BW 211 D-4

Table of ContentsTechnical 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 67BOMAG 5BW 211 D-4

Table of Contents5.21 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 97BOMAG6 BW 211 D-4

BW 211 D-4

1 Technical DataBOMAG 7

Technical DataFig. 4

Dimensions inmm

A B D H H2 K L O1 O2 S W

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

WeightsOperating weight (CECE)with ROPS and cabin

kg 10950 11930

Axle load, drum (CECE) kg 6280 7260Rear axle load (CECE) kg 4670 4670Static linear load kg/cm 29,5 -

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

% 47 47

EngineEngine manufacturer Deutz DeutzType BF4M 2012C BF4M 2012CCooling Water WaterNumber of cylinders 4 4Rated power DIN ISO3046

kW 98 98BOMAG8 BW 211 D-4

Technical DataRated speed rpm 2300 2300Fuel Diesel DieselElectrical equipment V 12 12Drive system hydrostatic hydrostaticDriven axles 2 2

BrakesService brake hydrostatic hydrostaticParking brake hydr.-mech. hydr.-mech.

SteeringType of steering articulated articulatedSteering operation hydrostatic hydrostatic

VibrationVibrating drum 1 1Drive system hydrostatic hydrostaticFrequency Hz 30/36 30/36Amplitude mm 1,8/0,9 1,64/0,82

TiresTire size 23.1/18-26/TL-8PR AWT 23.1-26/12TL R1Air pressure bar 1,1 1,4

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

* BW 211 D-4 BW 211 PD-4BOMAG 9BW 211 D-4

Technical DataThe 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 wasstanding on an elastic base.

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

Noise valueThe 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 ISO11204 for sound pressure level (LpA) at the place of the operator.

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

Vibration of the entire boy (drivers seat)The weighted effective acceleration value determined in accordance with ISO 7096 is 0.5 m/sec2.

Hand-arm vibration valuesThe weighted effective acceleration value determined in accordance with EN 500/ISO 5349 is 2.5 m/sec2.BOMAG10 BW 211 D-4

BW 211 D-4

2 Safety regulationsBOMAG 11

Safety regulationsGeneralThis BOMAG machine is built in accordancewith the latest technical standard and the validtechnical rules and regulations. There is, how-ever, a risk of danger for persons and propertyif:l the machine is used for purposes other than

those it is intended forl the machine is operated by untrained person-

nell the machine is modified or converted in an un-

professional wayl 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 instructionsl generally acknowledged safety and road traffic

regulationsl country specific safety regulations. It is the

duty of the operator to know and observethese regulations. This applies also for localregulations and the regulations for varioustypes of manual work. If the recommendationsin this manual differ from the regulations validin your country, you must strictly observe theregulations in your country.

Intended useThis 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.

Unintended useDangers may, however, arise from the machine ifit is used by untrained personnel in an unprofes-sional way or if it is used for purposes other thanthose mentioned in these instructions.Do not work with vibration on hard concrete, on acured 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 trainedand authorized persons which are at least 18years of age. The responsibilities for the operationof 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 repairthe machine.Maintenance and repair tasks require specificknowledge and must therefore only be carried outby trained and qualified personnel.

Conversions and alterations to the ma-chineUnauthorized 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 authorizedany original parts or special equipment not sup-plied by us. The installation and/or use of suchproducts can impair the active and/or passive driv-ing safety. The manufacturer expressly excludesany liability for damage resulting from the use ofnon-original parts or accessories.

Safety notes in the operating and main-tenance instructions:

! DangerSections marked like this point out possibledangers for persons.BOMAG12 BW 211 D-4

Safety regulations! CautionSections marked like this point out possibledangers for the machine or for parts of the ma-chine.

i NoteSections marked like this provide technical infor-mation concerning the optimal economical use ofthe machine.

EnvironmentSections marked like this highlight activitiesfor 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/decalson the machineKeep stickers/decals complete (see spare partscatalogue) and fully legible and observe theirmeaning.Replace damaged or illegible stickers/decals im-mediately.

Loading the machineUse only strong and stable loading ramps. Theramp inclination must be lower than the gradabilityof the machine.Secure the machine against turning over or slip-ping off.Secure the machine on the transport vehicleagainst rolling off, slipping and turning over.Persons are highly endangered ifl they step or stand under loads being liftedl they remain in the drive range of the machine

during a demonstration or during loading.The machine must not swing about when lifted offthe ground.Use only safe lifting gear of sufficient load bearingcapacity.Attach the lifting gear only to the specified liftingpoints.

Towing the machineYou should generally use a tow bar.Max. towing speed 1 km/h (1.6 mph), max. towingdistance 500 m (1640 ft.).Before releasing the multi-disc brakes secure themachine properly against unintended rolling.

Checking the Roll Over ProtectionStructure (ROPS)

i NoteOn machines with cabin the ROPS is an integralpart of the cabin.The machine frame must not be distorted, bent orcracked 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 withthe prescribed specifications and correctly tight-ened (observe the tightening torque values).Screws and nuts must not be damaged, bent ordeformed.With the cabin installed check also the condition ofthe cabin mounts (rubber elements and screws).Neither must any additional parts be welded orbolted on, nor must any holes be drilled without thepermission of the manufacturer, since this may im-pair the strength of the structure.

Starting the machineBefore startingOperation of the machine is only permitted whensitting in the operator's seat.Use only machines which have been properlyserviced at regular intervals.Become acquainted with the equipment, the con-trol elements, the working mode of the machineand 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 machineBOMAG 13BW 211 D-4

Safety regulationsl the machine is free of any oily and combustiblematerial

l all handrails, steps and platforms are free ofgrease, oils, fuels, dirt, snow and ice

l the engine compartment hood is closed andlocked

To climb onto the machine use steps and hand-rails.Check before starting, whether:l the machine shows any obvious defectsl all protective devices are properly secured in

their placel steering, brakes, control elements, lighting

and warning horn are in orderl the seat is correctly adjustedl the mirrors (if available) are clean and correct-

ly adjusted.Do not start the machine if any gauges, controllights or controls are defective.Do not take any loose objects with you or fastenthem to the machine.On machines with ROPS you should always wearyour seat belt!

StartingStart and operate the machine only from the oper-ator's seatFor starting set all control levers to "neutral posi-tion".Do not use any starting aids such as Start Pilot orether.After starting check all gauges.

Starting with jump leadsConnect plus with plus and minus with minus(ground cable) - always connect the ground cablelast and disconnect it first! Wrong connectionsmay cause severe damage in the electric system.Never start the engine by bridging the electricalconnections on the starter, because the machinewould probably start to move immediately.

Starting in closed roomsExhaust gases are toxic! Always ensure an ade-quate supply of fresh air when starting in closedrooms!

Driving the machinePersons in the endangered areaIf the machine has turned over and the cabin dooris jammed, use the right hand cabin window as anemergency exit.Before starting or resuming work and especiallywhen driving backwards, check that there are nopersons 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 ofthe machine while the engine is running. Danger ofsquashing!

