Operating Instruction

Maintenance Instruction
Original Operating Instructions

BW 216 D-40 / BW 216 PD-40

S/N 101 583 39 1023> / S/N 101 583 40 1001>

Single drum roller

008 058 61 © 08/2014

2
 Table of contents

Table of contents
1 Foreword................................................................................................................................................ 7
2 Technical data..................................................................................................................................... 11
3 Safety regulations............................................................................................................................... 19
4 Indicators and Controls...................................................................................................................... 33
4.1 General notes.............................................................................................................................. 35
4.2 Description of indicators and control elements ...................................................................... 36
4.3 Display and control elements BTM........................................................................................... 48
4.4 Description of indicating and control elements BTM.............................................................. 49
4.5 Line diagram (EVIB)only BTM prof ..................................................................................................... 52
4.6 Description of line diagram (EVIB)only BTM prof ............................................................................. 54
4.7 Bar diagram (EVIB)only BTM prof ...................................................................................................... 56
5 Operation............................................................................................................................................. 57
5.1 General......................................................................................................................................... 58
5.2 Tests before taking into operation ........................................................................................... 59
5.3 Electronic immobilizerOptional equipment ........................................................................................ 60
5.4 Starting the engine...................................................................................................................... 61
5.5 Driving the machine ................................................................................................................... 64
5.6 Stopping the machine, operating the parking brake............................................................... 67
5.7 Shutting down the engine.......................................................................................................... 68
5.8 Switching the vibration on and off............................................................................................ 70
5.9 What to do in events of emergency........................................................................................... 72
5.10 Adjusting the seat..................................................................................................................... 73
5.11 Operating the heating/air conditioning systemOptional equipment .............................................. 74
5.12 Operating the hood................................................................................................................... 76
5.13 BTM 05 settings before start-upOptional equipment ....................................................................... 77
5.14 Measuring pass with BTMOptional equipment ................................................................................ 81
5.15 Finishing compaction of a track.............................................................................................. 85
5.16 Printing measuring data after completing compactiononly BTM prof ........................................ 86
5.17 Changing the paper roll in the measuring value printeronly BTM prof ...................................... 87
5.18 Changing the printer ribbon in the measuring value printeronly BTM prof ............................... 88
5.19 Towing in case of an engine failure........................................................................................ 89
5.20 Loading/transport..................................................................................................................... 92
6 Maintenance........................................................................................................................................ 95
6.1 General notes on maintenance.................................................................................................. 96
6.2 Fuels and lubricants................................................................................................................... 98
6.2.1 Engine oil................................................................................................................................... 98
6.2.2 Fuel.......................................................................................................................................... 100
6.2.3 Coolant..................................................................................................................................... 101
6.2.4 Hydraulic oil.............................................................................................................................. 103
6.2.5 Gear oil..................................................................................................................................... 104
6.2.6 Exciter system.......................................................................................................................... 104
6.3 Table of fuels and lubricants................................................................................................... 105
6.4 Running-in instructions............................................................................................................ 107

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 Table of contents

6.4.1 General.................................................................................................................................... 107

6.4.2 After 250 operating hours......................................................................................................... 107
6.4.3 After 500 operating hours......................................................................................................... 107
6.4.4 After 1000 operating hours....................................................................................................... 107
6.5 Maintenance table..................................................................................................................... 109
6.6 Every 10 operating hours......................................................................................................... 111
6.6.1 Check the engine oil level........................................................................................................ 111
6.6.2 Checking the fuel level............................................................................................................. 111
6.6.3 Check the coolant level............................................................................................................ 113
6.6.4 Check the hydraulic oil level .................................................................................................... 113
6.6.5 Check, clean the water separator............................................................................................ 114
6.7 Every 250 operating hours....................................................................................................... 116
6.7.1 Check the tire pressure............................................................................................................ 116
6.7.2 Clean the cooling fins on engine and hydraulic oil cooler........................................................ 116
6.7.3 Check the oil level in the drive axle.......................................................................................... 117
6.7.4 Check the oil level in the wheel hubs....................................................................................... 118
6.7.5 Check the oil level in the axle reduction gear........................................................................... 119
6.7.6 Check the oil level in the drum reduction gear......................................................................... 119
6.7.7 Check the oil level in the vibration bearings............................................................................. 120
6.7.8 Check the parking brake.......................................................................................................... 120
6.7.9 Checking, replacing the refrigerant compressor V-beltOptional equipment ...................................... 122
6.8 Every 500 operating hours....................................................................................................... 124
6.8.1 Changing engine oil and oil filter cartridge............................................................................... 124
6.8.2 Checking, tensioning, replacing the V-belt............................................................................... 125
6.8.3 Draining the fuel tank sludge.................................................................................................... 128
6.8.4 Battery service......................................................................................................................... 129
6.8.5 Service the air conditioningOptional equipment ................................................................................ 130
6.8.6 Cleaning the circulation air filter for the heatingOptional equipment ................................................. 134
6.9 Every 1000 operating hours..................................................................................................... 135
6.9.1 Check, adjust the valve clearance........................................................................................... 135
6.9.2 Change the fuel filter cartridge................................................................................................. 137
6.9.3 Change the fuel pre-filter cartridge........................................................................................... 138
6.9.4 Check the engine mounts........................................................................................................ 140
6.9.5 Change the oil in the vibration bearings................................................................................... 140
6.9.6 Changing the oil in the drum reduction gear............................................................................ 141
6.9.7 Changing the oil in the drive axle............................................................................................. 142
6.9.8 Changing the oil in the wheel hubs.......................................................................................... 144
6.9.9 Changing the oil in the axle reduction gear.............................................................................. 145
6.9.10 Retighten the fastening of the axle on the frame................................................................... 145
6.9.11 Tightening the wheel nuts...................................................................................................... 146
6.9.12 Checking the ROPS............................................................................................................... 146
6.9.13 Check the travel control......................................................................................................... 147
6.10 Every 2000 operating hours................................................................................................... 148
6.10.1 Changing hydraulic oil and breather filter .............................................................................. 148
6.10.2 Changing the hydraulic oil filter ............................................................................................. 149
6.10.3 Changing the coolant............................................................................................................. 150

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 Table of contents

6.11 Every 3000 operating hours................................................................................................... 153

6.11.1 Checking the injection valves................................................................................................. 153
6.12 As required.............................................................................................................................. 154
6.12.1 Air filter maintenance............................................................................................................. 154
6.12.2 Retightening the padfoot shell................................................................................................ 157
6.12.3 Adjusting the scrapers............................................................................................................ 157
6.12.4 Clean the machine................................................................................................................. 158
6.12.5 Changing the tires.................................................................................................................. 158
6.12.6 Change the fresh air filter in the cabin................................................................................... 159
6.12.7 Fill the provision tank for the windscreen washer systemOptional equipment ................................ 159
6.12.8 Tightening torques................................................................................................................. 160
6.12.9 Engine conservation .............................................................................................................. 160
7 Trouble shooting............................................................................................................................... 161
7.1 General notes............................................................................................................................ 162
7.2 Starting the engine with jump leads........................................................................................ 163
7.3 Reading out faults BVC/BTM05............................................................................................... 164
7.4 Engine........................................................................................................................................ 166
8 Cab assembly before initial start-up............................................................................................... 169
8.1 Preparations.............................................................................................................................. 171
8.2 Cabin assembly......................................................................................................................... 173
8.3 Final function tests and checks............................................................................................... 181
9 Disposal............................................................................................................................................. 183
9.1 Final shut-down of machine..................................................................................................... 184

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 Table of contents

6 BW 216 D-40 / BW 216 PD-40

 Foreword

1 Foreword

BW 216 D-40 / BW 216 PD-40 7

 Foreword

BOMAG manufactures machine for earth, asphalt and refuse

compaction, stabilizers/recyclers as well as milling machine
and finishers.
BOMAG’s vast experience in connection with state-of-the-art
production and testing methods, such as lifetime tests of all
important components and highest quality demands guar-
antee maximum reliability of your machine.
This manual comprises:
n Safety regulations
n Operating instructions
n maintenance instructions
n Trouble shooting
Using these instructions will
n help you to become familiar with the machine.
n avoid malfunctions caused by unprofessional operation.
Compliance with the maintenance instructions will
n enhance the reliability of the machine on construction sites,
n prolong the lifetime of the machine,
n reduce repair costs and downtimes.
BOMAG will not assume liability for the function of the machine
n if it is handled in a way not complying with the usual modes of
use,
n if it is used for purposes other than those mentioned in these
instructions.
No warranty claims can be lodged in case of damage resulting
from
n operating errors,
n insufficient maintenance and
n wrong fuels and lubricants.
Please note!
This manual was written for operators and maintenance personnel
on construction sites.
Always keep this manual close at hand, e.g. in the tool compart-
ment of the machine or in a specially provided container. These
operating and maintenance instructions are part of the machine.
You should only operate the machine after you have been
instructed and in compliance with these instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil Engineering Liability
Association ”Safety Rules for the Operation of Road Rollers and
Soil Compactors” and all relevant accident prevention regulations.
For your own personal safety you should only use original
spare parts from BOMAG.
For your machine BOMAG offers service kits to make mainte-
nance easier.

8 BW 216 D-40 / BW 216 PD-40

 Foreword

In the course of technical development we reserve the right

for technical modifications without prior notification.
These operating and maintenance instructions are also available in
other languages.
Apart from that, the spare parts catalogue is available from your
BOMAG dealer against the serial number of your machine.
Your BOMAG dealer will also supply you with information about the
correct use of our machines in soil and asphalt construction.
The above notes do not constitute an extension of the warranty
and liability conditions specified in the general terms of business of
BOMAG.
We wish you successful work with your BOMAG machine.
BOMAG GmbH
Copyright by BOMAG

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

Supplement the above data together with the commis-

sioning protocol.
During commissioning our organisation will instruct you
in the operation and maintenance of the machine.
Please observe strictly the safety regulations and all
notes on risks and dangers!

Fig. 1

BW 216 D-40 / BW 216 PD-40 9

 Foreword

Fig. 2

Fig. 3

10 BW 216 D-40 / BW 216 PD-40

 Technical data

2 Technical data

BW 216 D-40 / BW 216 PD-40 11

 Technical data

Fig. 4

BW 216 D-40 A B D H H2 K L O1/2 S W

Dimensions in mm 2960 2300 1500 2268 2985 490 5930 85 35 2130
Dimensions in inch 117 91 59 89 118 19.2 233 3.3 1.4 84

Weights
Max. operating weight 17100 kg 37699 lbs
Operating weight (CECE) with ROPS-cabin 15200 kg 33510 lbs
Axle load, drum (CECE) 10200 kg 22487 lbs
Axle load, wheels (CECE) 5000 kg 11023 lbs
Static linear load 47.9 kg/cm 268.2 pli

Travel characteristics
Travel speed (1) 0 – 4 km/h 0 – 2.5 (machine type
dependent)
Travel speed (2) 0 – 5 km/h 0 – 3.1 (machine type
dependent)
Travel speed (3) 0 – 7 km/h 0 – 3.7 (machine type
dependent)
Travel speed (4) 0 – 11 km/h 0 – 7 (machine type
dependent)
Max. gradability without/with vibration (soil 48% / 45% 48% / 45%
dependent)

12 BW 216 D-40 / BW 216 PD-40

 Technical data

Drive
Engine manufacturer Deutz Deutz
Type BF4M 1013 C BF4M 1013 C
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 3046 114 kW 114 kW
Rated power SAE J 1995 153 hp 153 hp
Rated speed 2200 min-1 2200 rpm
Electrical equipment 12 V 12 V
Drive system hydrostatic hydrostatic
Permissible ambient temperatures -20 ... +50 °C -4 ... +122 °F

Brakes
Service brake hydrostatic hydrostatic
Parking brake hydro-mechanical hydro-mechanical

Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrostatic hydrostatic
Steering angle ± 35 ° ± 35 °
Oscillation angle ± 12 ° ± 12 °
Inner track radius 3494 mm 138 in

Vibration
Drive system hydrostatic hydrostatic
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.80/0.90 mm 0,071/0,035 in
Centrifugal force (1/2) 275/202 61822/ 45411 lbf

Tires
Tire size 23.1-26 12PR 23.1-26 12PR
Air pressure, nominal value 1.4 bar 20 psi
Air pressure, span 0.8 – 1.4 bar 12 – 20 psi

BW 216 D-40 / BW 216 PD-40 13

 Technical data

Filling capacities
Fuel (diesel) 250 l 66 gal us

14 BW 216 D-40 / BW 216 PD-40

 Technical data

Fig. 5

BW 216 PD-40 A B D H H2 K L O1/2 S W

Dimensions in mm 2960 2300 1480 2268 2985 490 5930 85 25 2130
Dimensions in inch 117 91 58 89 118 19.2 233 3.3 1.0 84

Weights
Max. operating weight 16400 kg 36156 lbs
Operating weight (CECE) with ROPS-cabin 15700 kg 34613 lbs
Axle load, drum (CECE) 10700 kg 23589 lbs
Axle load, wheels (CECE) 5000 kg 11023 lbs

Travel characteristics
Travel speed (1) 0 – 4 km/h 0 – 2.5 (machine type
dependent)
Travel speed (2) 0 – 5 km/h 0 – 3.1 (machine type
dependent)
Travel speed (3) 0 – 7 km/h 0 – 3.7 (machine type
dependent)
Travel speed (4) 0 – 11 km/h 0 – 7 (machine type
dependent)
Max. gradability without/with vibration (soil 50% / 47% 50% / 47%
dependent)

Drive

BW 216 D-40 / BW 216 PD-40 15

 Technical data

Engine manufacturer Deutz Deutz

Type BF4M 1013 C BF4M 1013 C
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 3046 114 kW 114 kW
Rated power SAE J 1995 153 hp 153 hp
Rated speed 2200 min-1 2200 rpm
Electrical equipment 12 V 12 V
Drive system hydrostatic hydrostatic
Permissible ambient temperatures -20 ... +50 °C -4 ... +122 °F

Brakes
Service brake hydrostatic hydrostatic
Parking brake hydro-mechanical hydro-mechanical

Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrostatic hydrostatic
Steering angle ± 35 ° ± 35 °
Oscillation angle ± 12 ° ± 12 °
Inner track radius 3494 mm 138 in

Vibration
Drive system hydrostatic hydrostatic
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.70/0.86 mm 0,067/0,034 in
Centrifugal force (1/2) 275/202 61822/ 45411 lbf

Drums and tires

Tire size 23.1-26 12PR 23.1-26 12PR
Air pressure, nominal value 1.4 bar 20 psi
Air pressure, span 0.8 – 1.4 bar 12 – 20 psi
Padfeet, quantity 150 150
Height of padfeet 100 100

16 BW 216 D-40 / BW 216 PD-40

 Technical data

Area of one padfoot 137 cm2 21.2 in2

Filling capacities
Fuel (diesel) 250 l 66 gal us

BW 216 D-40 / BW 216 PD-40 17

 Technical data

18 BW 216 D-40 / BW 216 PD-40

 Safety regulations

3 Safety regulations

BW 216 D-40 / BW 216 PD-40 19

 Safety regulations

General This BOMAG machine has been built in compliance with the
latest technical standard and complies with the applicable
regulations and technical rules. However, dangers for persons
and property may arise from this machine, if:
n it is used for purposes other than the ones it is intended for,
n it is operated by untrained personnel,
n it is changed or converted in an unprofessional way,
n the safety instructions are not observed.
Each person involved in the operation, maintenance and
repair of the machine must therefore read and comply with
these safety regulations. If necessary, this must be confirmed
by obtaining the signature of the customer.
Furthermore, the following obviously also applies:
n applicable accident prevention instructions,
n generally accepted safety and road traffic regulations,
n country specific safety regulations. It is the duty of the operator
to be acquainted with these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.

Intended use This machine must only be used for:

n medium to heavy compaction work in earth construction (road
sub-bases)
n probably compaction of bituminous material, e.g. road surface
layers.

Unintended use Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by intended use is the sole responsibility of the
customer or driver/operator, the manufacturer cannot be made
liable.
Examples for unintended use are:
n work with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
n driving on unstable subbases or too small contact area (danger
of tipping over)
n using the machine for towing
n use to pull down walls or demolish buildings
Transporting persons, except the machine driver, is prohibited.
Starting and operation of the machine in explosive environments
and in underground mining is prohibited.

Remaining dangers, remaining Despite careful work and compliance with standards and regula-
risks tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.

20 BW 216 D-40 / BW 216 PD-40

 Safety regulations

Both the machine as well as all other system components comply

with the currently valid safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even when using the machine
for the purpose it is intended for and following all information given
in the operating instructions.
A remaining risk can also not be excluded beyond the actual
danger zone of the machine. Persons remaining in this area must
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
All persons remaining ion the area of the machine must be
informed about the dangers that arise from the operation of the
machine.

Regular safety inspections Have the machine inspected by an expert (capable person) as
required for the conditiosn the machine is working under, but at
least once every year.