DrivingIn events of emergency actuate the emergencystop switch immediately. Do not use the emergen-cy stop push button as service brake.Restart the machine only after the danger, that hascaused the actuation of the emergency stop, hasbeen eliminated.If the machine has come in contact with high-volt-age power lines:l do not leave the operator's standl warn others from coming too close to the ma-

chine or touching itl if possible drive the machine out of the danger

zone

l have the power shut off.Operate the machine only from the operator'sseat.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 machineis standing.Do not use the machine to transport persons.Stop the machine if you notice unusual noises orthe development of smoke. Investigate the causeand have the fault corrected.Keep a sufficient distance to excavations and em-bankments and make sure that you work does notimpair the stability of the machine.BOMAG14 BW 211 D-4

Safety regulationsDo not work with vibration on hard concrete, on acured concrete layer or heavily frozen ground.When passing under flyovers, bridges, tunnels,electric power lines etc. keep a sufficient distance.

Driving on slopes and gradientsDo not drive up and down gradients, which exceedthe max. gradability of the machine.On lopes always drive directly up or down. Changeto the lower speed range before approaching theslope.Wet and loose soils reduce the ground adhesion ofthe machine and inclinations and slopes consider-ably. Higher risk of accident!

Behaviour in trafficMatch the speed of the machine to the workingconditions.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 vibrationWhen compacting with vibration check the effectof the vibration on nearby buildings and under-ground supply lines (gas, water, sewage, electricpower supply), stop vibratory compaction if neces-sary.Do not work with vibration on hard (frozen, con-crete) ground. Risk of bearing damage!

Parking the machinePark 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 positionl apply the parking brakel shut the engine down and pull the ignition key

out.

l lock the cabinl secure the machine against unauthorized use.Do not jump off the machine, use access stepsand hand rails.Always secure parked machines, which could bein the way, with appropriate measures.

Parking on slopes and gradientsSecure the machine against rolling, place metalchocks in front of and behind the drums.

Filling the fuel tankDo 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 notlet it seep into the ground.Wipe off spilled fuel. Keep fuel free of dirt and wa-ter.Leaking fuel tanks can cause explosions. Ensuretight fit of the fuel tank filling cover, replace it if nec-essary.

Fire protection measuresMake yourself acquainted with the location and theoperation of fire extinguishers. Observe fire warn-ing and fire fighting installations.

MaintenanceObserve the maintenance tasks described in theoperating and maintenance instructions, includingthe 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 byqualified and authorized personnel.When performing maintenance work above bodyheight use the access steps on the machine or anyother safe ladders and working platforms. Do notuse 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 stableground.Pull the key out of the ignition switch.Lock the articulated joint with the articulation lock.BOMAG 15BW 211 D-4

Safety regulationsWorking on hydraulic linesAlways relieve the pressure in the hydraulic circuitbefore working on hydraulic lines. Hydraulic oil es-caping under pressure may penetrate through theskin and cause severe injury. In case of being in-jured by hydraulic oil you should immediately seekmedical advice, as otherwise this may lead to se-rious infections.When adjusting the hydraulic system do not standbehind or in front of the drum/wheels.Do not change the setting of high pressure reliefvalves.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 hydraulicoils 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 fortight and leak-free fit.

Changing hydraulic hosesAll hydraulic hoses must be inspected visually atregular 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 accordancewith 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.

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 ensurethat the correct type of hose (pressure range) isused at the right place.

Working on the engineShut the engine down before opening the enginecompartment 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 ofenvironmentally.Do not leave any tools or other objects, whichcould cause damage, in the engine compartment.Idle speed and full load speed must not bechanged, since this would have a negative effecton the exhaust gas values and cause damage toengine and drive.Turbo chargers work with high speeds and hightemperatures. Keep hands, tools and materialsaway from the intake and outlet openings of theturbo 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 equipmentBefore working on electrical equipment disconnectthe battery and cover it with insulating material.Do not use any fuses with higher ampere ratingsor repair a fuse with a piece of wire. Fire hazard!Always disconnect the battery before starting towled on the machine.

Working on the batteryWhen working on the battery do not smoke, do notuse open fire.Do not let acid come in contact with skin andclothes. If being injured by acid flush off with clearwater and seek for medical advice.BOMAG16 BW 211 D-4

Safety regulationsMetal objects (e.g. tools, rings, wrist watches)must not contact the battery poles - danger ofshort circuit and burns!When recharging maintenance free batteries re-move the plugs to avoid the accumulation of explo-sive gases.When using an external battery to start the ma-chine follow the respective instructions.Dispose of old batteries environmentally.Switch the charging current off before removingthe charge clamps.Ensure good ventilation, especially when chargingthe battery in a closed room.

Working on the fuel systemDo not inhale fuel fumes.No open fire, do not smoke, do not spill any fuel.Catch running out fuel, do not let it seep into theground and dispose of environmentally.

Working on wheels and tiresExplosion like bursting of tires and parts of rimsand tires can cause severe or even deadly injuries.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 thehighest specified pressure.Check wheels and tires every day for specifiedpressure, cuts, bulges, damaged wheel rims,missing wheel studs and nuts. Do not drive withdamaged tires or wheels.Anti-stick emulsions for tires must only be mixedusing water and concentrated anti-stick agent ac-cording to the specifications of the manufacturer ofthe anti-stick agent. Observe the regulations forthe protection of the environment.

CleaningDo 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 notsubject electrical components and insulating ma-

terials to the direct water jet, but cover them be-forehand.l Do not guide the water jet into the exhaust or

into the air filter.

After maintenance workReinstall all protective devices after completingthe maintenance work.

RepairAttach a warning tag to the steering wheel if themachine is defective.Repairs must only be performed by qualified per-sons who have been instructed for this purpose.Use our repair instructions.Exhaust gases are highly dangerous! Always en-sure an adequate supply of fresh air when startingin closed rooms!

TestDepending on the type of application and the op-erating conditions vibratory equipment has to beexamined by a specialist whenever required, butat least once every year.BOMAG 17BW 211 D-4

Safety regulationsBOMAG18 BW 211 D-4

BW 211 D-4

3 Indicators and ControlsBOMAG 19

Indicators and ControlsFig. 5BOMAG20 BW 211 D-4

Indicators and Controls1 Ignition switch2 Instrument cluster3 Vent for heating and ventilation, driver4 Vent for heating and ventilation, footwell5 Push button vibration6 Travel lever7 Rotary switch vibration, high/low frequency8 Rotary switch for speed range selection9 Emergency stop push button

10 Push button for warning horn11 Rotary momentary contact switch for engine

speed12 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 equipmentBOMAG 21BW 211 D-4

Indicators and Controls3.1 General notes

Please read this section thoroughly before operat-ing this machine if you are not yet conversant withthe indicators and control elements. All functionsare described in detail hereunder.Paragraph 4 Operation contains only concise de-scriptions of the individual operating steps.

3.2 Description of indicatorsand control elements

Fig. 6No. 1 = Ignition switchPosition "P"/"0" = ignition off, the key can be

pulled out, engine not running.Position "I" = ignition on, all control and

warning lights on the faultmonitoring board light up for amoment. The lighting can beswitched on.

i NoteThe engine can only be started when the travel le-ver is in braking position.The ignition switch is provided with a lock againstrepetitive 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

! CautionRun the engine warm for a short while beforestarting to work. Do not let the engine run atidling speed for longer than 10 minutes.Do not shut the engine down all of a suddenfrom full speed, but let it idle for a while fortemperature equalization.BOMAG22 BW 211 D-4

Indicators and ControlsFig. 7No. 2 = Instrument cluster

i NoteWith the ignition switch in position I all gauges andinstruments are switched on for 3 seconds.a red = flashes if the engine temperature ex-

ceeds 135 C, the warning buzzersounds, the engine is shut down after2 minutes.Switch off vibration, run engine withidle speed or shut down engine ifnecessary, clean engine oil coolerand 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, repairthe engine if necessary.

c yellow = Engine air filter, lights if air filter car-tridge is soiled, clean or replace ifnecessary.

d yellow = Charge control light, lights if battery isnot being charged.Check V-belt, if necessary repair thegenerator.

e yellow = lights if the hydraulic oil filter is con-taminated, the engine is shut downafter 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 thewarning buzzer will sound, engine isshut down after 4 seconds.

g red = Parking brake, with lever shifted toparking brake position, with driversseat unoccupied.

h green = Direction indicator, flashes when thedirection indicator switch is actuated.

i yellow = Water separator in fuel pre-cleaner.Lights when the water proportion inthe transparent section of the fuel fil-ter reaches the contacts.

j red = flashes, when the coolant provision(filling level) is too low, the engine isshut down after 2 minutes.

k yellow = not usedl red = Hazard light, flashes when the haz-

ard light is activatedm = Operating hour meter, counts the op-

erating hours while the engine is run-ning. All maintenance work must beperformed according to the indicatedoperating hours.

n = Fuel tank filling levelWhen falling below the lowest fillinglevel the last green LED will light andthe red LED will additionally come on.When the fuel tank is empty only thered LED will flash.

No. 3 = Vents for air conditioning, heatingand ventilation, driver

No. 4 = Vents for air conditioning, heatingand ventilation, footwell*

* Optional equipmentBOMAG 23BW 211 D-4

Indicators and ControlsFig. 8No. 5 = Push button for vibrationl Select or actuate the frequencies with the vi-

bration selector switch.l Switch the vibration on or off by pressing the

push button.

Fig. 9No. 6 = Travel leverPosition "mid-dle" = Braking position service brakePosition "middle,right" = Parking brake, to start the en-

ginePosition "I" = Forward travelPosition "II" = Backwards travel

i NoteIf the engine speed drops under load when drivingon steep gradients, take the travel lever slightlyback towards neutral. This relieves the hydraulicsystem and reduces the load on the diesel engine.

Fig. 10No. 7 = Rotary switch for vibrationPosition "Mid-dle" = Vibration offPosition "Right" = low amplitude, high frequencyPosition "Left" = high amplitude, low frequency

Fig. 11No. 8 = Rotary switch for speed range selec-

tionPosition "turtle" = Working speedPosition "rab-bit" = Transport speedBOMAG24 BW 211 D-4

Indicators and ControlsFig. 12No. 9 = Emergency stop switchThe engine will be shut down and the brake willclose.

! DangerDanger of accident!Operate only in emergency situations duringoperation, do not use as a service brake.The machine should only be started again afterthe danger, that caused the actuation of theemergency stop switch, has been removed.operate = push the button completely

down, it will automatically lockin end position.

unlock = turn the button clockwise andrelease it.

to drive = move the travel lever first tobraking position, then start theengine and choose the traveldirection.

For safety reasons the travel system of the ma-chine will only be enabled after the travel lever hasbeen shifted back to braking position.

Fig. 13No. 10 = Push button for warning horn

Fig. 14No. 11 = Rotary momentary contact switch for

engine speedElectric engine speed adjustmentPosition left = Idle speed position

i NoteNormal position for engine start.Position right = Full throttle position, operating

position for driving and vibra-tion

! CautionAlways drive and vibrate with max. enginespeed! Control the travel speed with the travellever.BOMAG 25BW 211 D-4

Indicators and ControlsFig. 15No. 12 = Rotary switch for direction indicators

left / right*

Position "mid-dle" = Direction indicators disabledPosition "left orright" = Front and rear direction indica-

tors for the corresponding sideof the machine light up, thecontrol light in the instrumentcluster flashes.

Fig. 16No. 13 = Rotary switch for hazard light system

**

Position "left" = Hazard light switched off, con-trol lights off.

Position "right" = Hazard light switched on, con-trol light 1 in instrument clusterlights up.

Fig. 17No. 14 = Rotary switch for light system (StV-

ZO)***Position "left" = Light offPosition "mid-dle" = Sidelights on, with ignition

switch in position "I" or "P"Position "right" = Travel light on, with ignition

switch in position "I".

Fig. 18No. 15 = Rotary switch for working lights****

Position "left" = Light offPosition "right" = Working lights on, with ignition

switch in position "I".

* Optional equipment** Optional equipment

*** Optional equipment**** Optional equipmentBOMAG26 BW 211 D-4

Indicators and ControlsFig. 19No. 16 = Lever, steering wheel adjustment

! DangerDanger of accident!Do not adjust the steering wheel while driving.pull up = adjust height of steering wheelpress down = adjust inclination of steering

wheel

Fig. 20No. 17 = Lever, swivelling of drivers seat

! DangerDanger of accident!Always lock the drivers seat in one of the lock-ing positions while driving.Do not swivel the drivers seat while driving.swivel = Stop the machine and apply

the parking brake. Pull the le-ver up and swivel the driversseat to the desired position.

i NoteSwivelling angle max. 20 to either side.

Fig. 21No. 18 = 2-pole socketCurrent only with the ignition switch in position "I"or when the engine is running.

Fig. 22No. 19 = Fuses in electric installation boxF03, 15A = VibrationF05, 15A = SocketF07, 15A = Hazard light*

F09, 10A = Parking tail light, left*F10, 10A = Parking tail light, right*F11, 15A = Head lights, StVZO*F13, 30A = StartingF14, 15A = Engine solenoidF18, 10A = Working head lights, relay*F19, 15A = Working head lights, front, left*

* Optional equipmentBOMAG 27BW 211 D-4

Indicators and ControlsF22, 15A = Working head lights, rear*F23, 10A = Warning hornF24, 10A = Monitoring, gaugesF25, 10A = Solenoid valve brake/travelF39, 15A = Cab*F70, 15A = Indicator*F105, 20A = Engine speed control

! DangerFire hazard!Do not use fuses with higher ampere ratingsand do not bridge fuses.

Fig. 23

a = toggle switch for flashing beacon

b = toggle switch for front windscreen wiper/washerup = 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/washerup = windscreen wiper moves to

end position and stops.down = Switches on wiping of rear

windscreen.Push button = Rear windscreen is sprayed

during wiping.

d = toggle switch for rear windscreen heating

Fig. 24No. 20 = Fuse box, cabin

! DangerFire hazard!Do not use fuses with higher ampere ratingsand 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(5), 10A = (F41) flashing beacon(6), 15A = (F144) cab socket(7), 15A = (F143) rear windscreen heating(8), 5A = (F42) potential 30, cab light

Fig. 25No. 21 = Control panel for ventilator, air condi-

tioning, heatingBOMAG28 BW 211 D-4

Indicators and Controlse = Rotary switch for cabin ventilatorPosition Off = cabin ventilator switched off.Position 1, 2 and3 = ventilator stages of different

strengths

f = Push button for air conditioning*

press = air conditioning switched on.

i NoteThe lights above the push buttons light up.With rotary switch (g) the air conditioning unit canbe regulated within the blue range.press again = air conditioning switched off.

i NoteThe light goes out.

g = Rotary switch for cabin heater (tempera-ture selector switch)Position Off = cabin heater switched off.Position bluerange = temperature selection for air

conditioning.Position redrange = Temperature selection for cab-

in heater.