Who is allowed to operate the Only trained, instructed and authorized persons of at least 18 years
machine? of age are permitted to drive and operate this machine. For opera-
tion of the machine the responsibilities must be clearly specified
and complied with.
Persons under the influence of alcohol, medicine or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.

Changes and conversions to the Unauthorized changes to the machine are prohibited for safety rea-
machine sons.
Original parts and accessories have been specially designed for
this machine.
We wish to make explicitly clear that we have not tested or
approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse
effect on the active and/or passive safety.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.

Damage, deficiencies, misuse of Machines which are not safe to operate or in traffic must be imme-
safety installations diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.

BW 216 D-40 / BW 216 PD-40 21

 Safety regulations

Notes on safety in the operating

and maintenance instructions: WARNING!
Paragraphs marked like this highlight possible dangers
for persons.

NOTICE!
Paragraphs marked like this highlight possible dangers
for machines or parts of the machine.

Paragraphs marked like this contain technical informa-

tion for the optimal economical use of the machine.

ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubricants
as well as replacement parts.
Observe the regulations for the protection of the envi-
ronment.

Loading the machine Use only strong and stable loading ramps. The ramp inclination
must be lower than the gradability of the machine.
Secure the machine against turning over or slipping off.
Secure the machine on the transport vehicle against rolling off,
slipping and turning over.
Persons are highly endangered if
n they step or stand under loads being lifted
n they remain in the drive range of the machine during a demon-
stration or during loading.
The machine must not swing about when lifted off the ground.
Use only safe lifting gear of sufficient load bearing capacity.
Attach the lifting gear only to the specified lifting points.

Towing the machine You should generally use a tow bar.

Max. towing speed 1 km/h (1.6 mph), max. towing distance 500 m
(1640 ft.).
Before releasing the multi-disc brakes secure the machine properly
against unintended rolling.

22 BW 216 D-40 / BW 216 PD-40

 Safety regulations

Checking the Roll Over Protective

Structure (ROPS) On machines with cab the ROPS is an integral part of
the cab.

The frame of the machine must not be warped, bent or cracked in

the area of the ROPS fastening.
The ROPS must not show any rust, damage, hairline cracks or
open fractures.
The actual weight of the machine must not exceed the testing
weight of the ROPS.
The ROPS must not rattle about when driving. This indicates that it
is not properly fastened. All bolted connections must comply with
the specifications and should be absolutely tight (observe the tight-
ening torques). Screw and nuts must not be damaged, bent or
deformed.
With the cab assembled check also the state of the cabin mounts
(rubber elements and screws).
No accessories may be welded or bolted on and no additional
holes must be drilled without the consent of the manufacturer,
since this will impair the strength of the unit.
The ROPS must therefore also not be straightened or repaired if it
is damaged.
A defect ROPS must generally be replaced with an original spare
part in close coordination with the manufacturer.

Starting the machine Before starting

Operation of the machine is only permitted when sitting in the oper-
ator's seat.
Use only machines which have been properly serviced at regular
intervals.
Become acquainted with the equipment, the control elements, the
working mode of the machine and the area you will be working in.
Use your personal protective outfit (hard hat, safety boots etc.).
Check before mounting the machine if:
n there are persons or obstructions beside or under the machine
n the machine is free of any oily and combustible material
n all handrails, steps and platforms are free of grease, oils, fuels,
dirt, snow and ice
n the engine compartment hood is closed and locked
To climb onto the machine use steps and handrails.
Check before starting, whether:
n the machine shows any obvious defects
n all protective devices are properly secured in their place
n steering, brakes, control elements, lighting and warning horn
are in order
n the seat is correctly adjusted
n the mirrors (if available) are clean and correctly adjusted.

BW 216 D-40 / BW 216 PD-40 23

 Safety regulations

Do not start the machine if any gauges, control lights or controls

are defective.
Do not take any loose objects with you or fasten them to the
machine.
On machines with ROPS you should always wear your seat belt!
Starting
Start and operate the machine only from the operator's seat
For starting set all control levers to "neutral position".
Do not use any starting aids such as Start Pilot or ether.
After starting check all gauges.
Starting with jump leads
Connect plus with plus and minus with minus (ground cable) -
always connect the ground cable last and disconnect it first! Wrong
connections may cause severe damage in the electric system.
Never start the engine by bridging the electrical connections on the
starter, because the machine would probably start to move imme-
diately.
Starting in closed rooms
Exhaust gases are toxic! Always ensure an adequate supply of
fresh air when starting in closed rooms!

Driving the machine Persons in the danger area

If a machine has turned over and the cabin door is jammed, the
right hand cabin window can be used as an escape door.
Before taking up work, also after breaks, you should always con-
vince yourself that the danger zone is free of persons or obstruc-
tions, especially when driving in reverse.
Give warning signals, if necessary. Stop work immediately if per-
sons remain in the danger zone, despite the warning.
Do not step or stand in the articulation area of the machine when
the engine is running. Danger of squashing!
Driving
Always wear the seat belt when driving.
Do not drive on bases with insufficient load bearing capacity.
Do not drive on ice and snow.
In events of emergency and in case of danger actuate the emer-
gency stop switch immediately. Do not use the emergency stop
switch as service brake.
Restart the machine only after the danger that caused the actua-
tion of the emergency stop switch has been eliminated.
If the machine has contacted high-voltage power lines:
n do not leave the operator’s stand,
n warn others from coming close to or touching the machine,

24 BW 216 D-40 / BW 216 PD-40

 Safety regulations

n if possible drive the machine out of the danger zone,

n have the power switched off.
Operate the machine only from the operator’s stand.
Keep the cabin doors closed.
Do not adjust the driver’s seat while driving.
Do not climb onto or off the machine while the machine is driving.
Change the travel direction only at standstill.
Do not use the machine to transport persons.
In case of unusual noises and development of smoke perform
trouble shooting and have the fault corrected.
Always keep a sufficient distance to excavation walls and embank-
ments and do not use working methods that could impair the sta-
bility of the machine.
Do not work with vibration on hard concrete, cured bitumen layers
or extremely frozen ground.
Always keep a sufficient distance when passing through subways,
under bridges, tunnels, electric power lines etc.
Driving on inclinations and slopes
Do not drive on gradients exceeding the maximum gradability of
the machine.
On slopes drive extremely careful and always directly up or down
the slope. Change to a lower gear before starting to drive.
Wet and loose soils considerably reduce the ground adhesion of
the machine on inclinations and slopes. Higher risk of accident!
Inclination
The tipping angle was measured in static condition on level, hard
ground with the machine stopped, no steering and without vibra-
tion.
With loose soil, acceleration/deceleration, running vibration,
steering or attached accessoriies the tipping angle may be consid-
erably lower.
Driving across slopes should therefore be strictly avoided, because
of the high risk of tipping over and the related risk of severe or
even fatal accidents.
You should therefore always drive straight up or down a slope.
Fig. 6 Behaviour in traffic
Match the speed to the working conditions. Do not make extreme
steering movements when driving with high speed, danger of tip-
ping over!
Always give way to loaded transport vehicles.
Switch the lights on if the visibility is poor.
Keep away from edges and embankments.
Checking the effect of vibration

BW 216 D-40 / BW 216 PD-40 25

 Safety regulations

When compacting with vibration you must check the effect on

nearby buildings and underground supply lines (gas, water,
sewage, electric power), if necessary stop compaction work with
vibration.
Do not activate the vibration on hard (frozen, concrete) ground.
Danger of bearing damage!

Parking the machine Park the machine on horizontal, level, firm ground.
Before leaving the machine:
n Straighten the articulated joint to provide easier access to the
machine.
n return the control lever to neutral position
n apply the parking brake
n shut the engine down, pull the ignition key off
n close the cabin
n secure the machine against unintended use.
Do not jump off the machine, but use hand grips and access steps.
Mark machines, which could be in the way, with a clearly visible
sign.
Parking on slopes and inclinations
Secure the machine against rolling, place metal chocks in front of
and behind the wheels. The wheel chocks must be provided by the
operating company.

Refuelling Do not inhale any fuel fumes.

Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Monitor the entire refuelling process.
Do not spill any fuel. Catch running out fuel, do not let it seep into
the ground.
Wipe off spilled fuel. Keep dirt and water away from the fuel.
A leaking fuel tank can cause an explosion. Ensure tight fit of the
fuel tank cover, if necessary replace immediately.
Fire protection measures
Familiarise yourself with the location and the operation of fire
fighting equipment. Observe all fire reporting and fire fighting possi-
bilities.

Maintenance work Comply with the maintenance work described in these operating
and maintenance instructions, including the information concerning
the replacement of parts.
Maintenance work must only be performed by qualified and author-
ized persons.

26 BW 216 D-40 / BW 216 PD-40

 Safety regulations

Support the engine hood for all maintenance and repair work in the
engine compartment.
Do not touch hot engine parts.
For overhead maintenance and assembly work use the access
steps and working platforms provided or other secure means. Do
not use machine parts as access steps.
Keep unauthorized persons away from the machine.
Do not perform maintenance work while the machine is driving or
the engine is running.
Park the machine on horizontal, level, firm ground.
Remove the key from the ignition switch.
Secure the articulated joint with the articulation lock.
Work on hydraulic lines
Relieve hydraulic pressures before working on hydraulic lines.
Hydraulic oil escaping under pressure can penetrate the skin and
cause severe injury. When being injured by hydraulic oil consult a
medical doctor immediately, as otherwise this may cause severe
infections.
Do not step in front of or behind the drums/wheels when per-
forming adjustment work in the hydraulic system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature – danger of
scalding!
Any hydraulic oil must be caught and disposed of in an environ-
mentally friendly manner.
Always catch and dispose of hydraulic oils separately.
Do not start the engine after draining the hydraulic oil.
Once all work is completed (with the system still depressurized!)
check all connections and fittings for leaks.
Changing hydraulic hoses
Hydraulic hoses must not be mixed up by mistake.
Hydraulic hoses must be visually inspected at regular intervals.
Hydraulic hoses must be immediately replaced if:
n the outer layer is damaged down to the inlay (e.g. chafing,
cuts, cracks),
n embrittlement of the outer layer (formation of cracks in the
hose material)
n the hose shows deformations in pressurized and depressurized
condition, which do not comply with the genuine shape of the
hydraulic hose,
n the hose shows deformations in bends, e.g. squeezing, buck-
ling, layer separation, formation of blisters,
n parts of the hose are leaking,
n hoses are not correctly installed,
n the hydraulic hose has separated from the fitting,

BW 216 D-40 / BW 216 PD-40 27

 Safety regulations

n the fitting shows corrosion that impairs both function and

strength,
n fittings are damaged or deformed, whereby the function and
strength of the hose - hose connection is impaired.
n the permissible storage and usage period is exceeded.
Only genuine BOMAG replacement hydraulic hoses ensure that
the correct hose type (pressure range) is used at the right location.
Working on the engine
Do not work on the fuel system while the engine is running -
danger to life due to high pressures!
n Wait another minute after the engine has stopped.
n Keep out of the danger zone during the initial test rung.
n In case of leaks return to the workshop immediately.
n Make sure that the engine cannot be started unintentionally
during service and repair work.
Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, catch running out oil and dispose of environ-
mentally.
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of environmentally.
Do not leave any tools or other objects, that could cause damage,
in the engine compartment.
The settings for idle speed and highest speed must not be
changed, since this would affect the exhaust gas values and cause
damage to engine and power train.
Turbo chargers work with high speeds and high temperatures.
Keep hands, tools and materials away from the intake and outlet
openings of the turbo charger and do not touch any hot surfaces.
Check and change coolant only when the engine is cold.
Catch coolant and dispose of environmentally.
Working on electric parts of the machine
Before starting to work on electric parts of the machine disconnect
the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not bridge
fuses - fire hazard!
Disconnect battery and plugs from the control units before starting
welding work on the machine.
Working on the battery
When working on the battery do not smoke, do not use open fire!
Do not let acid come in contact with hands or clothes! When
injured by acid flush off with clear water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must not come in
contact with the battery poles – danger of short circuit and burning!
When recharging non-serviceable batteries remove all plugs, to
avoid the accumulation of explosive gases.

28 BW 216 D-40 / BW 216 PD-40

 Safety regulations

Observe the applicable instructions when starting with an auxiliary

battery.
Dispose of old batteries according to regulations.
Switch off the charging current before removing the charging
clamps.
Ensure sufficient ventilation, especially if the battery is to be
charged in a closed room.
Working on the fuel system
Do not inhale any fuel fumes.
Avoid open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the ground and dis-
pose off environmentally.
Working on wheels and tires
Explosion-like bursting of tires or parts of tires and rims can cause
most severe or even deadly injuries.
Install the tires only if are sufficiently experienced and with the right
tools at hand. If necessary have the tires assembled in a qualified
workshop.
Always ensure the correct tire pressure and do not exceed the
specified maximum pressure.
Check tires and wheels every day for specified pressure, cuts,
bulges, damaged rims, missing wheel studs or nuts. Do not drive
with damaged tires or wheels.
Ant-sticking emulsions for tires must only consist of water and anti-
sticking agent, in a concentration in accordance with the specifica-
tions of the manufacturer of the anti-sticking agent. Observe appli-
cable environmental regulations.
Working on the air conditioning
Faults on the air conditioning should only be remedied by profes-
sional personnel.
According to the regulation for pressure reservoirs all pressure res-
ervoirs must be repeatedly inspected by a specialist.
In connection with this inspection the drier/collector unit must be
visually examined twice every year. During these inspections spe-
cial attention must be paid to corrosion and mechanical damage.
Do not perform welding work in the vicinity of the air conditioning.
Danger of explosion!
Do not clean the condenser in the air conditioning system with a
hot water jet. Danger of explosion!
Do not release refrigerant into the atmosphere, but dispose of envi-
ronmentally.
Cleaning work
Do not perform cleaning work while the motor is running.
Do not use gasoline or other easily inflammable substances for
cleaning.

BW 216 D-40 / BW 216 PD-40 29

 Safety regulations

When cleaning with steam cleaning equipment do not subject elec-

trical parts and insulation material to the direct jet of water, or cover
it beforehand.
n Do not guide the water jet into the exhaust and into the air
filter.
After maintenance work
After all maintenance work is completed reinstall all guards and
safety installations.

Repair Mark a defective machine by attaching a warning tag to the

steering wheel.
Repair work must only be performed by qualified and authorized
persons. Use our repair instructions for this work.
Exhaust gases are highly dangerous! Always ensure an adequate
supply of fresh air when starting in closed rooms!
Do not work on the fuel system while the engine is running -
danger to life!
The system is under high pressure! Keep away from leakages in
the high pressure system, because fuel squirting out may cause
severe injury. After shutting down the engine wait for another
minute, until the pressure has dropped to a permissible level. In
case of leakages you should contact the Service Department of the
engine manufacturer and refrain from starting the engine.
Test
The safety of compaction equipment must be checked by a spe-
cialist as required in dependence on the application and the oper-
ating conditions, however at least once every year.

Information and safety stickers/ Keep stickers/decals complete (see spare parts catalogue) and
decals on the machine fully legible and observe their meaning.
Replace damaged or illegible stickers/decals immediately.

30 BW 216 D-40 / BW 216 PD-40

 Safety regulations

Fig. 7: Stickers and decals

1 Warning sticker "Danger of crushing"
2 Information sticker "Vehicle voltage 12 V"
3 Information sticker "Hydraulic oil"
4 Information sticker "Diesel"
5 Operation sticker "Hood handle"
6 Information sticker "Lifting point"
7 Information sticker "Lashing point"
8 Information sticker "Engine oil drain"
9 Prohibition sticker "High pressure cleaner"
10 Information sticker "Hydraulic oil and coolant drains"

BW 216 D-40 / BW 216 PD-40 31

 Safety regulations

Instruction sticker - Always wear your seat belt

Fig. 8

Information sticker - Emergency exitOptional equipment

Fig. 9

Information sticker "Bio Hydraulic Oil"Optional equipment

Fig. 10

Information sticker "Panolin 46"Optional equipment

Fig. 11

32 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

4 Indicators and Controls

BW 216 D-40 / BW 216 PD-40 33

 Indicators and Controls

Fig. 12

34 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

1 Start switch
2 Instrument cluster
3 Rotary switch for cabin fan1
4 Rotary switch for air conditioning1
5 Vent for heating and ventilation, driver
6 Vent for heating and ventilation, footwell
7 Push button vibration
8 Travel lever
9 Rotary switch for vibration, amplitude selection
10 Rotary switch for travel ranges
11 Emergency stop push button
12 Push button for warning horn
13 Rotary momentary contact switch for engine speed
14 Rotary switch direction indicators1
15 Rotary switch for hazard light system1
16 Rotary switch for light system1
17 Rotary switch for working lights1
18 Rotary switch for cabin heater1
1 - Optional equipment

4.1 General notes

If you are not yet familiar with the control and display elements on
this machine you should read this section thoroughly before
starting any operation on the machine. Here all functions are
described in detail.
The section "Operation" contains only brief descriptions of the indi-
vidual control steps.

BW 216 D-40 / BW 216 PD-40 35

 Indicators and Controls

4.2 Description of indicators and control elements

n Start switch

Position "P", "0" Ignition off, key can be pulled out

Position "I", "II" Ignition on, all control and warning
lights in the instrument cluster light up
for 3 seconds (test function). The oil
pressure warning light flashes, charge
control light and parking brake
warning light stay on. The preheating
control light lights up in case of low
Fig. 13
temperatures.

The engine can only be started if both travel levers are

in “neutral”.
The starter switch is designed with a re-start lock. For
a new starting attempt the ignition key must first be
turned back to position "0".

Position "START" Turn further against spring pressure,

the engine starts, turn the ignition key
back to position "I" once the engine
has started.

NOTICE!
Run the engine warm for a short while before starting
work. Do not rev up a cold engine to high idle speed/
full load speed.
Do not shut down the engine all of a sudden from full
load speed, but let it idle for about 2 minutes.

36 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

n Instrument cluster

With the ignition switch in position "I" all control and

warning lights are switched on for a moment.

a yellow Water in fuel warning light Lights

when the water content in the fuel pre-
cleaner reaches the sensor contacts.
Warning buzzer sounds. The engine is
shut down after 2 seconds. Clean the
water separator.
b yellow Preheating control light Lights when
Fig. 14 temperatures are low (pre-heating for
starting)
c not used
d red Engine oil pressure warning light
Flashes when the engine oil pressure
is too low, the warning buzzer sounds,
the engine is shut down after 10 sec-
onds. Check engine oil level, repair
the engine if necessary.
e red Coolant level warning lamp Flashes if
the coolant level is too low, the
warning buzzer sounds, the engine is
shut down after 10 seconds. Check
coolant level. Check cooling system
for leaks, repair if necessary.
f yellow Charge control light Lights if the bat-
tery is not being charged. Check the
V-belt, if necessary repair the gener-
ator.
g not used
h red Warning light engine overheating
Flashes if the engine overheats, the
warning buzzer sounds, the engine is
shut down after approx. 2 minutes.
Clean engine oil cooler, repair the
engine is necessary.
i not used
j green Indicator control light
k red Parking brake warning light Lights
when the parking brake is applied

BW 216 D-40 / BW 216 PD-40 37

 Indicators and Controls

l Operating hour meter Counts the

operating hours while the engine is
running. All maintenance work must
be performed according to the indi-
cated operating hours.
m Fuel level gaugeOptional equipment

n Rotary switch for cabin fan

Position 0 Cabin fan switched off.

Position 1, 2 and 3 Fan stages of different strengths

Fig. 15

n Rotary switch for air conditioning systemOptional equipment

Only switch the air conditioning system on when the

rotary switch for the cabin fan in position 1, 2 or 3.

Position 0 Air conditioning switched off.

Fig. 16
Position min. and max. Air conditioning control segment

n Vent for heating and ventilation, driver

n Vent for heating and ventilation, footwell

n Push button vibration

. Switching the vibration on

press again Switching the vibration off

Fig. 17

38 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

n Travel lever

Position "middle" Braking position service brake

Position "middle, right" Parking brake position, to start the
engine
Position "I" Forward travel
Position "II" Backwards travel

Fig. 18
If the engine speed drops under load when driving on
steep gradients, take the travel lever slightly back
towards neutral. This relieves the hydraulic system and
reduces the load on the diesel engine.

n Rotary switch for vibration, amplitude selection

Position left low amplitude, high frequency

Position "middle" Vibration off
Position right high amplitude, low frequency

Fig. 19

n Rotary switch for speed ranges without ASC

Position "turtle" Working speed range on level ground

Position "Drum" if the drum starts to slip
Position "Wheels" if the wheels are slipping
Position "rabbit" Transport speed range, e.g. to drive to
the work location

Fig. 20

BW 216 D-40 / BW 216 PD-40 39

 Indicators and Controls

n Emergency stop push button

WARNING!
Danger of accident!
Use only in events of emergency during operation.
Do not use as parking brake.
Restart the machine only after the danger that caused
the actuation of the emergency stop switch has been
eliminated.
Fig. 21 The machine is braked immediately, the engine is shut
down.

actuate press the button completely down, it

automatically locks in fully pressed
position.
switch off/unlock Turn button clockwise. Restart the
engine.

n Push button for warning horn

Fig. 22

n Rotary momentary contact switch for engine speed

Electric engine speed adjustment

Momentary contact posi- Idle speed position

tion left

Normal position for engine start.

Fig. 23

Momentary contact posi- Full throttle position, operating posi-

tion right tion for driving and vibration

40 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

NOTICE!
Always drive and vibrate with max. engine speed! Con-
trol the travel speed with the travel lever.

n Rotary switch for direction indicatorsOptional equipment

Position "middle" Direction indicators disabled

Position "left or right" Front and rear direction indicators on
the corresponding side are flashing.
Indicator control light in instrument
cluster flashes.

Fig. 24

n Rotary switch for hazard light system Optional equipment

Position "left" Hazard light system switched off

Position "right" Hazard light system switched on. All
flashing lamps and the flashing control
light in the instrument cluster are
flashing.

Fig. 25

n Rotary switch for lightingOptional equipment

Position Left Light off

Position "middle" Sidelights on, with ignition switch in
position "I" or "P"
Position Right Travel light on with ignition switch in
position "I"

Fig. 26

BW 216 D-40 / BW 216 PD-40 41

 Indicators and Controls

n Rotary switch for working lightsOptional equipment

Position "left" Light off

Position "right" Working lights on, with ignition switch
in position "I".

Fig. 27

n Rotary switch for cabin heater

Position "0" Cabin heater switched off

Position red range Temperature selection for cabin

heating

Fig. 28

n 2-pole socket
Current only with the ignition switch in position "I" or when the
engine is running.

Fig. 29

n Fuses in electric junction box

WARNING!
Fire hazard!
Do not use fuses with higher ampere ratings and do
not bridge fuses.

(15) 30A (F13) Start switch

Fig. 30
(16) 5A (F68) Electronic immobilizer
(17) 20A (F105) Engine speed
(18) 15A (F11) Front head lights

42 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

(19) 15A (F07) Hazard light

(21) 15A (F22) Working headlights, rear
(22) 15A (F19) Working headlights, rear
(23) 15A (F09) Parking and tail light, left
(24) 15A (F10) Parking and tail light, right
(25) 15A (F08) Direction indicators
(26) 10A (F18) Pre-fuse for working head lights
(27) 15A (F14) Engine solenoid
(28) 10A (F23) Warning horn
(29) 10A (F25) solenoid valve for driving and
braking
(30) 15A (F39) Main fuse for cabin
(31) 10A (F24) Instruments
(32) 15A (F03) Vibration
(33) 10A (F148) Control MESX, potential 15
(34) 10A (F84) Control, contact 54
(35) 15A (F146) Control MESX, potential 30
(37) 25A (F124) Fuel pre-heating

(80) 5A (F150) GPS Receiver

Fig. 31

n Main fuse for battery

125A (F00) Main fuse

The main fuse is located in the battery compartment

Fig. 32

BW 216 D-40 / BW 216 PD-40 43

 Indicators and Controls

n Toggle switch, cabin

a = toggle switch for flashing beacon
b = toggle switch for front windscreen wiper/washer

up windscreen wiper moves to end posi-

tion and stops.

Fig. 33 down Switches on front windscreen wiping.

Push button Front windscreen is sprayed during

wiping.

c = toggle switch for rear windscreen wiper/washer

up windscreen wiper moves to end posi-

tion and stops.

down Switches on wiping of rear wind-

screen.

Push button Rear windscreen is sprayed during

wiping.

d = toggle switch for rear windscreen heating

WARNING!
Fire hazard!
Do not use fuses with higher ampere ratings and do
not bridge fuses.

(1) 15A (F43) Wiper/washer, rear

(2) 15A (F44) Wiper/washer, front
Fig. 34
(3) 10A (F130) Night light
(4) 25A (F31) Cabin ventilator
(5) 10A (F41) Flashing beacon
(6) 15A (F144) Cab socket

44 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

(7) 15A (F143) Rear windscreen heating

(8) 10A (F42) Cab lights

n Cabin light
i = reading and dashboard light
j = toggle switch for reading and dashboard light
k = toggle switch for cabin light
l = cabin light

Fig. 35

n Air filter maintenance indicator

With the maintenance indicator the actual contamination level of
the air filter can be checked even when the engine is stopped.
Filter service is only required when the yellow piston has reached
the red writing "Service".
After completion of the filter service reset the indicator back to
"Zero" by pressing the button.

Fig. 36

n Service indicator hydraulic oil filter

Fig. 37

Check the service indicator at operating temperature and

with the engine running.

If necessary press the pin in.

Pin remains pressed in hydraulic oil filter element o.k.

Pin pops out replace the hydraulic oil filter element

BW 216 D-40 / BW 216 PD-40 45

 Indicators and Controls

n Fuel gauge
shows the fuel level in the fuel tank.

Fig. 38

n SpeedometerOptional equipment
Shows the travel speed of the machine.

outer scale km/h

inner scale mph

Fig. 39

n Tachometer for diesel engineOptional equipment

shows the rotational speed of the diesel engine.
Scale value x 100 = revolutions per minute

Fig. 40

n Vibration frequency displayOptional equipment

Shows the vibration frequency.

outer scale Frequency in min-1 x 100

inner scale Frequency in Hz

Fig. 41

46 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

n VoltmeterOptional equipment
Shows the current on-board voltage in Volt.

Fig. 42

n EVIBdisplayOptional equipment
is a compaction measuring unit for continuous display of the load
bearing characteristics (MN/m2) during the compacting pass.
EVIB value

Increase higher load bearing capacity

Constant end of compaction

Fig. 43
Modular upgrading to BTM plus / BTM prof and/or
BCM 05 possible.

BW 216 D-40 / BW 216 PD-40 47

 Indicators and Controls

4.3 Display and control elements BTM

Fig. 44
1 EVIB display
2 Display for jump operation
3 Push button F5 START
4 Push button F6 STOP
5 Push button F7 PRINT (only BTM prof)
6 Push button F8 DELETE
7 Vibration frequency display
8 Rotary switch setting of nominal value
9 Push button F14 nominal value increase
10 Push button F13 nominal value decrease
11 not used
12 not used
13 not used
14 not used
15 not used
16 not used
17 Speed display
18 Amplitude display
19 Printer for measuring values (only BTM prof)
20 Fault light

48 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

4.4 Description of indicating and control elements BTM

The BTM plus can be upgraded to BTM prof and/or

BCM 05.

Continuous compaction control The BOMAG compaction measuring systems EVIB-meter (BEM)
(CCC) and Terrameter BTM plus/prof are integrated in the work process
for continuous and surface covering evaluation of compaction and
load bearing capacity of soils and non-bonded bearing courses.
The EVIB-value, designated as vibration modulus, with the unit MN/
m2 is directly linked with the deformation modules EV1 or EV2
known from the plate load test acc. to DIN 18134.

n EVIB-Display
Display of the dynamic soil stiffness in MN/m2

n Display for jump operation

yellow Symbol Drum jumps

red Symbol Drum jumps excessively or tumbles

Select a smaller amplitude, if necessary!

n Button F5 START

press Starts recording of measuring values

Control field "F5" flashes green on the screen.

n Button F6 STOP

press Stops recording of measuring values

The green control field "F7" PRINT on the screen lights up.

Depending on the measuring result the green control

field "F5" CONTINUE or the red control field "F6" FIN-
ISHED will light up.

BW 216 D-40 / BW 216 PD-40 49

 Indicators and Controls

n Button F 7 Printonly with BTM prof

To print out the measuring data saved during the last pass press
button F7 PRINT.

short actuation Line diagram

long actuation ≥5 sec. Bar chart

Control field F7 goes out and the measuring value printer starts to
print out measuring data.

After the printing process has finished any amount of

diagrams can be printed out by pressing the same
button F7 (PRINT).

n Button F8 DELETE

press All stored faults are deleted.

NOTICE!
If the increase of the measuring value is to be calcu-
lated on a track press button F8 DELETE only when
changing the track.

n Frequency display
with vibration switched on this instrument shows the frequency
(rotating speed) of the exciter shaft.

n Rotary switch P3 pre-setting of nominal values

The desired maximum dynamic stiffness modulus EVIB [MN/m2] can
be pre-selected in 6 stages (45, 80, 100, 120,150 and Max.).
The selected value is shown on the screen in field "P3"

n Button F14 increase of nominal value

With each actuation of the button the presetting is raised by one
stage.
The selected value is shown on the screen in field "P3"

n Button F13 reduction of nominal value

50 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

With each actuation of the button the presetting is reduced by one

stage.
The selected value is shown on the screen in field "P3"

n Button F11 is not used

n Button F12 is not used

n Button F11 is not used

n Rotary switch P1 is not used

n Button F10 is not used

n Button F9 is not used

n Speed display
Shows the travel speed of the machine.

n Amplitude display
This gauge shows the current vertical amplitude of the machine.

n Printer for measuring values*

To print out the measuring data saved during the last pass press
button (7) "PRINT".

n Fault light
Inform the BOMAG After Sales Service if it lights up.

BW 216 D-40 / BW 216 PD-40 51

 Indicators and Controls

4.5 Line diagram (EVIB)only BTM prof

Fig. 45

52 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

1 Pass-No.
2 Travel direction
3 Machine equipment (BTM 05/BTM-E)
4 Software status of the measuring equipment
5 Machine number
6 Machine type
7 Amplitude
8 Maxiumum EVIB value
9 Miniumum EVIB value
10 Mean EVIB-value
11 EVIB-change
12 Medium frequency
13 Mean travel speed
14 Track length
15 Raster division in longitudinal direction
16 Marking (thick line) excessive jumping, tumbling of the drum
17 Longitudinal raster line
18 Measuring value raster line
19 Diagram line
20 Marking (thin line) jumping of the drum

BW 216 D-40 / BW 216 PD-40 53

 Indicators and Controls

4.6 Description of line diagram (EVIB)only BTM prof

n Pass
Total number of measured passes on this track.

n Travel direction

n Machine equipment

n Software status of the measuring equipment

n Machine number

n Machine type

n Amplitude
This gauge shows the vertical amplitude the machine has worked
with on this track.

n Maxiumum EVIB value

n Miniumum EVIB value

n Mean EVIB-value
This gauge shows the vertical amplitude the machine is currently
working with on this track.

n EVIB-change
EVIB-change in %. This always refers to the previous pass in the
same direction of travel.

n Medium frequency

n Mean travel speed

shows the mean value of speed driven during this pass.

Always shows the same travel speed in order to avoid

a falsification of the measuring results.

54 BW 216 D-40 / BW 216 PD-40

 Indicators and Controls

n Track length
Measured track length between START and STOP.

n Raster division in longitudinal direction

Is used to pinpoint individual measuring values on the measuring
curve.

The raster lines mark measuring track sections of 5 m

length.

Graduation of the measuring track (track length in printout) into

fixed sections.

n Marking of jump information

Indicates excessive jumping/tumbling of the drum on the marked
track section (thick line).

Select a smaller amplitude, if necessary!

n Longitudinal raster line

n Measuring value raster line

n Diagram line
Shows the EVIB-value at any point of the rolled track. The raster line
enables the location related assignment of the EVIB-value and the
location of a fault (over or under compaction).

n Marking of jump information

Indicates jumping of the drum on the marked track section (thin
line).

BW 216 D-40 / BW 216 PD-40 55

 Indicators and Controls

4.7 Bar diagram (EVIB)only BTM prof

The bar diagram differs from the line diagram only by the graphic
representation of measuring values. In the bar diagram the mean
values of 5 m sections are shown as bars. In addition, the EVIB
changes of the individual 5 m sections are specified in percent
after the second pass in the same travel direction.

56 BW 216 D-40 / BW 216 PD-40

 Operation

5 Operation

BW 216 D-40 / BW 216 PD-40 57

 Operation

5.1 General
If you are not yet acquainted with the controls and indicating
elements on this machine you should thoroughly read chapter
"Indicators and control elements" before starting work.
All indicators and control elements are described in detail in
this chapter.

58 BW 216 D-40 / BW 216 PD-40

 Operation

5.2 Tests before taking into operation

Before the everyday use or before a longer working period the fol-
lowing tests and inspections must be performed.

WARNING!
Danger of accident!
Please observe strictly the safety regulations in the
corresponding section of this instruction manual!

Park the machine on ground as level as possible.

Check:
fuel tank and fuel lines for leaks
screw joints for tight fit
function of steering
function of emergency stop
function of brakes
machine for cleanliness, damage
presence of the appropriate operating and maintenance
instructions
proper maintenance of the machine

For a description of the following tasks refer to the

chapter "maintenance every 10 operating hours".

Engine oil level, top up if necessary

Fuel level, top up if necessary.
Coolant level, top up if necessary
Hydraulic oil level, top up if necessary.
Water separator, clean if necessary

BW 216 D-40 / BW 216 PD-40 59

 Operation

5.3 Electronic immobilizerOptional equipment

Before starting the engine the anti-theft protection* must be dis-
armed by entering a code.