Fig. 26No. 22 = Cabin light

i = reading and dashboard light

j = toggle switch for reading and dashboardlight

k = toggle switch for cabin light

l = cabin light

Fig. 27No. 23 = Main fuse for battery125A = (F00)

i NoteBattery with main fuse is located in the enginecompartment

Fig. 28No. 24 = EVIBdisplay**

is a compaction measuring unit for continuous dis-play of the load bearing characteristics (MN/m2)during the compacting pass.

EVIB valueIncrease = higher load bearing capacity

* Optional equipment ** Optional equipmentBOMAG 29BW 211 D-4

Indicators and ControlsConstant = end of compactionBOMAG30 BW 211 D-4

BW 211 D-4

4 OperationBOMAG 31

Operation4.1 General notes

Please read section 3 Indicators and Control Ele-ments thoroughly before operating the machine ifyou are not yet fully familiar with the indicators andcontrol elements of the machine.All indicators and control elements are describedin detail in this chapter.

4.2 Tests before starting to op-erate

The following tests must be performed beforeeach work day or before a longer work period.

! DangerDanger of accident!Please observe strictly the safety regulationsin chapter 2 of these operating and mainte-nance instructions!l Park the machine on level ground.

Check:l Fuel tank and fuel lines for leaksl Bolted connections for tight fitl Function of the steeringl Check the machine for cleanliness and dam-

agel availability of the appropriate operating and

maintenance instructions,l check if the machine has been properly serv-

iced.

i NoteFor a description of the following work refer to thesection "maintenance every 10 operating hours"l engine oil level

i NoteHydraulic systems, which are filled with PanolinHLP Synth. 46, the same oil must be used for fill-ing up. In case of any other ester based oil consultthe 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.

! DangerFire hazard!Do not refuel in closed roomsl Check the fuel level, top up if necessary.BOMAG32 BW 211 D-4

Operationl Check water separator in the fuel system,drain if necessary.

l Adjust the scrapers if necessaryl Tire pressure. Pressure see technical data.

! CautionEnsure equal pressure in both tires.

4.3 Starting the engine

! DangerDanger of accident!Always wear your seat belt.

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.BOMAG 33BW 211 D-4

OperationFig. 31

l Check, whether the emergency stop switch(Fig. 31) is unlocked.

Fig. 32

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

Fig. 33

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

Fig. 34

All control and warning lights (Fig. 34) in the faultmonitoring 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.

! CautionPerform the starting process for maximum 20seconds without interruption and pause for aminute between starting attempts.If the engine has not started after two attemptsperform trouble shooting.

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".

! CautionDo not allow the engine to run longer than 10minutes with idle speed.BOMAG34 BW 211 D-4

Operation4.4 Starting with jump wires

Fig. 36

! CautionA wrong connection will cause severe damagein 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, asfar 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.).

! CautionIf no powerful consumer is switched on volt-age peaks may occur when separating the con-necting cables between the batteries, whichcould damage electrical components.l After starting disconnect the negative poles

(ground cable) first and the positive poles af-ter.

l Switch off the consumer.

4.5 Driving the machine

! DangerDanger of accident!Wet and loose soils considerably reduce theground adhesion of the machine on inclina-tions and slopes.Soil conditions and weather influences impairthe 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 thedrive range is absolutely safe.

! CautionAlways keep the cabin door closed while driv-ing with the machine. With the door openedand the machine fully articulated extreme os-cillations of the machine may damage thedoor.

i Note"Start engine", see previous sections.The machine is equipped with a seat contactswitch (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, thesignal horn is activated and the engine shut downafter four seconds.If the driver occupies the seat again within this pe-riod of four seconds, the machine will continuetravelling.BOMAG 35BW 211 D-4

OperationFig. 37

l Close the cabin door (Fig. 37).

Fig. 38

l Sit down on the seat (Fig. 38).

Fig. 39

l Fasten your seat belt (Fig. 39).

Fig. 40

l Select the desired travel speed range (Fig.40).

Fig. 41

l Turn the rotary switch (Fig. 41) to "Max" posi-tion (full throttle).

Fig. 42

l Push the travel lever (Fig. 42) to the left out ofbraking position and move it slowly to the de-sired travel direction.BOMAG36 BW 211 D-4

Operationi NoteShift the travel lever out of "0"-position slowly toforward or reverse, the machine will drive forwardor reverse at a speed which corresponds with thedisplacement of the travel lever.Returning the travel lever towards neutral willbrake the machine and in "0"-position of the travellever the machine will stop.

! DangerDanger of accident!When stopping on inclinations and slopes pullthe travel lever to the right and lock it in brak-ing position.

Important notes on travel operation

! CautionWhen changing the travel direction hold thetravel lever for a moment in "0"-position, untilthe machine has stopped, before actuating tothe new travel direction.Do not operate jerkily!When driving up and down inclinations movethe travel lever slowly back towards neutral tobrake the machine.If the engine speed drops when driving up ex-treme inclinations move the ravel lever slightlyback, if necessary change to the lower speedrange.

4.6 Switching the vibration onand off

! DangerRisk of damage!When compacting with vibration you mustcheck the effect of nearby buildings and un-derground supply lines (gas, water, sewage,electric power), if necessary stop compactionwith vibration.Do not activate the vibration on hard (frozen,concrete) ground. Danger of bearing damage!

Fig. 43

l Switch to working speed (Fig. 43) (turtle).

Pre-selecting the vibration

Fig. 44

l Pre-select amplitude/frequency with the rotaryswitch (Fig. 44).BOMAG 37BW 211 D-4

OperationSwitch the vibration on

Fig. 45

l Turn the rotary switch (Fig. 45) to position"Max" (full throttle).

! CautionSwitch the vibration on only at max. enginespeed.

Fig. 46

l Press the push button (Fig. 46) in the travel le-ver while driving, the drum will vibrate.

Switching the vibration offl Press the push button again and after work

switch the rotary vibration switch to position"0".

4.7 Operating the parkingbrake, stopping the ma-chine

Fig. 47

l Return the travel lever (Fig. 47) slowly to "neu-tral"-position and engage it to the right parkingbrake position.

The machine is automatically braked by the hydro-static drive and parking brake closes.

i NoteThe parking brake also closes automatically whenshutting the engine down.BOMAG38 BW 211 D-4

Operation4.8 Shutting the engine down

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

Fig. 48

l Return the travel lever (Fig. 48) slowly to "neu-tral"-position and engage it to the right in brak-ing position.

Fig. 49

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

i NoteDo not shut the engine down all of the sudden fromfull speed, but let it idle for a while for temperatureequalization.

Fig. 50

l Turn the ignition switch (Fig. 50) to position "0"or "P" and pull the ignition key out.

i NoteThe parking brake closes automatically whenshutting the engine down.

! DangerDanger of accident!Secure the machine against unauthorized use,pull the ignition key out, lock the cabin door.BOMAG 39BW 211 D-4

Operation4.9 Emergency exit

If the machine should turn over and the cabin dooris closed, the right hand side cabin window can beused as an emergency exit.

4.10 Adjusting the steeringwheel

Fig. 51

l Adjustment of steering wheel in height, pull le-ver (Fig. 51) up and move the steering wheelto the desired height.

l Adjustment of steering wheel inclination, presslever down and adjust the inclination of thesteering wheel.