With the electronic immobilizer armed, the light emit-

ting diode (a) Ä Fig. 46 flashes slowly.

Fig. 46

Slowly enter the six-digit user code.

When entering the code, the light emitting diode (6)

lights up with every digit.

Press the diamond button.

The electronic immobilizer is now disarmed and the engine

can be started within the next 15 minutes.

60 BW 216 D-40 / BW 216 PD-40

 Operation

5.4 Starting the engine

WARNING!
Danger of accident!
Start the engine only from the operator’s seat.

NOTICE!
In this chapter it is assumed that the operator is fully
acquainted with the function of the different control ele-
ments on the machine.

Fasten your seat belt Ä Fig. 47.

Fig. 47

Check, whether the travel lever Ä Fig. 48 is engaged to the

right in brake position.

Fig. 48

Switch the rotary switch for vibration amplitude pre-selection

Ä Fig. 49 to position "0".

Fig. 49

BW 216 D-40 / BW 216 PD-40 61

 Operation

Check, whether the emergency stop switch Ä Fig. 50 is

unlocked.

Fig. 50

Turn the ignition key Ä Fig. 51 to position "I".

Fig. 51

All control and warning lights Ä Fig. 52 in the instrument cluster

light up for a moment.
The engine oil pressure warning light (d) flashes, the charge con-
trol light (f) and the parking brake warning light (k) stay on.
Under cold ambient temperatures the preheating control lamp (b)
will also light up. Do not start before the preheating control lamp (b)
has gone out.Optional equipment

NOTICE!

Fig. 52 Run the starting process for maximum 20 seconds

without interruption and pause for a minute between
starting attempts.
If the engine has not started after two attempts, deter-
mine the cause.

The starter switch is designed with a re-start lock. The

ignition key must first be turned back to position "0"
before a new starting attempt can be made.

62 BW 216 D-40 / BW 216 PD-40

 Operation

Turn the ignition key Ä Fig. 53 through position "II" to posi-

tion "III", the starter will crank the engine.
As soon as the engine ignites return the ignition key to posi-
tion "I".

The engine oil pressure warning light and the charge control light
go out. The parking brake warning light stays on.

NOTICE!
Fig. 53 Run the engine warm for a short while before starting
work. Do not rev up a cold engine to high idle speed/
full load speed.

BW 216 D-40 / BW 216 PD-40 63

 Operation

5.5 Driving the machine

WARNING!
Danger of accident!
Wet and loose soils considerably reduce the ground
adhesion of the machine on inclinations and slopes.
Soil conditions and weather influences impair the grad-
ability of the machine.
Do not drive up and down inclinations exceeding the
maximum gradability of the machine (see technical
data).
Do not drive without wearing your seat belt.
Always give way to loaded transport vehicles!
Before starting to drive make sure that the drive range
is absolutely safe.

NOTICE!
Always keep the cabin door closed while driving with
the machine. With the door opened and the machine
fully articulated extreme oscillations of the machine
may damage the door.

The machine is equipped with a seat contact switch

(safety feature).Only with option SN1
If the driver gets up from his seat while driving, the
signal horn is activated and the machine is slowed
down to standstill after four seconds. When the driver
sits down again the machine will continue the travel.
Before resuming operation sit down on the seat,
engage the travel lever in "0"-position (brake position),
then operate the travel lever again to the desired travel
direction.

Close the cabin door Ä Fig. 54.

Fig. 54

64 BW 216 D-40 / BW 216 PD-40

 Operation

Select the desired travel speed range Ä Fig. 55.

Fig. 55

Turn the rotary momentary contact switch for engine speed

Ä Fig. 56 clockwise to "MAX".

Fig. 56

Shift the travel lever Ä Fig. 57 out of braking position to the

left to disengage.
Move the travel lever slowly to forward or reverse.

The machine drives forward or backward with a speed that corre-

sponds with the actuation of the travel lever.

Fig. 57

Return the travel lever to position "0".

The machine decelerates to standstill.

WARNING!
Danger of accident!
When stopping on inclinations and slopes pull the
travel lever to the right and lock it in braking position.

BW 216 D-40 / BW 216 PD-40 65

 Operation

Important notes on travel operation

NOTICE!
When changing the travel direction hold the travel
lever for a moment in "0"-position, until the machine
has stopped, before actuating to the new travel direc-
tion.
Do not operate jerkily! Control the travel speed with the
travel lever.
When driving up and down inclinations move the travel
lever slowly back towards neutral to brake the
machine.
If the engine speed drops under load when driving on
steep gradients, take the travel lever slightly back
towards neutral.

66 BW 216 D-40 / BW 216 PD-40

 Operation

5.6 Stopping the machine, operating the parking brake

Return the travel lever Ä Fig. 58 slowly to "neutral"-position
and engage it to the right in braking position.

The machine is automatically braked by the hydrostatic drive and

the parking brake is applied.

Fig. 58

The parking brake warning lamp (k) Ä Fig. 59 lights up.

The parking brake also closes automatically when

shutting the engine down.

Fig. 59

BW 216 D-40 / BW 216 PD-40 67

 Operation

5.7 Shutting down the engine

NOTICE!
Straighten the articulated joint to provide easier access
to the machine.

Return the travel lever Ä Fig. 60 slowly to "neutral"-position

and engage it to the right in braking position.

The machine is automatically braked by the hydrostatic drive and

the parking brake is applied.

Fig. 60

The parking brake warning lamp (k) Ä Fig. 61 lights up.

The parking brake also closes automatically when

shutting the engine down.

Fig. 61

Turn the momentary contact switch for engine speed

Ä Fig. 62 anti-clockwise to position "MIN" (idle speed).

NOTICE!
Do not shut down the engine all of a sudden from full
load speed, but let it idle for about 2 minutes.

Fig. 62

68 BW 216 D-40 / BW 216 PD-40

 Operation

Turn the starter switch Ä Fig. 63 to position "0" or "P" and

pull the ignition key out.

The parking brake closes automatically when shutting

the engine down.

WARNING!
Fig. 63 Danger of accident!
Secure the machine against unauthorized use, pull the
ignition key out, lock the cabin door.

BW 216 D-40 / BW 216 PD-40 69

 Operation

5.8 Switching the vibration on and off

WARNING!
Risk of damage!
When compacting with vibration you must check the
effect of nearby buildings and underground supply
lines (gas, water, sewage, electric power), if necessary
stop compaction with vibration.

NOTICE!
Danger of bearing damage!
Do not activate the vibration on hard (frozen, concrete)
ground.

Turn the rotary travel speed range switch Ä Fig. 64 to posi-

tion "turtle".

Fig. 64

Pre-selecting the vibration

Preselect the desired amplitude with the rotary switch for
vibration amplitude preselection Ä Fig. 65.

Fig. 65

Switching the vibration on

NOTICE!
Switch the vibration on only at max. engine speed.

70 BW 216 D-40 / BW 216 PD-40

 Operation

Turn the rotary momentary contact switch for engine speed

Ä Fig. 66 clockwise to "MAX".

Fig. 66

Actuate the vibration push button Ä Fig. 67 in the travel

lever while driving.

Fig. 67

Switching the vibration off

Press the vibration push button again.

After the end of work turn the vibration amplitude prese-

lecting switch Ä Fig. 68 back to position "0".

Fig. 68

BW 216 D-40 / BW 216 PD-40 71

 Operation

5.9 What to do in events of emergency

Actuating the emergency stop
switch WARNING!
Danger of accident!
In events of emergency and in case of danger actuate
the emergency stop switch immediately.
Start travel operation of the machine only after the
danger that caused the actuation of the emergency
stop switch has been eliminated.

NOTICE!
Do not use as service brake. The deceleration is
extremely high. In case of frequent use the wear on
the multi-dics brakes will be very high.

Press the button of the emergency stop switch Ä Fig. 69

completely down, it automatically locks in fully pressed posi-
tion.

Shuts the engine down and closes the brake.

Fig. 69

Turn the button clockwise to unlock the emergency stop

switch.
Start the engine again, see chapter "Starting the engine".

Emergency exit
If a machine has turned over and the cabin door is jammed,
the right hand cabin window can be used as an escape door.

Fig. 70

72 BW 216 D-40 / BW 216 PD-40

 Operation

5.10 Adjusting the seat

WARNING!
Danger of accident!
Do not adjust the driver’s seat while driving.

To adjust the seat in longitudinal direction pull the lever

Ä Fig. 71 up and push the seat forward or back.

Fig. 71

To adjust the weight adjust the lever accordingly.

To adjust the inclination of the backrest turn the knob and tilt
the backrest forward or back.

Fig. 72

BW 216 D-40 / BW 216 PD-40 73

 Operation

5.11 Operating the heating/air conditioning systemOptional equipment

NOTICE!
Always keep the air inlet slots on the cabin free of
snow, foliage etc.!

The heating power depends on the coolant tempera-

ture.
The air conditioning system only works when the
engine is running and the fan is switched on.
Operation of the air conditioning system increases the
fuel consumption.
Switch the air conditioning on every month for about
10 minutes.

Heating the interior

Close all windows completely.

Turn the air nozzles (a) Ä Fig. 73 to direct the air flow down
into the footwell.
In case of cold or damp weather direct the air flow towards
the windscreen and door screens.
Switch on the fan with the rotary switch (c).
Regulate the temperature with the rotary switch (b).

Fig. 73

Cooling the interior

Close all windows completely.

Direct the air flow towards the body/face (a).

Switch on the fan (c).
If necessary switch off the heating (b).
Switch on the air conditioning system with rotary switch (d)
and regulate the temperature.

74 BW 216 D-40 / BW 216 PD-40

 Operation

Reducing the humidity

In case of damp weather direct the air flow towards the wind-
screen and door screens.
Switch on the fan with the rotary switch (c).
Regulate the temperature to "Max" with the rotary switch (b).
Switch the air conditioning (d) on.

BW 216 D-40 / BW 216 PD-40 75

 Operation

5.12 Operating the hood

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

Bottom position
Unlock the lock Ä Fig. 74.
To open the hood press in the button and turn the handle.

Fig. 74

Pull the support out of the bracket and support the hood
Ä Fig. 75.

Fig. 75

Top position
Push the hood to top position.

Pull the spring pin Ä Fig. 76 out of the bracket.

Secure the hood i´n the protection tube with spring plug.

Fig. 76

76 BW 216 D-40 / BW 216 PD-40

 Operation

5.13 BTM 05 settings before start-upOptional equipment

Changing the units system
Turn the ignition key Ä Fig. 77 to position "I".

The control unit shows the start screen.

Fig. 77

Press key ’’?“ (menu) Ä Fig. 78.

The menu appears on the screen.

Fig. 78

Press key "F4" Ä Fig. 79.

The screen page to select the unit system appears on

the screen.

Fig. 79

BW 216 D-40 / BW 216 PD-40 77

 Operation

Press key "F5" Ä Fig. 80 and choose the units system.

Imperial 0 metric units

Imperial 1 imperial units

Fig. 80

After the desired change press key "F14" Ä Fig. 81. The
"Save" symbol on the screen lights up green for a moment as
confirmation.

After releasing the key "F14" the system automatically

returns to the start screen and the control triggers a
restart.

Fig. 81

Switch the ignition off and on again Ä Fig. 82.

Both Asphalt Manager control unit and printer have

been set to the new units system.

Fig. 82

Setting the printer languageOptional

equipment
With a printer* connected the language in the printout
can be changed via the Asphalt Manager control unit.

78 BW 216 D-40 / BW 216 PD-40

 Operation

Turn the ignition key to position "I" Ä Fig. 83.

The control unit shows the start screen.

Fig. 83

Press key ’’?“ (menu) Ä Fig. 84.

The menu appears on the screen.

Fig. 84

Press key "F6" Ä Fig. 85.

The printer language screen page appears.

Fig. 85

Use keys "F11" or "F12" to choose the desired printer lan-

guage Ä Fig. 86.

The screen shows country flags, which represent the

associated language.

Fig. 86

BW 216 D-40 / BW 216 PD-40 79

 Operation

Press key "F14" to save the language setting Ä Fig. 87. The
"Save" symbol on the screen lights up green for a moment as
confirmation.

Fig. 87

Press key "ESC" Ä Fig. 88 to return to the start screen.

Fig. 88

80 BW 216 D-40 / BW 216 PD-40

 Operation

5.14 Measuring pass with BTMOptional equipment

General notes
The soil measuring values (EVIB) recorded during dif-
ferent passes can only be compared if the recording of
measuring values took place in operating mode
"Manual" with the same amplitude, frequency and
travel speed and on exactly the same track.
Measuring values must only be compared for passes
performed in the same direction.
The following description describes an measuring pass
in forward. Measuring passes in reverse must be per-
formed accordingly.

Measuring pass
Turn the ignition key Ä Fig. 89 to position "I"

The BTM plus/prof performs a self-test.

Fig. 89

Control field F5 Ä Fig. 90 lights green.

Fig. 90

BW 216 D-40 / BW 216 PD-40 81

 Operation

Turn the ignition key Ä Fig. 91 to position „II engine start.

Fig. 91

Mark the track to be compacted Ä Fig. 92.

NOTICE!
Since the transducer unit is mounted on the left hand
side of the drum, it is necessary to arrange the tracks
so that track 1 is processed first, followed by further
tracks offset to the left.

Maximum track length 150 m.

Forward:
Fig. 92

Mark 1 Start of track

Mark 2 End of track

The operator may also remember the start and the end
of the track by means of distinct points.

Pre-select working speed Ä Fig. 93.

Fig. 93

82 BW 216 D-40 / BW 216 PD-40

 Operation

Turn the rotary switch Ä Fig. 94 for engine speed to position

"MAX".

Fig. 94

Shift the travel lever Ä Fig. 95 fully to position „I“.

The machine accelerates up to the preadjusted travel speed.

NOTICE!
Differences in the travel speeds falsify the measuring
result!

Fig. 95

Switch the vibration on Ä Fig. 96.

NOTICE!
Before reaching mark 1 the nominal exciter shaft
speed must have been reached and a valid Evib-value
should be displayed.

Fig. 96

When mark 1 is reached, press button F5 “START”

Ä Fig. 97.

Control field to the left of F5 lights green.

The EVIB- display shows the present value.

Fig. 97

BW 216 D-40 / BW 216 PD-40 83

 Operation

When the end of the track, mark 2, is reached, press the

button F6 “STOP” Ä Fig. 98.

Fig. 98

Stop the machine.

The first forward pass is finished.

Control field F5 lights green. This means, that the compaction is

not yet completed. One or several passes are still required.

84 BW 216 D-40 / BW 216 PD-40

 Operation

5.15 Finishing compaction of a track

Drive forward and reverse passes on a track until the green
control field to the left of F5 Ä Fig. 99 goes out and the red
control field F6 below lights up after pressing the stop button
F6.

The compaction process on this track is finished.

Criterion for a finished track:
Compared with the previous track the increase of the EVIB-value in
the same travel direction was less than 10%. This criterion is also
Fig. 99 fulfiled if the EVIB decreases.

Another pass on this track does not make any sense,

because an increase in load bearing capacity is hardly
possible with this machine.

If necessary print out the measuring data for this track (see
following section).

Repeat the complete compaction process on the next track

Ä Fig. 100 to record measuring values.

Fig. 100

BW 216 D-40 / BW 216 PD-40 85

 Operation

5.16 Printing measuring data after completing compactiononly BTM prof

Measuring data can be printed after completion of any

pass.
Always check the paper provision before starting work.
Change the paper roll if a red stripe appears on the
paper.

At the end of the measurement press push button F7

"PRINT" Ä Fig. 101.

short actuation Line diagram

long actuation ≥5 sec. Bar chart

Control field F7 goes out and the measuring value printer starts to
print out measuring data.
Fig. 101

After the printing process has finished any amount of

diagrams can be printed out by pressing the same
button F7 (PRINT).

If no further printouts of this track are needed, press the

button F8 “DELETE” Ä Fig. 102 when the red control lamp
F6 “FINISHED” lights up.

The red control field F6 “FINISHED” goes out and the green control
field F5 “CONTINUE” lights up.
BTM plus/prof is ready to compact the next track.

Fig. 102

86 BW 216 D-40 / BW 216 PD-40

 Operation

5.17 Changing the paper roll in the measuring value printeronly BTM prof

Use a new paper roll if a red stripe appears on the

paper.

Unscrew the star handles Ä Fig. 103 and remove the cover.

Fig. 103

Remove shaft 1 Ä Fig. 104 with the rest of the paper roll (2).

Fig. 104

Insert a new paper roll Ä Fig. 105.

Feed the paper into the guide (1) on the printer.
Actuate the toggle switch (2) in direction of arrow, until the
paper comes out of the printer.
Reassemble the cover.

Fig. 105

BW 216 D-40 / BW 216 PD-40 87

 Operation

5.18 Changing the printer ribbon in the measuring value printeronly BTM prof

In case of faint or poorly legible diagrams the printer

ribbon needs to be replaced.

Unscrew the star handles Ä Fig. 106 and remove the cover.