! DangerDanger of accident!After the adjustment make sure that the steer-ing wheel adjustment is securely locked inplace.BOMAG40 BW 211 D-4

Operation4.11 Adjusting the seat

Fig. 52

l To adjust the seat in longitudinal direction dis-engage lever e (Fig. 52) upwards and push theseat forward or back.

l To adjust the weight turn lever (d) and read theweight in sight glass (c).

l To adjust the inclination of the backrest oper-ate lever (a) and tilt the backrest forward orback.

l To swivel the seat pull lever (b) up and turn theseat to the desired direction.

Fig. 53

l To adjust the height of the seat lift the seat up(Fig. 53) until it engages at the desired level.

When lifting the seat completely it will sink down tolowest position.

4.12 Operating the hood

! DangerDanger of accident!If the hood needs to be opened further formaintenance or repair work, support it safely.

Opening the hood

Fig. 54

l Unlock the lock (Fig. 54).l To open the hood press in the button and turn

the handle.

Fig. 55

l Pull the support (Fig. 55) out of the bracket.BOMAG 41BW 211 D-4

OperationFig. 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. 57

l Push up the hood and place the support rodinto its receptacle.

Closing the hood

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.BOMAG42 BW 211 D-4

Operation4.13 Towing in case of an enginefailure

! DangerSecure the machine with wheel chocks againstunintentional rolling.

! DangerDanger of accident!When using towing ropes tow the machineonly uphill.When towing downhill you must use a rigidtowing device.l Secure the machine with wheel chocks

against unintentional rolling.l Attach the towing ropes safely to the front or

rear lifting eyes.

! CautionTowing speed 1 km/h, max. towing distance500 m.

l Open the tailgate.

Fig. 59

l Slacken the middle hexagon on both valves(Fig. 59) for approx. 2 to 3 turns.

! CautionDo not turn the valves out completely.

Fig. 60

l To release the brake turn counter nuts 1 (Fig.60) approx. 8 mm back.

l Turn the brake releasing screws (2) complete-ly in against the stop.

! CautionFrom this stop turn the screw in for maximumanother turn to release the brake!Turn the screws in evenly on both sides.l Turn the screws in alternately for turn at a

time.l Repeat this measure on the opposite wheel

side.

Fig. 61

l Remove plug 1 (Fig. 61).l Place an U-section (5) across the brake hous-

ing (2) and turn the screw (4) into the tappedbore (3), until it bottoms.

l Turn the nut (6) down and tighten it approx.one revolution. The drum must rotate freely.BOMAG 43BW 211 D-4

OperationAfter towing

! CautionBefore 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 movingagain.

Fig. 62

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

i NoteIf 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 lubricatethe screw with silicone grease.Reinstall the screw with a new seal ring and adjustthe protrusion as described above.BOMAG44 BW 211 D-4

Operation4.14 Transport

! DangerDanger of accident!Use only stable loading ramps of sufficientload bearing capacity. Make sure that personsare not endangered by the machine tipping orsliding off.Lash the machine down, so that it is securedagainst rolling, sliding and turning over.Do not stand or step under loads being lifted.Always use shackles on the lifting points forloading, tying or lifting the machine.

Fig. 64

l Pull the spring pin (Fig. 64) out.l Engage the articulation lock and secure it with

the spring pin.

Fig. 65

l Engage the articulation lock and secure it withthe spring pin (Fig. 65).

Fig. 66

l Lash the machine on the transport vehicle(Fig. 66), use the four lashing eyes on frontand rear frame for this purpose.

l Support the front frame to avoid overstressingof the rubber buffers.

Fig. 67

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

Weights: See technical datal After transport release the articulation lock

again and store it in the receptacle.BOMAG 45BW 211 D-4

OperationBOMAG46 BW 211 D-4

BW 211 D-4

5 MaintenanceBOMAG 47

Maintenance5.1 General notes on mainte-nance

When servicing the machine pay careful attentionto all applicable safety instructions.Thorough maintenance of the machine ensuresmaximum reliability and prolongs the lifetime of im-portant components. The necessary effort can byno means be compared with the problems andmalfunctions 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 (transportlock) before starting to work in the articulationarea of the machine.

EnvironmentCatch running out oils, coolant and fuel and donot let them seep into the ground or into thesewage system. Dispose of oils, coolant andfuels environmentally.

Notes on the fuel systemThe 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 periodof time before drawing off fuel.

l Do not let the suction hose disturb the sludgeon the bottom of the drum.

l Do not draw off fuel from near the bottom ofthe fuel drum.

l Fuel left in the fuel drum is not suitable for theengine and should only be used for cleaningpurposes.

Notes on the engine performanceCombustion air and fuel injection rates of the die-sel engine have been carefully adjusted and deter-mine the engine's performance and temperaturelevel 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, youshould consult the after sales service of BOMAGor the service department of the engine manufac-turer.

Notes on the hydraulic systemDuring maintenance work in the hydraulic systemcleanliness is of utmost importance. Make surethat no dirt or other impurities can enter into thesystem. Small particles can flute valves, causepumps to seize and block restrictors and pilotbores, thereby causing costly repairs.l If during the daily oil level check the oil level is

found to have dropped, check all lines, hosesand components for leakages.

l Seal external leaks immediately. If necessaryinform the responsible service department.

l Do not store drums with hydraulic oil outside,or at least keep them under a cover. Duringweather changes water may penetratethrough the bunghole.

l Always fill the hydraulic system using the fillingand filtering unit (BOMAG part-no.007 610 01). This unit is equipped with a finefilter, which filters the hydraulic oil and pro-longs the lifetime of the system filter.

l Clean fittings, filler caps and their immediatesurrounding area before removing them, sothat no dirt can fall in.

l Do not leave the tank opening unnecessarilyopen, cover it so that no dirt can fall in.BOMAG48 BW 211 D-4

MaintenanceNotes on the cooling systemOn water cooled engines the preparation andmonitoring of the coolant is of utmost importance,as otherwise engine failures caused by corrosion,caviation and freezing may occur.The coolant is a mixture of water and a coolingsystem protection agent.The cooling system must be permanently moni-tored. Apart from the coolant level inspection thisincludes also the inspection of the concentration ofcooling system protection agent.The concentration of the cooling system protectionagent can be checked with commercially availabletest instruments (glycomat).

! DangerHealth hazard!The mixing of nitride based cooling systemprotection agents with amine based agents willcause the generation of highly toxic nitro-samines.

EnvironmentCooling system protection agents must be dis-posed of environmentally.

5.2 Fuels and lubricants

Engine oilQualityLubrication oils are classified according to theirperformance and quality class. Oils according toother comparable specifications may be used.

The exact assignment of the approved oil qualitiesand oil change intervals can be taken from the fol-lowing section "Lubrication oil change intervals".Consult your local service station if in doubt.

Oil viscosityMulti-purpose oils should be generally used.Since lubrication oil changes its viscosity with thetemperature, 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 byusing the opposite oil viscosity chart (Fig. 68) as areference.Occasionally falling short of the temperature limitswill impair the cold starting ability, but will notcause any engine damage. In order to keep theoccurring wear as low as possible, occassional ex-ceeding of the limits should not happen over alonger period of time.

Approved engine oilsDeutz DQC II DQC IIIACAE E3/96/E5-02 E4-99API CH-4/CG-4 -DHD DHD-1 -BOMAG 49BW 211 D-4

MaintenanceFig. 68

With their better temperature and oxidation stabil-ity synthetic lubrication oils offer quite a few bene-fits.

Oil change intervalsThe longest permissible time a lubrication oilshould 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 performedat least once per year, irrespective of the operatinghours reached.

ACEA*

E3-96/E5-02E4-99 = 500 operating hours

API**

CG-4/CH-4 = 500 operating hours

! CautionThese intervals apply only when using a dieselfuel with maximum 0.5 % sulphur by weight

and for ambient temperatures higher than -10C.When using fuels with a sulphur content ofmore than 0.5% to 1% or under ambient tem-peratures below -10 C the oil change intervalsspecified in the table must be halved. For fuelswith a sulphur content of more than 1% youshould consult the responsible service agen-cy.

FuelsQualityYou should only use commercially available branddiesel fuel with a sulphur content below 0.5% andensure strict cleanliness when filling in. A highersulphur content has a negative effect on the oilchange intervals. Use only winter-grade diesel fuelunder low ambient temperatures. The fuel levelshould always be topped up in due time so that thefuel tank is never run dry, as otherwise filter and in-jection lines need to be bled.When using fuels with a Cetan number < 49 poorstarting 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 590l BS 2869l ASTM D 975-78: 1-D and 2-D.l Nato Codes: F-54, F-34, F44 und XF63

Winter fuel

! DangerFire hazard!Diesel fuels must never be mixed with gaso-line.For winter operation use only winter diesel fuel, toavoid clogging because of paraffin separation. Atvery low temperatures disturbing paraffin separa-tion can also be expected when using winter dieselfuel.

* European Engine Oil Sequences** American Petroleum InstituteBOMAG50 BW 211 D-4

MaintenanceIn most cases a sufficient cold resistance can alsobe achieved by adding flow enhancing fuel addi-tives. Consult the engine manufacturer.

Operation with rape seed oil methyl ester (RMEBio Diesel)Due to the extreme quality differences of RMEW-fuels available on the market, which are caused bythe non-existence of a standardization, BOMAGdoes generally not approve any RME-fuels. If thisis neglected the warranty will become null andvoid!However, if you still intend to operate the machinewith RME-fuels you should observe the followinginformation: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 andneed to be replaced on a regular basis orshould be replaced by parts made of fluorinat-ed rubber. However, fluorinated rubber is notresistant against normal diesel fuel.

l If the fuel filter is clogged the filter change in-tervals must be shortened accordingly.

Coolant, anti-freeze agentUse only soft tap water (drinking water) to preparethe coolant mix.As a protection against frost, corrosion and boilingpoint anti-freeze agents must be used under anyclimatic conditions.The proportion of cooling system protection agentmust be between min. 35% and max. 45% to thewater.

! CautionDo not mix different coolants and additives ofany other kind.

EnvironmentCooling system protection agents must be dis-posed of environmentally.

Hydraulic oilThe hydraulic system is operated with hydraulic oilHV 46 (ISO) with a kinematic viscosity of46 mm2/s at 40C. For topping up or for oil chang-es use only high-quality hydraulic oil, type HVLPaccording to DIN 51524, part 3, or hydraulic oilstype HV according to ISO 6743/3. The viscosity in-dex (VI) should be at least 150 (observe informa-tion of manufacturer).Bio-degradable hydraulic oilOn request the hydraulic system can also be filledwith ester based biodegradable hydraulic oil (Pan-olin HLP Synth. 46). The biologically quickly de-gradable hydraulic oil meets all demands of amineral oil based hydraulic oil according to DIN51524.In hydraulic systems filled with Panolin HLP Synth.46 always use the same oil to top up. Whenchanging from mineral oil based hydraulic oil to anester based biologically degradable oil, you shouldconsult the lubrication oil service of the oil manu-facturer for details.Check the filter more frequently after this change.

! CautionOil change bio-degradable hydraulic oil:Perform regular oil analyses for content of wa-ter and mineral oil.Replace the hydraulic oil filter element every500 operating hours.

Oil for drive axleFor the drive axle use only multi-purpose transmis-sion oil of API-class GL5 with viscosity class SAE90.The additives in this oil ensure low wear lubricationunder all operating conditions.

Lubrication greaseFor lubrication use only EP-high pressure grease,lithium saponified (penetration 2).BOMAG 51BW 211 D-4

Maintenance5.3 Table of fuels and lubri-cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter AttentionObserve the level marks

Engine Engine oil ACEA: E3-96/E5-02 or approx. 8,5 litres withoutoil 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 litres46 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 litresBOMAG52 BW 211 D-4

Maintenance5.4 Running-in instructions

The following maintenance work must be per-formed when running in new machines oroverhauled engines:

! CautionUp to approx. 250 operating hours check theengine oil level twice every day.Depending on the load the engine is subjectedto, the oil consumption will drop to the normallevel after approx. 100 to 250 operating hours.

After a running-in time of 30 minutesl Retighten the V-belt

After 50 operating hoursl 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 bearingsl Oil change in drive axlel Oil change in wheel hubs

After 500 operating hoursl Oil change vibration bearingsBOMAG 53BW 211 D-4

Maintenance5.5 Maintenance chart

No. Maintenance work Remark

Ru

nn

ing-

inin

str

uc

tion

sa

fter

50o

pera

ting

hou

rs

ev

ery

10o

pera

ting

hou

rs,

daily

ev

ery

250

ope

ratin

gho

urs

ev

ery

500

ope

ratin

gho

urs

ev

ery

1000

ope

ratin

gho

urs

ev

ery

2000

ope

ratin

gho

urs

ev

ery

3000

ope

ratin

gho

urs

as

requ

ired

5.6 Check the engine oil level Dipstick mark X5.7 Check the water separator X5.8 Check the fuel level X5.9 Check the hydraulic oil level Inspection glass X5.10 Check the coolant level Inspection glass X5.11 Check the dust separator X5.12 Check the tire pressure X5.13 Clean the cooling fins on engine and

hydraulic oil coolerX

5.14 Check the oil level in the drive axle X5.15 Check the oil level in the wheel hubs X5.16 Check the oil level in the vibration

bearingsX

5.17 Change engine oil and oil filter car-tridge*

min. 1x per year X

5.18 Change the fuel filter cartridge X5.19 Drain the sludge from the fuel tank X5.20 Service the battery Pole grease X5.21 Change the fuel pre-filter cartridge X5.22 Check, replace the refrigerant com-

pressor V-beltX

5.23 Service the air conditioning X5.24 Check, adjust the valve clearance Intake = 0,3 mm

Exhaust = 0,5 mmXBOMAG54 BW 211 D-4

Maintenance5.25 Check, replace the ribbed V-belt X5.26 Check the engine mounts X X5.27 Oil change in drive axle min. 1x per year X X5.28 Oil change in wheel hubs min. 1x per year X X5.29 Oil change vibration bearings** see foot note, min. 1

x per yearX X

5.30 Retighten the fastening of the axle onthe frame

X

5.31 Tighten the wheel nuts X X5.32 Check the ROPS X5.33 Clean the oil bath air filter min. 1x per year X5.34 Change hydraulic oil and breather fil-

ter***at least every 2years

X

5.35 Change the hydraulic oil filter**** at least every 2years

X

5.36 Change the coolant at least every 2years

X

5.37 Check the injection valves X5.38 Service the combustion air filter min. 1x per year,

safety cartridge atleast every 2 years

X

5.39 Adjust the scrapers X5.40 Adjust the parking brake X5.41 Change the tires X5.42 Change the fresh air filter in the cabin X5.43 Tightening torques X5.44 Engine conservation X

No. Maintenance work Remark

Ru

nn

ing-

inin

str

uc

tion

sa

fter

50o

pera

ting

hou

rs

ev

ery

10o

pera

ting

hou

rs,

daily

ev

ery

250

ope

ratin

gho

urs

ev

ery

500

ope

ratin

gho

urs

ev

ery

1000

ope

ratin

gho

urs

ev

ery

2000

ope

ratin

gho

urs

ev

ery

3000

ope

ratin

gho

urs

as

requ

iredBOMAG 55BW 211 D-4

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.BOMAG56 BW 211 D-4

Every 10 operating hoursEvery 10 operating hours

5.6 Check the engine oil level

! DangerDanger of injury!Support the engine hood for all maintenanceand repair work.

i NoteThe machine must be parked horizontally with theengine shut down.