Fig. 106

Lift the tongue at point 1 Ä Fig. 107 and take the printer
ribbon (2) out of the printer.
Insert the new printer ribbon into the printer, then press in the
tongue (1) on the right.
Tension the printer ribbon by turning the rotary button (3) in
direction of arrow.

Fig. 107

Reassemble the cover.

88 BW 216 D-40 / BW 216 PD-40

 Operation

5.19 Towing in case of an engine failure

WARNING!
Danger of accident! Danger of injury!
Apply appropriate measures (e.g. with metal wheel
chocks, to be provided by the operating company) to
secure the machine against rolling away before
releasing the parking brake.
When using towing ropes tow the machine only uphill.
When towing downhill you must use a tow bar.
The machine cannot be steered.
Use a towing vehicle with sufficient traction and
braking power for the unbraked towed load.
Do not touch hot engine parts.

NOTICE!
Tow the machine only after having released the
parking brake.
Towing speed 1 km/h, max. towing distance 500 m.

Secure the machine with wheel chocks against unintentional

rolling.
Attach chains or towing ropes to the lifting points .
Open the engine compartment hood and secure it.

Fig. 108

NOTICE!
Do not turn the valves out completely!

Slacken the middle hexagon on both valves for approx. 2 to 3

turns.

Fig. 109

BW 216 D-40 / BW 216 PD-40 89

 Operation

To release the brake turn counter nuts (1) approx. 8 mm

back.

NOTICE!
From this stop turn the screw in for maximum
another turn to release the brake!
Turn the screws in evenly on both sides.

Turn the brake releasing screws (2) in alternately for ¼ turn

Fig. 110 at a time.
Repeat this measure on the opposite wheel side.

After towing
NOTICE!
Apply appropriate measures (e.g. with metal wheel
chocks) to secure the machine against rolling away
before disconnecting the tow bar.

Turn the high pressure relief valve cartridges tightly back in.
Turn all brake releasing screws of the axle evenly back out,
until they are light moving again.
Turn the brake releasing screws back in again, until they abut
against the brake piston.

Fig. 111

Unscrew the brake releasing screws for two turns and tighten
the counter nuts.
Repeat this adjustment procedure on the opposite wheel
side.

If necessary replace the sealing ring under the

counter nut if it is leaking.
For this purpose completely unscrew the brake
releasing screw, replace the seal ring and lubri-
cate the screw with silicone grease.
Fig. 112
Reinstall the screw with a new seal ring and
adjust the protrusion as described above.

90 BW 216 D-40 / BW 216 PD-40

 Operation

BW 216 D-40 / BW 216 PD-40 91

 Operation

5.20 Loading/transport

WARNING!
Danger of accident! Life hazard!
Use only stable loading ramps of sufficient load
bearing capacity. The ramp inclination must be less
than the gradability of the machine.
Make sure that persons are not endangered by the
machine tipping or sliding off.
During demonstration and when loading the machine
do not remain in the danger zone of the machine.
Always use shackles on the lifting points for loading or
tying the machine down.
Check all lifting and lashing points for damage before
lifting or lashing down the machine. Do not use a dam-
aged or in any other way impaired lifting and lashing
eyes.
Lift the machine only with suitable lifting gear. Use only
safe lifting gear of sufficient load bearing capacity Min-
imum lifting capacity of lifting gear: see operating
weight in chapter "Technical Data".
The machine must not swing about when being lifted.
Do not step or stand under suspended loads.
Lash the machine down, so that it is secured against
rolling, sliding and turning over.
After transport release the articulation lock again and
store it in the receptacle.

Pull the spring pin Ä Fig. 113 out.

Lift up the articulation lock and swivel it by 180°.

Fig. 113

92 BW 216 D-40 / BW 216 PD-40

 Operation

Engage the articulation lock and secure it with the spring pin
Ä Fig. 114.

Fig. 114

Lash the machine on the transport vehicle Ä Fig. 115, use

the four lashing eyes on front and rear frame for this purpose.
Support the front frame to avoid overstressing of the rubber
buffers.

Fig. 115

Loading by crane
WARNING!
Life hazard!
Do not step or stand under suspended loads.

For lifting use the four lifting eyes Ä Fig. 116 and appro-
priate lifting gear.

Fig. 116

BW 216 D-40 / BW 216 PD-40 93

 Operation

Fig. 117

Position of centre of gravity Ä Fig. 117:

Machine L [mm] H [mm]

BW 216 -4 1000 ± 80 860 ± 30

The tolerances account for all possible options, such

as cabin, additional weight etc.

After transport
WARNING!
Danger of accident!
The machine cannot be steered if the articulation lock
is applied.

After the transport loosen the articulation lock Ä Fig. 118

again, fix it in its receptacle and lock it with the spring plug.

Fig. 118

94 BW 216 D-40 / BW 216 PD-40

 Maintenance

6 Maintenance

BW 216 D-40 / BW 216 PD-40 95

 Maintenance

6.1 General notes on maintenance

When performing maintenance work always comply with the appro-
priate safety regulations.
Thorough maintenance of the machine guarantees far longer safe
functioning of the machine and prolongs the lifetime of important
components. The effort needed for this work is only little compared
with the problems that may arise when not observing this rule.
The terms right/left correspond with travel direction forward.
Support the engine hood for all maintenance and repair work.
Do not touch hot engine parts.
Always clean machine and engine thoroughly before starting
maintenance work.
For maintenance work stand the machine on level ground.
Perform maintenance work only with the engine shut down.
Relieve hydraulic pressures before working on hydraulic
lines.
Before working on electric parts of the machine disconnect
the battery and cover it with insulation material.
When working in the area of the articulated joint attach the
articulation lock (transport lock).

ENVIRONMENT!
During maintenance work catch all oils and fuels and
do not let them seep into the ground or into the
sewage system. Dispose of oils and fuels environmen-
tally.
Keep used filters in a separate waste container and
dispose of environmentally.
Catch biodegradable oils separately.

Notes on the fuel system The lifetime of the diesel engine depends to a great extent on the
cleanliness of the fuel.
Keep fuel free of contaminants and water, since this will
damage the injection elements of the engine.
Drums with inside zinc lining are not suitable to store fuel.
When choosing the storage place for fuel make sure that
spilled fuel will not harm the environment.
Do not let the hose stir up the slurry at the bottom of the
drum.
The fuel drum must rest for a longer period of time before
drawing off fuel.
The rest in the drum is not suitable for the engine and should
only be used for cleaning purposes.

96 BW 216 D-40 / BW 216 PD-40

 Maintenance

Notes on the performance of the On diesel engines both combustion air and fuel injection quantities
engine are thoroughly adapted to each other and determine power, tem-
perature level and exhaust gas quality of the engine.
If your engine has to work permanently in "thin air" (at higher alti-
tudes) and under full load, you should consult the customer service
of BOMAG or the customer service of the engine manufacturer.

Notes on the cooling system Prepare and check coolant with highest care, since otherwise the
engine may be damaged by corrosion, cavitation and freezing.
Coolant is prepared by adding an ethylene-glycol based anti-freeze
agent with corrosion inhibiting properties to the cooling water.
Mixing with cooling system protection agent is necessary in all cli-
matic zones. It prevents corrosion, lowers the freezing point and
raises the boiling point of the coolant.

Notes on the hydraulic system During maintenance work on the hydraulic system cleanliness is of
major importance. Make sure that no dirt or other contaminating
substances can enter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clog nozzles and pilot
bores, thereby making expensive repairs inevitable.
If, during the daily inspection of the oil level the hydraulic oil
level is found to have dropped, check all lines, hoses and
components for leaks.
Seal external leaks immediately. If necessary inform the
responsible customer service.
Do not store drums with hydraulic oil outdoors, or at least
under a cover. Water can be drawn in through the bunghole
when the weather changes.
We recommend to use our filling and filtering unit with fine
filter to fill the system. This ensures finest filtration of the
hydraulic oil, prolongs the lifetime of the hydraulic oil filter
and protects the hydraulic system.
Clean fittings, filler covers and the area around such parts
before disassembly to avoid entering of dirt.
Do not leave the tank opening unnecessarily open, but cover
it so that nothing can fall in.

BW 216 D-40 / BW 216 PD-40 97

 Maintenance

6.2 Fuels and lubricants

6.2.1 Engine oil
6.2.1.1 General
Modern diesel engines put high demands on the lubrication oil
used. The engine powers that have continuously increased over
the past few years lead to higher thermal loads for the lubrication
oil. Apart from that, the lubrication oil is additionally loaded by con-
tamination because of the reduced lubrication oil consumption and
the prolonged lubrication oil change intervals.
For this reason it is necessary to follow the requirements and rec-
ommendations in these operating instructions in order not to
reduce the lifetime of the engine.
Engine oils of the same specification can generally be mixed
among each other. However, mixing of engine oil should be
avoided, because the poorest characteristics of a mixture will
always prevail.
The use of additives for lubrication oils is not permitted.
The lubrication oil quality has a considerable influence on the life-
time, performance and thus the economy of the engine. The fol-
lowing is generally valid: the better the lubrication oil quality, the
better its properties.

6.2.1.2 Oil quality

For use in DEUTZ engines the lubrication oils are classified in
DEUTZ Lubrication Oil Quality Classes (DQC).
Use only oils complying with DQC III-10 or DQC IV-10.

The list of approved lubrication oils is also available in the

Internet under the following address:

www.deutz.com
de SERVICE \ Betriebsstoffe und Additive \ Deutz
Quality Class \ DQC-Freigabeliste
en SERVICE \ Operating Liquids and Additives \ Deutz
Quality Class \ DQC Release List

98 BW 216 D-40 / BW 216 PD-40

 Maintenance

6.2.1.3 Oil viscosity

Since lubrication oil changes its viscosity with the temperature, the
ambient temperature at the operating location of the engine is of
utmost importance when choosing the viscosity class (SAE-class) .
Multi-purpose oils should generally be used.
Too high viscosity can cause starting difficulties, too low ´viscosity
can jeopardize the lubrication effect and result in a high lubrication
oil consumption.
Optimal operating conditions can be achieved by using the oil vis-
cosity chart as a reference.
At ambient temperatures below -40 °C (-40 °F) the lubrication oil
must be pre-heated (e.g. by parking the machine indoors).

Fig. 119: Oil viscosity diagram

6.2.1.4 Oil change intervals

The longest permissible time a lubrication oil should remain in an
engine is 1 year. If the following oil change intervals are not
reached over a period of one year, the oil change should be per-
formed at least 1x per year, irrespective of the operating hours
reached.
Oil change intervals with DQC III-10, DQC IV-10: 500 operating
hours.
The lubrication oil change interval must be halved if at least one of
the following conditions does apply:
n Permanent ambient temperatures below -10 °C (14 °F)
n Lubrication oil temperatures below 60 °C (84 °F)
n Sulphur content in fuel exceeding 0.5 %

BW 216 D-40 / BW 216 PD-40 99

 Maintenance

6.2.2 Fuel
6.2.2.1 General
You should only use commercially available brand diesel fuel with
a sulphur content below 0,5% and ensure strict cleanliness when
filling in.
A higher sulphur content has a negative effect on the oil change
intervals.
Fuels with a sulphur content of more than 1.0 % are not permitted.
The fuel level should always be topped up in due time so that the
fuel tank is never run dry, as otherwise filter and injection lines
need to be bled.

6.2.2.2 Fuel quality

The following fuel specifications are permitted:
n EN 590
n DIN 51628
n ASTM D975 Grade-No. 1-D and 2-D.
n JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lubrication
properties acc. to EN 590

6.2.2.3 Winter fuel

For winter operation use only winter diesel fuel, to avoid clogging
because of paraffin separation.
At very low temperatures disturbing paraffin separation can also be
expected when using winter diesel fuel.
Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are
available for Arctic climates.

NOTICE!
Danger of engine damage!
– The admixture of petroleum and the addition of
"flow enhancing additives" (fuel additives) is not
permitted.

6.2.2.4 Storage
Even traces of zinc, lead and copper can cause deposits in the
injection nozzles, especially in modern Common-Rail injection sys-
tems.
Zinc and lead coatings in refuelling systems and fuel lines are not
permitted.

100 BW 216 D-40 / BW 216 PD-40

 Maintenance

Copper containing materials (copper lines, brass items) should be

avoided, because they can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.

6.2.3 Coolant
6.2.3.1 General
For fluid cooled engines the cooling fluid must be prepared by
admixing a cooling system protection agent to the fresh water and
should be checked within the specified maintenance intervals.
This prevents damage caused by corrosion, cavitation, freezing
and overheating.

6.2.3.2 Water quality

The correct quality of water is highly important when preparing
coolant. Clear and clean water within the boundaries of the fol-
lowing analysis values should generally be used.

Analysis values
pH-value at 20 °C (68 °F) 6.5 - 8.5
Chlorine-ion content max. 100 mg/l
Sulphate ion content max. 100 mg/l
Water hardness (ion content of max. 3.56 mmol/l
calcium and magnesium )
max: 356 mg/l (ppm)
Germ degree: max. 20 °dH
English degree: max: 25 °eH
French degree: max: 35.6 °fH
Bacteria, fungi, yeasts not permitted

Information concerning the water quality can be obtained from the

waterworks.
If the fresh water analysis values are unknown, these must be
determined with the help of a water analysis.
If the values of the analysis deviate, the water must be treated
accordingly:
pH-value too low - Adding of caustic lye of soda or caustic
potash solution.
Water hardness too - Mix with soft, distilled or fully demineral-
high ized water
Chlorides and/or sul- - Mix with distilled or fully demineralized
phates too high water

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 Maintenance

NOTICE!
Danger of engine damage!
– Another analysis must be made after the fresh
water has been prepared.

6.2.3.3 Cooling system protection agent

As a protection against frost, corrosion and boiling point anti-freeze
agents must be used under any climatic conditions.
Coolant is prepared by adding an ethylene-glycol based anti-freeze
agent with corrosion inhibiting properties to the cooling water.
We therefore highly recommend our BOMAG cooling system pro-
tection agent.
If our cooling system protection agent is not available for any
important reasons, you may, in exceptional cases, use products
that have been approved by the engine manufacturer.

The list of approved lubrication oils is also available in the

Internet under the following address:

www.deutz.com
de SERVICE Betriebsstoffe und Additive DeutzQuality-
Class DQC-Freigabeliste
en SERVICE \ Operating Liquids and Additi-ves \
Cooling System Conditioner

Products of the same product group (see Deutz Technical Circular

Cooling System Protection Agents) can be mixed with each other.
The BOMAG cooling system protection agent corresponds with
product group A.

NOTICE!
Danger of engine damage!
– Do not mix different coolants and additives of any
other kind.
– Before changing the product you must clean the
entire cooling system.
– Consult our customer service if in doubt.
– The cooling system protection agent must be used
all year round, to provide adequate corrosion pro-
tection.

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 Maintenance

The following mixing ratio must not be fallen short of or

exceeded:

Cooling system Fresh water Cold protection

protection agent down to
min. 35% 65% -22 °C (-8 °F)
40% 60% -28 °C (-18 °F)
45% 55% -35 °C (-31 °F)
max. 50% 50% -41 °C (-42 °F)

NOTICE!
Danger of engine damage!
– A proportion of more than 50% of cooling system
protection agent causes a drop in cooling power.
– The use of corrosion protection oils as cooling
system protection agents is not permitted.

6.2.4 Hydraulic oil

6.2.4.1 Mineral oil based hydraulic oil
The hydraulic system is operated with hydraulic oil HV 46 (ISO)
with a kinematic viscosity of 46 mm2/s at 40 °C (104 °F) and
8 mm2/s at 100 °C (212 °F).
For topping up or for oil changes use only high-quality hydraulic oil,
type HVLP according to DIN 51524, part 3, or hydraulic oils type
HV according to ISO 6743/3.
The viscosity index (VI) should be at least 150 (observe informa-
tion of manufacturer).

6.2.4.2 Bio-degradable hydraulic oil

The hydraulic system can also be operated with a synthetic ester
based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Panolin HLP
Synth.46 meets all demands of a mineral oil based hydraulic oil
according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46 always use
the same oil to top up.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable oil, you should consult the lubrica-
tion oil service of the oil manufacturer, or our customer service for
details.

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 Maintenance

NOTICE!
Risk of damage!
– Check the filter more frequently after this change.
– Perform regular oil analyses for content of water
and mineral oil.
– Replace the hydraulic oil filter element every 500
operating hours.

6.2.5 Gear oil

For the gearboxes use only multi-purpose gear oils ISO VG 220 of
API GL5-class with a minimum viscosity of 20 mm2/s at 100 °C
(212 °F).
This is a hypoid lubricant of highest quality class for extremely
loaded transmissions.
The additives in this oil ensure low wear lubrication under all oper-
ating conditions.

6.2.6 Exciter system

For the exciter unit use a fully synthetic gear oil SAE 75W-90,
API GL5.

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 Maintenance

6.3 Table of fuels and lubricants

Assembly Fuel or lubricant Spare parts Filling quantity
number
Summer Winter Observe the
level marks!
Engine oil SAE 10W/-40 009 920 06 14 l
Specification:Ä Chapter 6.2.1 ‘Engine oil’ 20 l (3.7 gal us)
on page 98
SAE 15W-40
SAE 5W-40
SAE 5W-30
Fuel Diesel Winter diesel fuel 250 l
Specification:Ä Chapter 6.2.2 ‘Fuel’ (66 gal us)
on page 100
Coolant Mixture of water and anti-freeze agent 009 940 08 16 l
Specification:Ä Chapter 6.2.3 ‘Coolant’ 20 l (4.2 gal us)
on page 101
Hydraulic system Hydraulic oil (ISO), HLP 46 009 930 09 80 l
Specification:Ä Chapter 6.2.4.1 ‘Mineral oil 20 l (21.1 gal us)
based hydraulic oil’ on page 103
or ester based biodegradable hydraulic oil
Specification:Ä Chapter 6.2.4.2 ‘Bio-degrad-
able hydraulic oil’ on page 103
Vibration bearings SAE 75W-90, API GL-5 009 925 05 1.0 l each
Specification:Ä Chapter 6.2.6 ‘Exciter 20 l (0.26 gal us)
system’ on page 104
Drive axle SAE 80W-140, API GL-5 009 925 07 11 l
Specification:Ä Chapter 6.2.5 ‘Gear oil’ 20 l (2.9 gal us)
on page 104
Axle reduction gear SAE 80W-140, API GL-5 009 925 07 1.9 l
20 l (0.52 gal us)
Drum drive reduction SAE 80W-140, API GL-5 009 925 07 3.2 l
gear
20 l (0.85 gal us)
Wheel hubs SAE 80W-140, API GL-5 009 925 07 2.0 l each
20 l (0.53 gal us)
Tires Water + calcium chloride 295 l + 100 kg
(80 gal us + 220
lbs)

BW 216 D-40 / BW 216 PD-40 105

 Maintenance

Assembly Fuel or lubricant Spare parts Filling quantity

number
Summer Winter Observe the
level marks!
or water + magnesium chloride 308 l + 87 kg
(81 gal us + 192
lbs)
Air conditioning Refrigerant R134a 1500 g
(3.3 lbs)

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 Maintenance

6.4 Running-in instructions

6.4.1 General
The following maintenance work must be performed when running
in new machines or overhauled engines:

NOTICE!
Danger of engine damage!
– Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected to, the
oil consumption will drop to the normal level after
approx. 100 to 250 operating hours.

6.4.2 After 250 operating hours

Tighten all bolted connections on air intake, exhaust, oil
sump and engine mounts
Retighten the bolted connections on the machine.
Retighten the wheel nuts.
Change engine oil and filter.
Change oil in drive axle.
Change oil in wheel hubs.
Change oil in axle reduction gear.
Change oil in drum drive reduction gear.
Change oil vibration bearings.

6.4.3 After 500 operating hours

Change engine oil and filter.
Change oil in drum drive reduction gear.
Change oil in vibration bearings.

6.4.4 After 1000 operating hours

Change oil in drive axle.
Change oil in wheel hubs.
Change oil in axle reduction gear.
Change oil in drum drive reduction gear.
Change oil in vibration bearings.
Retighten the wheel nuts.

BW 216 D-40 / BW 216 PD-40 107

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108 BW 216 D-40 / BW 216 PD-40

 Maintenance

6.5 Maintenance table

No. Maintenance works Page
Every 10 operating hours
6.6.1 Check the engine oil level 111
6.6.2 Checking the fuel level 111
6.6.3 Check the coolant level 113
6.6.4 Check the hydraulic oil level 113
6.6.5 Check, clean the water separator 114
Every 250 operating hours
6.7.1 Check the tire pressure 116
6.7.2 Clean the cooling fins on engine and hydraulic oil cooler 116
6.7.3 Check the oil level in the drive axle 117
6.7.4 Check the oil level in the wheel hubs 118
6.7.5 Check the oil level in the axle reduction gear 119
6.7.6 Check the oil level in the drum reduction gear 119
6.7.7 Check the oil level in the vibration bearings 120
6.7.8 Check the parking brake 120
6.7.9 Checking, replacing the refrigerant compressor V-beltOptional equipment 122
Every 500 operating hours
6.8.1 Changing engine oil and oil filter cartridge 124
6.8.2 Checking, tensioning, replacing the V-belt 125
6.8.3 Draining the fuel tank sludge 128
6.8.4 Battery service 129
6.8.5 Service the air conditioningOptional equipment 130
6.8.6 Cleaning the circulation air filter for the heatingOptional equipment 134
Every 1000 operating hours
6.9.1 Check, adjust the valve clearance 135
6.9.2 Change the fuel filter cartridge 137
6.9.3 Change the fuel pre-filter cartridge 138
6.9.4 Check the engine mounts 140
6.9.5 Change the oil in the vibration bearings 140
6.9.6 Changing the oil in the drum reduction gear 141
6.9.7 Changing the oil in the drive axle 142
6.9.8 Changing the oil in the wheel hubs 144

BW 216 D-40 / BW 216 PD-40 109

 Maintenance

No. Maintenance works Page

6.9.9 Changing the oil in the axle reduction gear 145
6.9.10 Retighten the fastening of the axle on the frame 145
6.9.11 Tightening the wheel nuts 146
6.9.12 Checking the ROPS 146
6.9.13 Check the travel control 147
Every 2000 operating hours
6.10.1 Changing hydraulic oil and breather filter 148
6.10.2 Changing the hydraulic oil filter 149
6.10.3 Changing the coolant 150
Every 3000 operating hours
6.11.1 Checking the injection valves 153
As required
6.12.1 Air filter maintenance 154
6.12.2 Retightening the padfoot shell 157
6.12.3 Adjusting the scrapers 157
6.12.4 Clean the machine 158
6.12.5 Changing the tires 158
6.12.6 Change the fresh air filter in the cabin 159
6.12.7 Fill the provision tank for the windscreen washer systemOptional equip- 159
ment
6.12.8 Tightening torques 160
6.12.9 Engine conservation 160

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 Maintenance

6.6 Every 10 operating hours

6.6.1 Check the engine oil level

WARNING!
Danger of injury!
Support the engine hood for all maintenance and
repair work.

The machine must be parked horizontally with the

engine shut down.

Pull the dipstick Ä Fig. 120 out, wipe it off with a lint-free,
clean cloth and reinsert it until it bottoms.
Pull the dipstick back out again.
If the oil level is below the "MAX" mark fill in oil.
If the oil level is above the “Max” mark determine the cause
and drain the oil off.

NOTICE!
Fig. 120
Before longer work periods you should always top the
oil up to the "MAX"-mark.

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

6.6.2 Checking the fuel level

NOTICE!
Do not drive the fuel tank dry, as otherwise the fuel
system needs to be bled.

BW 216 D-40 / BW 216 PD-40 111

 Maintenance

Check the fuel level on the fuel gauge Ä Fig. 121.

Fig. 121

Refuelling
WARNING!
Fire hazard!
When working on the fuel system do not use open fire,
do not smoke, do not spill any fuel.
Do not refuel in closed rooms.
Shut down the engine.

WARNING!
Health hazard!
Do not inhale any fuel fumes.

NOTICE!
Monitor the entire refuelling process.
For quality and quantity of fuel refer to the "table of
fuels and lubricants".

ENVIRONMENT!
Catch running out fuel, do not let it seep into the
ground.

Shut down the engine.

Clean the area around the filler opening.
Open the fuel tank cover Ä Fig. 122.

NOTICE!
Contaminated fuel can cause malfunction or even
damage of the engine.

Fig. 122 If necessary, fill in fuel through a funnel with screen.

112 BW 216 D-40 / BW 216 PD-40

 Maintenance

Top up with fuel (diesel or winter diesel).

Screw the fuel tank cover back on.

6.6.3 Check the coolant level

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

NOTICE!
If, during the daily inspection the coolant level is found
to have dropped, check all lines, hoses and engine for
leaks.
Do not use radiator sealant to seal leaks.
For quality and quantity of coolant refer to the "table of
fuels and lubricants".

Check the coolant level Ä Fig. 123.

To top up unscrew the filler cap and fill in coolant up to the
MAX-mark.

Fig. 123

6.6.4 Check the hydraulic oil level

NOTICE!
In hydraulic systems filled with Panolin HLP Synth. 46
always use the same oil to top up. With other ester
based oils consult the lubrication oil service of the
respective oil manufacturer.

BW 216 D-40 / BW 216 PD-40 113

 Maintenance

Check the hydraulic oil level in the inspection glass

Ä Fig. 124.

Normal level
approx. 3 cm below the top edge of the inspection glass.
Minimum level
Middle of inspection glass.

Fig. 124 NOTICE!

If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped, check all
lines, hoses and components for leaks.

If necessary fill in hydraulic oil through the filler neck.

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

6.6.5 Check, clean the water separator

WARNING!
Danger of injury!
Support the engine hood for all maintenance and
repair work.

The service intervals for the water separator depend

on the water content in the fuel and can therefore not
be determined precisely. After taking the engine into
operation you should therefore check the water sepa-
rator every day for signs of water.
If a to high quantity is drained off, the filter must be
refilled with fuel. See chapter "maintenance as
required", bleeding the fuel system.

ENVIRONMENT!
Catch running out fuel and dispose of environmentally.

114 BW 216 D-40 / BW 216 PD-40

 Maintenance

Slacken the drain plug Ä Fig. 125 for a few turns and catch
running out fuel / water.
Tighten the drain plug again and check for leaks, if necessary
replace the seal ring.

Fig. 125

BW 216 D-40 / BW 216 PD-40 115

 Maintenance

6.7 Every 250 operating hours

6.7.1 Check the tire pressure

NOTICE!
Because of the water filling in the tires, you should
always check the tire pressure with the tire valve in top
position!
Always close the valves with their dust caps.

Adaptation to operating conditions:

The tire pressure can be adapted to the operating con-
ditions within the specified limits.
A reduced tire pressure improves the traction espe-
cially on sandy soils. Higher tires pressures improve
the driving stability of the machine.
The total height of the machine can also be influenced
by changing the tire pressure.

With the tire inflation valve check the air pressure on tire
inflation valve 1 Ä Fig. 126 with a pressure gauge.

Nominal value, see "technical data".

Ensure equal pressure in all rubber tires!

Fig. 126

Screw the valve caps back on again.

6.7.2 Clean the cooling fins on engine and hydraulic oil cooler

WARNING!
Danger of injury!
Perform cleaning work only after the engine has
cooled down and with the engine stopped.

NOTICE!
Do not damage any cooling fins on the cooler core
when cleaning.

116 BW 216 D-40 / BW 216 PD-40

 Maintenance

Dirt on fan blades and oil cooler reduce the cooling

effect. Dirt deposits in these areas are substantially
supported by oil and fuel on these surfaces. For this
reason you should always seal any oil or fuel leaks in
the vicinity of the cooling fan or the oil cooler and clean
the cooling surfaces after.

Cleaning with compressed air

Start to blow out from the exhaust side.

Fig. 127

Blow the cooler Ä Fig. 127 out with compressed air.

Cleaning with cold cleansing agent

NOTICE!
Protect electrical equipment such as generator, regu-
lator and starter against the direct water jet.

Spray the engine with a suitable cleansing agent, e.g. cold

cleanser, let it soak in for a while and spray it off with a
strong water jet.
Run the engine warm for a while to avoid corrosion.

6.7.3 Check the oil level in the drive axle

Park the machine on level ground.

BW 216 D-40 / BW 216 PD-40 117

 Maintenance

Unscrew the oil level inspection plug Ä Fig. 128 and check
the oil level.

The second level inspection plug as at the back.

After filling in oil wait until the oil has evenly distributed
inside the axle.

The oil level must reach the bottom edge of the level bore.
Fig. 128

Top up oil, if necessary.

For quality of oil refer to the table of fuels and lubricants.

Turn the level inspection plug tightly back in.

6.7.4 Check the oil level in the wheel hubs

NOTICE!
Check the oil level in both wheel hubs.
For quality of oil refer to the "table of fuels and lubri-
cants".

Park the machine so that the plug (1) Ä Fig. 129 is in hori-
zontal position.
Clean the area around the plug and unscrew the plug.
Check the oil level. The oil level must reach the bottom edge
of the bore, top up oil if necessary.

Fig. 129

Screw the plug back in tightly.

118 BW 216 D-40 / BW 216 PD-40

 Maintenance

6.7.5 Check the oil level in the axle reduction gear

Unscrew the filler and oil level inspection plug Ä Fig. 130
and check the oil level.

The oil level must reach the bottom edge of the bore, top up oil if
necessary.
For quality of oil refer to the table of fuels and lubricants.

Fig. 130

Retighten the filler and level inspection plug.

6.7.6 Check the oil level in the drum reduction gear

Check
Unscrew the oil level inspection plug Ä Fig. 131 and check
the oil level.

The oil level must reach the bottom edge of the bore, top up oil if
necessary.

Fig. 131

Filling up
Move the drum until drain and filler plugs are exactly verti-
cally in line.

Unscrew the filler plug at the top Ä Fig. 132 and fill in oil,
until it reaches the bottom edge of the inspection bore.

NOTICE!
Investigate the cause for the oil loss, if necessary seal
the gearbox

Fig. 132

For quality of oil refer to the table of fuels and lubricants.

Retighten the filler and level inspection plug.

BW 216 D-40 / BW 216 PD-40 119

 Maintenance

6.7.7 Check the oil level in the vibration bearings

NOTICE!
Check only at operating temperature after running the
machine approx. 1/2 hour with vibration.
Danger of bearing damage! Make sure that no dirt falls
into the exciter housing.
If a loss of oil is found perform trouble shooting, repair
the drum if necessary.
For quality of oil refer to the "table of fuels and lubri-
cants".

Park the machine on level ground.

Move the drum, until oil level inspection plug (1) Ä Fig. 133
on the left hand side of the drum is in bottom position.
Thoroughly clean the area around the level inspection and
filler plug.
Unscrew level inspection plug (1).

Some oil should run out of the inspection bore.

Fig. 133

If necessary unscrew oil filler plug (2) and fill in some oil
through the oil filler bore (2), until oil starts to drip out through
the inspection bore.
Screw oil filler (2) and level inspection plug (1) back in tightly.
Repeat this inspection on the other side.

6.7.8 Check the parking brake

WARNING!
Life hazard!
Before checking the parking brake make sure that
there are no persons or obstacles in front or behind the
machine.

Park the machine on level ground.

Open the engine hood.

120 BW 216 D-40 / BW 216 PD-40

 Maintenance

Pull the plug off the brake solenoid valveÄ Fig. 134.
Start the engine.

Fig. 134

Turn the rotary momentary contact switch for engine speed

Ä Fig. 135 clockwise to "MAX".

Fig. 135

Shift the travel lever Ä Fig. 136 out of braking position to the
left to disengage.
Pull the travel lever back first.
Then shift the travel lever forward.

NOTICE!
The machine should not move during this test.
Fig. 136 However, if the machine moves the parking brake
needs to be adjusted or repaired.
Adjustments to the parking brake must only be made
by authorized service personnel!
Only operate the machine after the travel control has
been repaired.

Reconnect the plug to the parking brake solenoid valve

Ä Fig. 134.
Close the engine hood.

BW 216 D-40 / BW 216 PD-40 121

 Maintenance

6.7.9 Checking, replacing the refrigerant compressor V-beltOptional equipment

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

Check the V-belt

Inspect the entire circumference of the V-belt Ä Fig. 137 vis-
ually for damage and cracks. Replace damaged or cracked
V-belts.
Check with thumb pressure whether the V-belt can be
depressed more than 10 to 15 mm (0.4 – 0.6 inches)
between the V-belt pulleys, retighten if necessary.

Fig. 137

Tighten the V-belt.

Slightly slacken fastening screws 1, 2 and 3 Ä Fig. 138.
Press the compressor in direction of arrow, until the correct
V-belt tension is reached.
Retighten all fastening screws.

Fig. 138

Changing the V-belt

Slightly slacken the fastening screws 1, 2 and 3.
Press the compressor against the direction of arrow com-
pletely against the engine.
Take the old V-belt off.
Fit the new V-belt to the V-belt pulleys.
Tension the V-belt as previously described.

122 BW 216 D-40 / BW 216 PD-40

 Maintenance

NOTICE!
Check the V-belt tension after a running time of 30
minutes.

BW 216 D-40 / BW 216 PD-40 123

 Maintenance

6.8 Every 500 operating hours

6.8.1 Changing engine oil and oil filter cartridge

Perform this maintenance work at the latest after one

year.

WARNING!
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil filter.

NOTICE!
Drain the oil only when the engine is warm.
For quality and quantity of oil refer to the "table of fuels
and lubricants".

Unscrew the drain plug and catch running out oil.

Turn the drain plug tightly back in.

Fig. 139

Thoroughly clean the outside of the filter cartridge.

Unscrew the filter cartridge using an appropriate filter
wrench.
Clean the sealing face on the filter carrier from any dirt.
Slightly oil the rubber seal on the new filter cartridge.