Fig. 69

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

! CautionBefore longer work periods you should alwaystop the oil up to the "MAX"-mark.

For quality and quantity of oil refer to the tableof fuels and lubricants.

5.7 Check, clean the water sep-arator

! DangerDanger of injury!Support the engine hood for all maintenanceand repair work.

i NoteThe service intervals for the water separator de-pend on the water content in the fuel and cantherefore not be determined precisely. After takingthe engine into operation you should thereforecheck the water separator every day for signs ofwater.

If a to high quantity is drained off, the filter must berefilled with fuel. See chapter "maintenance as re-quired", bleeding the fuel system.

EnvironmentCatch running out fuel and dispose of environ-mentally.

Fig. 70

l Slacken the drain plug (Fig. 70) for a few turnsand catch running out fuel / water.

l Tighten the drain plug again and check forleaks, if necessary replace the seal ring.BOMAG 57BW 211 D-4

Every 10 operating hours5.8 Check the fuel level

! DangerFire hazard!When working on the fuel system do not useopen fire, do not smoke, do not refuel in closedrooms, do not inhale any fuel fumes.

Fig. 71

l Check the fuel level on the fuel level gauge "n"(Fig. 71) with the ignition switched on.

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

Fig. 72

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

! CautionContaminated fuel can cause malfunction oreven damage of the engine.If necessary, fill in fuel through a funnel withscreen.

l If necessary top up with fuel (diesel or winterdiesel).

For quality of fuel refer to the table of fuels andlubricants.BOMAG58 BW 211 D-4

Every 10 operating hours5.9 Checking the hydraulic oillevel

! CautionIn mit Panolin HLP Synth. 46, the same oil mustbe used for filling up. In case of any other esterbased oil consult the lubrication service de-partment of the respective oil manufacturer.

Fig. 73

l Check the oil level in the inspection glass (Fig.73) on the hydraulic oil tank.

Normal levelapprox. 3 cm below the upper edge of the inspec-tion glass.

Minimum levelmiddle of inspection glass.

! CautionIf during the daily oil check the oil level isfound to have dropped, check all lines, hosesand components for leakages.l If necessary fill in hydraulic oil through the filler

neck.

For quality and quantity of oil refer to the tableof fuels and lubricants.

5.10 Check the coolant level

! DangerDanger of scalding!Fill up coolant only when the engine is cold.

Fig. 74

l Check the coolant level (Fig. 74).

! CautionIf, during the daily inspection the coolant levelis found to have dropped, check all lines, hos-es and engine for leaks.l To top up unscrew the filler cap and fill in cool-

ant up to the MAX-mark.

For quality of coolant refer to the chapter 5.2,fuels and lubricants.BOMAG 59BW 211 D-4

Every 10 operating hours5.11 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.

* OptionBOMAG60 BW 211 D-4

Every 250 operating hoursEvery 250 operating hours

5.12 Checking the tire pressure

! CautionSince the tires are filled with water, you shouldalways turn the inflation valve to top positionto check the tire pressure!Always close the valves with the dust cap.

Fig. 76

l Check the tire pressure with a pressure gaugeand the tire inflation valve 1 (Fig. 76) in top po-sition.

Nominal value see "technical data".

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

5.13 Clean the cooling fins onengine and hydraulic oilcooler

! DangerDanger of injury!Perform cleaning work only after the enginehas cooled down and with the engine stopped.

! CautionDo not damage any cooling fins on the coolercore when cleaning.

i NoteDirt on fan blades and oil cooler reduce the coolingeffect. Dirt deposits in these areas are substantial-ly supported by oil and fuel on these surfaces. Forthis reason you should always seal any oil or fuelleaks in the vicinity of the cooling fan or the oilcooler and clean the cooling surfaces after.

Cleaning with compressed air

Fig. 77

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

air.BOMAG 61BW 211 D-4

Every 250 operating hoursCleaning with cold cleansing agent

! CautionProtect electrical equipment such as genera-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 awhile and spray it off with a strong water jet.

l Run the engine warm for a while to avoid cor-rosion.

5.14 Check the oil level in thedrive axle

l Park the machine on level ground.

Fig. 78

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

i NoteThe 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 thelevel bore.l Top up oil, if necessary.

For quality of oil refer to the table of fuels andlubricants.l Turn the level inspection plug tightly back in.BOMAG62 BW 211 D-4

Every 250 operating hours5.15 Checking the oil level in left/right wheel hubs

Fig. 79

l Move the machine until the oil level inspectionplug 1 (Fig. 79) is in horizontal position.

l Clean and unscrew the plug.The oil level must reach the bottom edge of thebore.l Top up oil, if necessary.

For quality of oil refer to the table of fuels andlubricants.l Screw the plug back in tightly.l Repeat this inspection on the other side.

5.16 Check the oil level in the vi-bration bearings

i NoteCheck only at operating temperature after runningthe 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 inbottom 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 oilstarts to drip out through the inspection bore.

For quality of oil refer to the table of fuels andlubricants.l Screw oil filler (2) and level inspection plug (1)

back in tightly.l Repeat this inspection on the other side.

! CautionIf a loss of oil is found perform trouble shoot-ing, repair the drum if necessary.BOMAG 63BW 211 D-4

Every 500 operating hoursEvery 500 operating hours

5.17 Changing engine oil and oilfilter cartridges

! CautionThe oil change at 500 operating hours refers tothe 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 iswarm.

! DangerDanger of scalding!When draining off hot oil.By hot oil when unscrewing the engine oil fil-ter.

EnvironmentCatch running out oil and dispose of environ-mentally together with the engine oil filter car-tridge.

Fig. 81

l Unscrew the drain plug (Fig. 81) and catchrunning out oil.

l Turn the drain plug tightly back in.

Fig. 82

l Thoroughly clean the outside of both filter car-tridges (Fig. 82).

l Unscrew both filter cartridges using an appro-priate filter wrench.

i NoteThe filter cartridges are fitted with a valve that pre-vents engine oil from running out during removaland installation.l Clean the sealing face on the filter carrier from

any dirt.l Slightly oil the rubber seal on the new filter car-

tridges.

Fig. 83

l Turn the new filter cartridges (Fig. 83) on byhand, until the seal contacts.

l Tighten the filter cartridges for another halfturn.BOMAG64 BW 211 D-4

Every 500 operating hoursFig. 84

l Fill in new engine oil (Fig. 84).For quality and quantity of oil refer to the tableof fuels and lubricants.l Tighten the oil filler cap properly.