Fig. 140

124 BW 216 D-40 / BW 216 PD-40

 Maintenance

Turn the new filter cartridge on by hand, until the seal con-
tacts.
Tighten the filter element for another half turn.

Fig. 141

Fill in new engine oil .

Tighten the oil filler cap properly.
After a short test run check the oil level on the dipstick . The
oil level should reach the MAX-mark, top up oil if necessary.
Check filter cartridge and drain plug for leaks.
Dispose of oil and oil filter cartridge environmentally.

Fig. 142

6.8.2 Checking, tensioning, replacing the V-belt

WARNING!
Danger of accident!
Perform this work only with the engine shut down!

Check the V-belt

Check the entire circumference of the V-belts Ä Fig. 143 for
damage and cracks. Replace damaged or cracked V-belts.
Check with thumb pressure whether the V-belt can be
depressed more than 10 to 15 mm between the V-belt pul-
leys, retighten if necessary.

Fig. 143

BW 216 D-40 / BW 216 PD-40 125

 Maintenance

Tensioning the generator V-belt

Slightly slacken fastening screws 1, 2 and 3 Ä Fig. 144.
Press the generator in direction of arrow, until the correct V-
belt tension is reached.
Retighten all fastening screws.

Fig. 144

Replacing the generator V-belt

remove fan and pump V-belts, see following section.
Slightly slacken the fastening screws 1, 2 and 3.
Press the generator against the direction of arrow completely
against the engine.
Take the old V-belt off.
Fit the new V-belt to the V-belt pulleys.
Tension the V-belt as previously described.
Install fan and pump V-belt.

NOTICE!
Check the V-belt tension after a running time of 30
minutes.

Tightening the V-belt, coolant/fuel

pump
Slacken the fastening screws 1 and 2 Ä Fig. 145 slightly.
Press the idler pulley in direction of arrow, until the correct V-
belt tension is reached.
Retighten all fastening screws.

Fig. 145

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 Maintenance

Replacing the V-belt, coolant/fuel

pump
Take of the fan V-belt, see following section.
Slightly slacken fastening screws 1 and 2.
Press the idler pulley in opposite direction to the arrow com-
pletely against the engine.
Take the old V-belt off.
Fit the new V-belt to the V-belt pulleys.
Tension the V-belt as previously described.
Reinstall the fan V-belt.

NOTICE!
Check the V-belt tension after a running time of 30
minutes.

Tensioning the fan V-belt

Slacken the fastening screws 1 and 2 Ä Fig. 146 slightly.
Press the idler pulley in direction of arrow, until the correct V-
belt tension is reached.
Retighten all fastening screws.

Fig. 146

Replacing the fan V-belt

Unscrew the fastening screws Ä Fig. 147 and push the fan
forward.

Fig. 147

BW 216 D-40 / BW 216 PD-40 127

 Maintenance

Slightly slacken fastening screws 1 and 2 Ä Fig. 148.

Press the idler pulley in opposite direction to the arrow com-
pletely against the engine.
Take the old V-belt off.
Fit the new V-belt to the V-belt pulleys.
Tension the V-belt as previously described.

Fig. 148 NOTICE!

Check the V-belt tension after a running time of 30
minutes.

6.8.3 Draining the fuel tank sludge

WARNING!
Fire hazard!
When working on the fuel system do not use open fire,
do not smoke!
Do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.

Unscrew the drain plug Ä Fig. 149 from the bottom of the
fuel tank and drain off approx. 5 litres of fuel.
Screw the drain plug back in with a new sealing ring.

Fig. 149

128 BW 216 D-40 / BW 216 PD-40

 Maintenance

6.8.4 Battery service

WARNING!
Danger of cauterisation ! Danger of explosion!
When working on the battery do not use open fire, do
not smoke!
The battery contains acid. Do not let acid come in con-
tact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
For recharging remove the plugs from the battery to
avoid the accumulation of highly explosive gases.

ENVIRONMENT!
Dispose of the old battery environmentally.

Maintenance free batteries also need care. Mainte-

nance free only means that the fluid level does not
need to be checked. Each battery suffers under self-
discharge, which may, in not checked occasionally,
even cause damage to the battery as a result of
exhaustive discharge.

The following therefore applies for the service life:

Switch off all consumers (e.g. ignition, light, inside light,
radio).
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% dis-

charged.
Recharge the battery immediately after an open-circuit
voltage of 12.25 V or less is reached. Do not perform quick
charging.

The open-circuit voltage of the battery occurs approx. 10 hours

after the last charging process or one hour after the last discharge.
After each charging process allow the battery to rest for one
hour before taking it into service.
For resting periods of more than one month you should
always disconnect the battery. Do not forget to perform reg-
ular open-circuit voltage measurements.

BW 216 D-40 / BW 216 PD-40 129

 Maintenance

NOTICE!
Exhausted batteries (batteries with formation of sul-
phate on the plates) are not covered under warranty!

Remove the battery cover.

Remove the battery Ä Fig. 150 and clean the battery com-
partment.
Clean the outside of the battery.
Clean battery poles and pole clamps and grease them with
pole grease (Vaseline).
Check the fastening of the battery.
On serviceable batteries check the acid level, if necessary
top up to the filling mark with distilled water.

Fig. 150

6.8.5 Service the air conditioningOptional equipment

Clean the condenser
WARNING!
Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause damage or
explosion of the system.
Use access steps and grips to mount and dismount the
machine.

NOTICE!
A soiled condenser results in a considerable reduction
of air conditioning power.
Under extremely dusty conditions it may be necessary
to clean the condenser several times per day.
If, during operation of the air conditioning system, the
warning buzzer sounds switch the air conditioning off
and clean the condenser.
In case of formation of foam have the air conditioning
system inspected by the service department.

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 Maintenance

Unscrew the condenser fastening screws Ä Fig. 151 and

fold the condenser forward.

Fig. 151

Clean the condenser fins on front and back with compressed

air or cold water .

Checking the refrigerant level

Start the engine.

Turn the rotary switch for the cab ventilator Ä Fig. 152 to
position "1".

Fig. 152

Choose a cooling temperature with the rotary switch for the

air conditioning system Ä Fig. 153 in the blue section.

Fig. 153

Open the air outlet nozzles.

Check, whether the out flowing air is noticeably cooler.

BW 216 D-40 / BW 216 PD-40 131

 Maintenance

The adjusted temperature must be below the actual

temperature inside the cabin, so that the compressor
will be switched on.

Check whether the white float Ä Fig. 154 inside the inspec-
tion glass of the drier/collector unit floats right at the top.

The refrigerant level is correct.

Fig. 154

If the white float Ä Fig. 155 inside the inspection glass of the
drier/collector unit floats at the bottom, inform the service
department.

The refrigerant level is not correct.

Fig. 155

Refrigerant must be filled up, if necessary check the air con-

ditioning system for leaks.

Checking the moisture level of the

drying agent
Check the moisture indication pearl Ä Fig. 156 inside the
inspection glass of the drier/collector unit.

orange Drying agent o.k.

colourless moisture level of drying agent too
high.

Fig. 156

Inform the service department. Replace drier/collector unit,

check air conditioning system.

132 BW 216 D-40 / BW 216 PD-40

 Maintenance

NOTICE!
Have the drier/collector unit replaced by the service
department every year before the operating season.

Checking the condition of the drier/

collector unit NOTICE!
According to the regulation for pressure reservoirs all
pressure reservoirs must be repeatedly inspected by a
specialist. In this sense repeated inspections are
external examinations, normally on pressure reservoirs
in operation. In connection with this inspection the
drier/collector unit must be visually examined twice
every year. During these inspections special attention
must be paid to corrosion and mechanical damage. If
the reservoir is not in proper condition it must be
replaced for safety reasons, as a precaution to protect
operators and third parties against any danger arising
from the handling and operation of pressure reservoirs.

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

Check the drier/collector unit Ä Fig. 157 for mechanical

damage or rust.

Fig. 157

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 Maintenance

6.8.6 Cleaning the circulation air filter for the heatingOptional equipment
Unscrew screws (1) Ä Fig. 158.
Pull the filter (2) downwards out.
Clean the filter, replace if necessary.
Assemble the filter and tighten the screws.

Fig. 158

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 Maintenance

6.9 Every 1000 operating hours

6.9.1 Check, adjust the valve clearance

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

Valve adjustment schematic

Valve 1 Ä Fig. 159 white = not adjustable
Valve (2) black = adjustable

Fig. 159

Crankshaft position 1 Ä Fig. 160 (4 cylinder engine)

Fig. 160

Crank the engine with the starter or a spanner by the V-belt

pulley until both valves on cylinder 1 are “overlapping”.

Overlapping means: Exhaust valve not yet closed, intake valve

starts to open.
Perform the adjustment of the valve by following the adjust-
ment diagram "crankshaft position 1", black mark.
For control purposes mark the respective rocker arm with
while chalk once the corresponding valve is adjusted.

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 Maintenance

Crankshaft position 2 Ä Fig. 161 (4 cylinder engine)

Fig. 161

Turn the crankshaft one revolution (360°) further.

Perform the adjustment of the valve by following the adjust-
ment diagram "crankshaft position 2", black mark.

Checking the valve clearance

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

Remove the valve cover Ä Fig. 162.

Crankshaft position as per "valve adjustment schematic".

Fig. 162

Check valve clearance 2 Ä Fig. 163 between rocker arm (1)

and valve (3) with a feeler gauge.

Intake valve 0,3 mm

Exhaust valve 0,5 mm

The feeler gauge must fit with little resistance.

Fig. 163

If the gap is too narrow or too wide for the feeler gauge, the
valve must be adjusted.

136 BW 216 D-40 / BW 216 PD-40

 Maintenance

Adjusting the valve clearance

Slightly slacken the counter nut. Adjust setscrew 7
Ä Fig. 164 with a screwdriver, until the feeler gauge (6) can
be inserted and pulled out with little resistance after retight-
ening the counter nut.
Perform tests and adjustments on all other adjustable valves.
Check the gasket of the valve cover, replace it if necessary.
Reassemble the cylinder head cover.
Swivel the ventilation valve back to correct position and
fasten it.
Fig. 164 Fasten the air filter again and ensure correct fit of combustion
air hoses and clamps.

6.9.2 Change the fuel filter cartridge

WARNING!
Fire hazard!
When working on the fuel system do not use open fire,
do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.

Loosen and unscrew the fuel filter cartridge Ä Fig. 165 using
an appropriate filter wrench.
Clean the sealing face on the filter carrier from any dirt.

Fig. 165

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 Maintenance

Slightly oil the rubber seal Ä Fig. 166 on the new filter car-
tridge.
Fill the filter cartridge with clean diesel fuel.
Turn the new filter cartridge on by hand, until the seal con-
tacts.
Tighten the filter element for another half turn.
Check the filter cartridge for leaks after a short test run.

Fig. 166

6.9.3 Change the fuel pre-filter cartridge

WARNING!
Danger of fire, health hazard!
When working on the fuel system do not use open fire,
do not smoke and do not spill any fuel.
Do not inhale any fuel fumes.

NOTICE!
Ensure strict cleanliness! Thoroughly clean the area
around the fuel filters.
The filter cartridge must never be filled beforehand.
After work on the fuel system bleed the system, per-
form a test run and check for leaks.
Additional bleeding of the fuel system by a 5 minute
test run in idle speed or low load is mandatory.

ENVIRONMENT!
Any fuel must be caught and disposed of in an envi-
ronmentally friendly manner.

138 BW 216 D-40 / BW 216 PD-40

 Maintenance

Change the fuel pre-filter cartridge

Tighten the cable on the water separator Ä Fig. 167.
(1) Loosen the bleeding screw and drain off fuel from the
bleeding screw.
(2) Loosen and unscrew the fuel pre-filter cartridge using an
appropriate filter wrench.
(3) Unscrew the water separator from the filter cartridge.
(4) Apply a thin coat of oil to the rubber seal of the water sep-
arator.
(5) Turn the water separator on by hand, until the seal con-
Fig. 167 tacts, then tighten hand-tight.
(6) Apply a thin coat of oil to the rubber seal of the filter ele-
ment (5).
(7) Turn the filter cartridge on by hand, until the seal con-
tacts, then tighten hand-tight.
Plug the water sensor cable back on.

Bleed the fuel system

Air in the fuel system causes irregular running of the
engine, a drop in engine power, stalls the engine and
makes starting impossible.
Therefore bleed the fuel system after changing the fuel
pre-filter or working on the fuel system.

Slacken the bleeding screw Ä Fig. 168 on the fuel pre-filter

for 2 to 3 turns.

Fig. 168

Operate the hand pump manually, until fuel flows out of the
slackened bleeding screw without air bubbles.
Then tighten the bleeding screw while pumping.
Check the filter cartridge for leaks

BW 216 D-40 / BW 216 PD-40 139

 Maintenance

6.9.4 Check the engine mounts

Tighten fastenings of intake and exhaust manifolds
Ä Fig. 169 on the cylinder heads.
Check sockets and clamps between air filter, exhaust turbo-
charger and charge air line as well as the lubrication air line
for tight fit and leaks.
Retighten the fastening screws for oil sump and engine
mounts.

Fig. 169

6.9.5 Change the oil in the vibration bearings

WARNING!
Danger of scalding!
When draining off hot oil.

NOTICE!
Drain oil only at operating temperature. For this pur-
pose run the machine approx. half an hour with vibra-
tion.
For quality and quantity of oil refer to the "table of fuels
and lubricants".

NOTICE!
Danger of bearing damage!
Make sure that no dirt falls into the exciter housing.
Overfilling causes overheating and destruction of the
vibration bearings!

ENVIRONMENT!
Catch running out oil and dispose of environmentally.

Perform this maintenance work at the latest after one

year.

140 BW 216 D-40 / BW 216 PD-40

 Maintenance

Move the drum, until the drain plug (1) is in bottom position.
Thoroughly clean the area around the level inspection and
filler plug.
Unscrew the drain plug, let the oil run out and catch it.
Turn the oil drain plug back in tightly after all oil has run out.

Fig. 170

Unscrew oil level inspection plug (1) on the drum and fill in oil
through the filler opening (2), until it starts to drip out from the
level inspection bore.
Screw oil filler (2) and level inspection plug (1) back in tightly.
Repeat the oil change on the opposite side.
Check the oil level once again at operating temperature (after
running the machine for about half an hour with vibration).

Fig. 171

6.9.6 Changing the oil in the drum reduction gear

NOTICE!
Drain oil only at operating temperature.

ENVIRONMENT!
Catch old oil and dispose of environmentally.

Perform this maintenance work at the latest after one

year.

Move the drum until drain and filler plugs are exactly verti-
cally in line.

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 Maintenance

Unscrew the filler plug at the top Ä Fig. 172.

Unscrew the drain plug at the bottom and catch running out
oil.
Turn the oil drain plug back in tightly after all oil has run out.

Fig. 172

Unscrew the level inspection plug Ä Fig. 173.

Fig. 173

Fill in oil through the filler bore Ä Fig. 174, until it reaches
the bottom edge of the inspection bore.

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

Fig. 174

Clean filler and level control plugs and screw them tightly
back in with new sealing rings.

6.9.7 Changing the oil in the drive axle

On other axle versions drain and filler plugs are of

slightly different design. Perform the oil change
accordingly.

142 BW 216 D-40 / BW 216 PD-40

 Maintenance

NOTICE!
Drain oil only at operating temperature.

ENVIRONMENT!
Catch old oil and dispose of environmentally.

Perform this maintenance work at the latest after one

year.

Park the machine on level ground.

Clean and unscrew all level inspection and drain plugs

Ä Fig. 175.
Drain and catch all oil.
Clean the drain plug and turn it back in with a new seal ring.

Fig. 175

Fill in oil through the oil level inspection bores Ä Fig. 176,
until it has reached the bottom edge of the bore.

The second level inspection plug as at the back.

After filling in oil wait until the oil has evenly distributed
inside the axle.

For quality and quantity of oil refer to the table of fuels and
Fig. 176 lubricants.

Retighten the filler and level inspection plug.

BW 216 D-40 / BW 216 PD-40 143

 Maintenance

6.9.8 Changing the oil in the wheel hubs

NOTICE!
Drain oil only at operating temperature.
Change the oil on both sides of the axle.

ENVIRONMENT!
Catch old oil and dispose of environmentally.

Perform this maintenance work at the latest after one

year.

Move the drive wheel, until the plug Ä Fig. 177 is in bottom
position.
Clean and unscrew the plug.
Drain and catch all oil.

Fig. 177

Move the drive wheel, until the plug Ä Fig. 178 is in hori-
zontal position on the housing.
Fill in oil, until it reaches the bottom edge of the bore .

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

Fig. 178

Turn the plug tightly back in.

144 BW 216 D-40 / BW 216 PD-40

 Maintenance

6.9.9 Changing the oil in the axle reduction gear

NOTICE!
Drain oil only at operating temperature.

ENVIRONMENT!
Catch old oil and dispose of environmentally.

Perform this maintenance work at the latest after one

year.

Unscrew the filler plug Ä Fig. 179.