! CautionBefore starting crank the engine with the start-er motor until the oil pressure warning lightgoes out.l After a short test run check the oil level on the

dipstick, if necessary top up to the top dipstickmark.

l Check filter cartridge and drain plug for leaksafter a short test run.

l Shut the engine down and wait for about 15minutes, so that all oil can flow back into the oilsump.

l Check the oil level again, if necessary fill up tothe Max.-mark.

5.18 Change the fuel filter car-tridge

! DangerFire hazard!When working on the fuel system do not useopen fire, do not smoke and do not spill any fu-el.Catch running out fuel, do not let it seep intothe ground.Do not inhale any fuel fumes.

Fig. 85

l Loosen and unscrew the fuel filter cartridge(Fig. 85) using an appropriate filter wrench.

l Clean the sealing face on the filter carrier fromany dirt.

Fig. 86

l Slightly oil the rubber seal (Fig. 86) on the newfilter cartridge.BOMAG 65BW 211 D-4

Every 500 operating hoursl Fill the filter cartridge with clean diesel fuel.l Turn the new filter cartridge on by hand, until

the seal contacts.l Tighten the filter element for another half turn.l Check the filter cartridge for leaks after a short

test run.

5.19 Draining the sludge fromthe fuel tank

! DangerFire hazard!When working on the fuel system do not useopen fire, do not smoke!Do not spill any fuel.Catch running out fuel, do not let it seep intothe 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.BOMAG66 BW 211 D-4

Every 500 operating hours5.20 Service the battery

! DangerDanger of cauterisation ! Danger of explosion!When working on the battery do not use openfire, do not smoke!The battery contains acid. Do not let acid comein contact with skin or clothes!Wear protective clothing!Do not lay any tools on the battery!

EnvironmentDispose of the old battery environmentally.

i NoteMaintenance free batteries also need care. Main-tenance free only means that the fluid level doesnot need to be checked. Each battery suffers un-der self-discharge, which may, in not checked oc-casionally, even cause damage to the battery as aresult of exhaustive discharge.

The following therefore applies for the servicelife:l Switch off all consumers (e.g. ignition, light, in-

side light, radio).l Check open-circuit voltage of the battery at

regular intervals. At least once per month.Reference values: 12.6 V = fully charged; 12.3 V =50% discharged.l Recharge the battery immediately after an

open-circuit voltage of 12.25 V or less isreached. Do not perform boost charging.

The open-circuit voltage of the battery occurs ap-prox. 10 hours after the last charging process orone 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. Donot forget to perform regular open-circuit volt-age measurements.

! CautionExhausted batteries (batteries with formationof sulphate on thge plates are not covered un-der warranty!l Open the engine hood and remove the cover-

ing.

Fig. 88

l Remove the battery (Fig. 88) and clean thebattery compartment.

l Clean the outside of the battery.l Clean battery poles and pole clamps and

grease them with pole grease (Vaseline).l Check the fastening of the battery.l On serviceable batteries check the acid level,

if necessary top up to the filling mark with dis-tilled water.

Charging voltage recommendation

Fig. 89BOMAG 67BW 211 D-4

Every 500 operating hours5.21 Change the fuel pre-filtercartridge

! DangerFire hazard!When working on the fuel system do not useopen fire, do not smoke and do not spill any fu-el.Catch running out fuel, do not let it seep intothe ground.Do not inhale any fuel fumes.

Fig. 90

l Unscrew the fuel filter cartridge (Fig. 90) usingan appropriate filter wrench.

l Clean the sealing face on the filter carrier fromany dirt.

Fig. 91

l Unscrew the water separator from the filtercartridge (Fig. 91).

Fig. 92

l Apply a thin coat of oil to the rubber seal of thewater separator 1 (Fig. 92).

l Screw the water separator on by hand (2), untilthe seal contacts.

l Tighten the water separator for another halfturn (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 theseal contacts.

l Tighten the filter element for another half turn(6).

l Check the filter cartridge for leaks after a shorttest run.

i NoteAir in the fuel system causes irregular running ofthe engine, a drop in engine power, stalls the en-gine and makes starting impossible.Therefore bleed the fuel system after changing thefuel prefilter.BOMAG68 BW 211 D-4

Every 500 operating hoursFig. 93

l Slacken the bleeding screw (Fig. 93) on thefuel pre-filter for 2 to 3 turns.

l Operate the hand pump manually, until fuelflows out of the slackened bleeding screw (Fig.93) without air bubbles.

l Then tighten the bleeding screw while pump-ing.

5.22 Checking, replacing the re-frigerant compressor V-belt*

! DangerDanger of injury!Work on the V-belt must only be performedwith the engine shut down.

Check the V-belt

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-beltcan be depressed more than 10 to 15 mm (0.4 0.6 inches) between the V-belt pulleys,retighten if necessary.

* Optional equipmentBOMAG 69BW 211 D-4

Every 500 operating hoursTighten 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-beltl 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.

! CautionCheck the V-belt tension after a running time of30 minutes.

5.23 Service the air conditioning*

Cleaning the condenser

! CautionA soiled condenser results in a considerablereduction of air conditioning power.Under extremely dusty conditions it may benecessary to clean the condenser severaltimes per day.If, during operation of the air conditioning sys-tem, the warning buzzer sounds switch the airconditioning off and clean the condenser.In case of formation of foam have the air con-ditioning system inspected by the service de-partment.

! DangerDanger of accident!Do not clean with a hot water jet. Heat willcause extreme overpressure, which couldcause 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 backwith compressed air or cold water.

* Optional equipmentBOMAG70 BW 211 D-4

Every 500 operating hoursChecking the refrigerant levell Start the engine.

Fig. 97

l Switch the air conditioning (Fig. 97) on.

Fig. 98

l Choose a cooling temperature with the rotaryswitch for cabin heater (Fig. 98) in the bluesection.

l Open the air outlet nozzles.l Check, whether the outflowing air is noticeably

cooler.

i NoteThe 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.

Fig. 99

l Check whether the white float (Fig. 99) insidethe inspection glass of the drier/collector unitfloats right at the top.

i NoteThe 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 thebottom, inform the service department.

i NoteThe refrigerant level is not correct.l Refrigerant must be filled up, if necessary

check the air conditioning system for leaks.BOMAG 71BW 211 D-4

Every 500 operating hoursChecking the moisture level of the dry-ing agent

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.l Inform the service department. Replace drier/

collector unit, check air conditioning system.

! CautionHave the drier/collector unit replaced by theservice department every year before the oper-ating season.

Checking the condition of the drier/col-lector unit

! CautionAccording to the regulation for pressure reser-voirs all pressure reservoirs must be repeated-ly inspected by a specialist. In this senserepeated inspections are external examina-tions, normally on pressure reservoirs in oper-ation. In connection with this inspection thedrier/collector unit must be visually examinedtwice every year. During these inspectionsspecial attention must be paid to corrosionand mechanical damage. If the reservoir is notin proper condition it must be replaced forsafety reasons, as a precaution to protect op-erators and third parties against any danger

arising from the handling and operation ofpressure reservoirs.

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

Fig. 102

l Check the drier/collector unit (Fig. 102) for me-chanical damage or rust.BOMAG72 BW 211 D-4

Every 1000 operating hours