Unscrew the oil drain plug and catch any oil running out.
Turn the oil drain plug back in tightly after all oil has run out.
Fill in oil through the filler and level inspection bore, until it
reaches the bottom edge of the bore.

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

Fig. 179

Clean the drain plug and screw it back in with a new seal
ring.

6.9.10 Retighten the fastening of the axle on the frame

Check all fastening nuts on axle mounting bolts Ä Fig. 180
for tight fit.

Fig. 180

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 Maintenance

6.9.11 Tightening the wheel nuts

Tighten the wheel nuts Ä Fig. 181 in a cross-type pattern.

Fig. 181

6.9.12 Checking the ROPS

On machines with cabin the ROPS (roll over protection

structure) is an integral part of the cabin.
Please observe also the corresponding section in the
safety regulations in this manual.

Check the cabin, especially the ROPS Ä Fig. 182 for cracks,
corrosion, damage and missing fastening elements.

Unusual movements and noises (vibrations) during

operation are signs for damage or loosened fastening
elements.

Fig. 182

Check the fastening screws for the cabin (ROPS) to the oper-
ator's platform for tight fit.
Check the suspension buffers for the operator's stand for
tight fit.
Check the condition and the fastening of the seat belt.

146 BW 216 D-40 / BW 216 PD-40

 Maintenance

6.9.13 Check the travel control

Move the travel lever Ä Fig. 183 forward, backwards and to
braking position. Thereby check for function, light movement,
clearance and damage.
In case of malfunction perform trouble shooting and replace
the corresponding parts.

NOTICE!
Only operate the machine after the travel control has
Fig. 183 been repaired.

BW 216 D-40 / BW 216 PD-40 147

 Maintenance

6.10 Every 2000 operating hours

6.10.1 Changing hydraulic oil and breather filter

See also the notes on the hydraulic system in the

chapter "General notes on maintenance".

WARNING!
Danger of scalding!
When draining off hot hydraulic oil!

NOTICE!
The hydraulic oil must also be changed after major
repairs in the hydraulic system.
Perform the oil change when the hydraulic oil is warm.
Replace the hydraulic oil filter elements with every
hydraulic oil change.
Change the filter only after the hydraulic oil change
and after the test run.
Clean the area round hydraulic oil tank, filler opening
and breather filter.
Do not start the engine after draining the hydraulic oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
For quality and quantity of oil refer to the "table of fuels
and lubricants".
When changing from mineral oil based hydraulic oil to
an ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manufac-
turer for details.

ENVIRONMENT!
Catch running out hydraulic oil and dispose of environ-
mentally.

Perform this maintenance work at the latest after two

years.

148 BW 216 D-40 / BW 216 PD-40

 Maintenance

Unscrew the plug and drain off all hydraulic oil.

Check the seal ring, replace if necessary and turn the plug
tightly back in.

Fig. 184

Remove the filler cap.

Fill in new hydraulic oil through the screen.

We recommend to use our filling and filtering unit with

fine filter to fill the system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the
hydraulic oil filter and protects the hydraulic system.

Fig. 185

Check the oil level in the inspection glass.

Nominal value:
approx. 3 cm below the upper edge of the inspection glass

The breather filter for the hydraulic oil tank is inte-

grated in the filler cap, you must therefore replace the
complete filler cap.

Close the tank with a new cap.

6.10.2 Changing the hydraulic oil filter

WARNING!
Danger of scalding!
Danger of scalding by hot oil when unscrewing the oil
filter.

BW 216 D-40 / BW 216 PD-40 149

 Maintenance

NOTICE!
If the filter has to be changed together with the
hydraulic oil, the filter must only be changed after the
oil change and after the test run.
Do not use the oil in the filter bowl again.

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

The filter element must be changed with every

hydraulic oil change and after major repairs in the
hydraulic system.

Unscrew the cap nut 4 Ä Fig. 186 and take the filter bowl (5)
with the filter element (3) off.
Examine the sealing face on the filter element thoroughly for
any visible dirt.

NOTICE!
Visible dirt may be an early sign for the failure of
system components and indicate the possible failure of
Fig. 186 components. In this case determine the cause and
replace or repair the defective components, if neces-
sary. Negligence may cause destruction to the entire
hydraulic system.
Do not clean or reuse the filter element.

Take the old filter element (3) out and clean the filter bowl
and the thread.
Reinstall the filter bowl with the new filter element, check the
condition of the O-rings (1) and (2), replace if necessary.
After a test run check the filter for leaks.

6.10.3 Changing the coolant

Perform this maintenance work at the latest after two

years.

150 BW 216 D-40 / BW 216 PD-40

 Maintenance

WARNING!
Danger of scalding!
Change the coolant only when the engine is cold.

NOTICE!
Do not start the engine after draining off the coolant.
In case of lubrication oil entering into the cooling
system or a suspicious turbidity caused by corrosion
residues or other suspended matter, the coolant must
be drained off and the complete cooling system needs
to be cleaned. Lubrication oil can damage the sealing
materials used in the engine.
When changing the coolant without any signs of con-
tamination, cleaning of the cooling system is not nec-
essary.
For quality and quantity of coolant refer to the "table of
fuels and lubricants".
Do not mix different coolants and additives, see sec-
tion "Fuelds and Lubricants - Coolant".

ENVIRONMENT!
Catch coolant and dispose of environmentally.

Unscrew the lid from the compensation tank.

Fig. 187

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 Maintenance

Unscrew the plug, let the coolant run out and catch it.
Check the condition of the coolant.

NOTICE!
Thoroughly flush the cooling system if the
coolant is contaminated by corrosion residues or
other suspended matter.
If lubrication oil has entered you must add a
cleansing agent in order to remove any residues
from the system. Follow the instructions of the
Fig. 188
manufacturer. If in doubt consult your local
service station or the engine manufacturer.

Remove the thermostat.

Fill in clean water.
Start the diesel engine and run it warm to operating tempera-
ture.
Allow the engine to cool down to approx. 50 °C.
Drain all water off.
When using a cleansing agent repeat the flushing process
twice with clear water.
Screw the plug back in once all coolant has run out.
Reinstall the thermostat .

NOTICE!
The anti-freeze concentration (additive) must be
at least 35 Vol% and maximum 50 Vol%.

Fill in coolant up to the MAX-mark and screw the filler cap

back on.
Start the diesel engine and run it warm to operating tempera-
ture.
Fig. 189 Check the coolant level again, top up if necessary.

152 BW 216 D-40 / BW 216 PD-40

 Maintenance

6.11 Every 3000 operating hours

6.11.1 Checking the injection valves

This work must only be performed by authorized

service personnel.
The injection valves must be replaced every 12000
operating hours.

BW 216 D-40 / BW 216 PD-40 153

 Maintenance

6.12 As required
6.12.1 Air filter maintenance

NOTICE!
Do not start the engine after having removed the air
filter.
If necessary, the air filter may be cleaned up to six
times. After one year at the latest it must be replaced
together with the safety element.
Cleaning does not make sense if the air filter element
is covered with a sooty deposit.
Do not use gasoline or hot fluids to clean the filter ele-
ment.
After cleaning the air filter must be inspected for
damage using a torch.
Do not continue to use a damaged air filter element. If
in doubt use a new air filter.
If the air filter is damaged, the safety element must be
replaced as well.
The safety element must not be cleaned.

We generally recommend to renew the air filter. A new

filter element is far less expensive than a possible
engine damage.

Servicing of the dry air filter is necessary when the yellow piston
Ä Fig. 190 has reached the red underlaid inscription "Service", but
at the latest after one year.

Fig. 190

After completion of the filter service reset the indicator back

to "Zero" by pressing the button.

154 BW 216 D-40 / BW 216 PD-40

 Maintenance

Open the engine hood Ä Fig. 191 completely and secure it.

Fig. 191

Loosen both locking hooks Ä Fig. 192 on the housing cover

and take the cover off.
Clean cover and dust discharge valve.

Fig. 192

Pull out the main filter element Ä Fig. 193 with light turning
movements.

WARNING!
Danger of injury!
Wear protective clothing (goggles, gloves).

Fig. 193

Blow the air filter Ä Fig. 194 out with dry compressed air
(max. 5 bar (70 psi)) from inside to outside by moving the
gun up and down inside the element, until it if free of dust.

Fig. 194

BW 216 D-40 / BW 216 PD-40 155

 Maintenance

Examine the air filter with a torch for cracks and holes in the
paper bellows Ä Fig. 195.
In case of damage replace the air filter and the safety ele-
ment.

Fig. 195

Slide the air filter carefully into the housing Ä Fig. 196.

NOTICE!
The dust discharge valve must point vertically down-
wards.
Make sure that the cover locks engage correctly.

Fig. 196

Reassemble the housing cover.

Replacing the safety element

NOTICE!
The safety element must not be cleaned and should
not be used again after it has been removed.

The safety element must be replaced:

if the air filter is damaged.
at the latest after 1 year.
if the air filter warning lamp comes on again after the air
filter has been cleaned.

156 BW 216 D-40 / BW 216 PD-40

 Maintenance

Remove the housing cover and pull the air filter off.
Pull the safety element Ä Fig. 197 out by turning it lightly.
Push in a new safety filter element.
Insert the air filter and reassemble the housing cover.

Fig. 197

6.12.2 Retightening the padfoot shell

After the installation of the padfoot shell, all fastening screws must
be retightened.
Run an approx. two minute test drive with vibration.
Park the machine in secured condition.
Retighten all fastening screws.
After approx. 60 minutes work retighten all fastening screws
again.

Fig. 198

6.12.3 Adjusting the scrapers

smooth drum only
Check the condition and adjustment of the front and rear
scrapers, adjust or replace the scraper rubber if necessary.
To adjust the scrapers 1 Ä Fig. 199 loosen the fastening
screws (2) in the slots and push the scraper bracket towards
the drum until the scraper touches.
Retighten the fastening screws.

Fig. 199

BW 216 D-40 / BW 216 PD-40 157

 Maintenance

padfoot drum only

Check condition and adjustment of scrapers 2 Ä Fig. 200,
adjust or replace the teeth if necessary.
To adjust the scrapers (2) slacken the fastening screws (1) in
the slots and move the scraper towards the drum, leaving a
gap of approx. 25 mm.
Retighten the fastening screws.

Fig. 200

6.12.4 Clean the machine

NOTICE!
When using a steam cleaner for cleaning do not sub-
ject electrical parts and insulation material to the direct
jet or cover these items beforehand.
Allow the engine to cool down before cleaning.

Clean the machine Ä Fig. 201 thoroughly at least once per

week.

When used on highly cohesive soils, on cement or trass-lime

mortar or for similar work, the machine must be thoroughly cleaned
every day.
Please observe that the correct function of the scrapers is ensured
and that no material will build up between rollers and frame.

Fig. 201

6.12.5 Changing the tires

WARNING!
Danger of accident!
Observe all safety regulations for the lifting of loads.

Place a jack (min. 5 t bearing capacity) under the rear frame

and jack the machine up so that the wheel can turn freely.
Unscrew the wheel nuts and take the wheel off.

158 BW 216 D-40 / BW 216 PD-40

 Maintenance

Attach the wheel Ä Fig. 202 and tighten the wheel nuts
crosswise with 550 Nm (405 ft. lb.).
Check the tire pressure, see technical data.

Fig. 202

6.12.6 Change the fresh air filter in the cabin

Unscrew fastening screws for the ventilation grid Ä Fig. 203
and remove the filter.
Insert a new filter and reassemble the ventilation grid.

Fig. 203

6.12.7 Fill the provision tank for the windscreen washer systemOptional equipment
Check the fluid level in the tank Ä Fig. 204, top up if neces-
sary.
For winter operation fill in the appropriate amount of ant-
freeze agent; refer to the specifications of the manufacturer
of the ant-freeze agent.

Fig. 204

BW 216 D-40 / BW 216 PD-40 159

 Maintenance

6.12.8 Tightening torques

* Strength classes for screws with untreated, non-lubricated sur-
face. Screw quality designations are stamped on the screw heads.
8.8 = 8G
10.9 = 10K
12.9 = 12K

Fig. 205

Axle - frame

M 22x1.5 710 Nm

Wheel nuts

M 22x1.5 550 Nm

The values result in a 90% utilization of the screw yield point at a

coefficient of friction μ total = 0,14. When using lubricant MOS2 the
specified tightening torques do not apply.

Self locking nuts must always be replaced by new

ones after they have been unscrewed.

6.12.9 Engine conservation

If the engine is to be shut down for a longer period of time (e.g.
over winter), please consult the service department of the engine
manufacturer for further details.

160 BW 216 D-40 / BW 216 PD-40

 Trouble shooting

7 Trouble shooting

BW 216 D-40 / BW 216 PD-40 161

 Trouble shooting

7.1 General notes

Please observe strictly the safety regulations in the corre-
sponding section of these operating and maintenance instruc-
tions.
Malfunctions are frequently caused by incorrect operation of the
machine or insufficient maintenance. Whenever a fault occurs you
should therefore thoroughly read these instruction on correct oper-
ation and maintenance.
If you cannot locate the cause of a fault or rectify it yourself by fol-
lowing the trouble shooting chart, you should contact our customer
service department.

162 BW 216 D-40 / BW 216 PD-40

 Trouble shooting

7.2 Starting the engine with jump leads

NOTICE!
A wrong connection will cause severe damage in
the electric system.
– Bridge the machine only with a 12 Volt auxiliary
battery.

Connect the plus pole of the external battery first with the
plus pole of the vehicle battery using the first jump lead.
Then connect the second battery cable first to the minus pole
of the current supplying auxiliary battery and then to engine
or chassis ground, as far away from the battery as possible.
Start the engine.

NOTICE!
Danger of damage to the electronic system!
If no powerful consumer is switched on voltage peaks
Fig. 206
may occur when separating the connecting cables
between the batteries, which could damage electrical
components.

Once the engine is running switch on a powerful consumer

(working light, etc.).
After starting disconnect the negative poles first and the posi-
tive poles after.
Switch off the consumer.

BW 216 D-40 / BW 216 PD-40 163

 Trouble shooting

7.3 Reading out faults BVC/BTM05

Turn the ignition key Ä Fig. 207 to position "I".

Fig. 207

Press key ’’?“ (menu) Ä Fig. 208.

The menu appears on the screen.

Fig. 208

Press key "F5" (diagnostics) Ä Fig. 209.

The screen with the currently available fault codes is

displayed.

Fig. 209

Currently present faults are indicated by a corresponding

fault code in the field "Actual Errors".

Fig. 210

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 Trouble shooting

Press key "ESC" Ä Fig. 210 to leave the screen page with
the actual fault codes.

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 Trouble shooting

7.4 Engine
Fault description Cause Remedy
The engine does not start Starter defective or pinion not Have examined by a specialist
engaging
Fuel tank empty Fill and bleed the tank
Temperature below starting limit Use winter fuel and engine oil acc. to
the ambient temperature.
Fuel filter clogged, in winter due Change the filter. use winter fuel
to paraffin separation.
Fuel lines leaking Check all line connections for leak-
ages and tighten the fittings.
Battery discharged or not con- Tighten the pole clamps, check the
nected cable connections
Injection valves or injection pump Have examined by a specialist
defective
The engine starts poorly and Battery power too low, battery Have the battery checked, clean the
works irregularly with poor clamps loose or oxidized, causing terminal clamps, tighten them and
power the starter to turn too slowly cover them with acid free grease
Especially during winter: the use Use engine oil suitable for the
of too viscous engine oil ambient temperature
Fuel supply restricted, in winter Change the fuel filter. Check the line
fuel system clogged due to par- connections for leaks and tighten the
affin separation fittings. Use winter fuel in the cold
season.
Incorrect valve clearance Adjust the valve clearance
Injection valve defective Have examined by a specialist
Injection lines leaking Check the lines for leakages
Turbo charger defective Have examined by a specialist
Dry air filter dirty clean, replace if necessary
Excessive play in the throttle Adjust the throttle cable, change it if
cable necessary
Excessive exhaust smoke Engine oil level too high Drain the oil to the upper dipstick
mark
Dry air filter dirty clean, replace if necessary
Exhaust gas turbo-charger defec- Have examined by a specialist
tive
Poor compression due to burned Have compression rings and pistons
or broken compression rings or examined by a specialist, adjust the
incorrect valve clearance valve clearance
Incorrect valve clearance Adjust the valve clearance

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 Trouble shooting

Fault description Cause Remedy

Engine overheats, shut down Cooling fins on radiator extremely Clean the cooling fins
immediately! soiled (the warning light "engine
oil temperature" lights)
Injection valve defective Have examined by a specialist
Engine oil level too low Top up engine oil to the upper dipstick
mark
Filling capacity of the injection Have adjusted by a specialist
pump not correctly adjusted
Cooling air flow restricted Clean the cooling air duct
V-belt loos or broken Tension or replace the V-belt
Poor engine power Engine oil level too high Drain the engine oil down to the upper
dipstick mark
Dry air filter dirty clean, change if necessary
Exhaust gas turbo-charger defec- Have examined by a specialist
tive
Charge air hose leaking Check fastening and connections
Incorrect valve clearance Adjust the valve clearance
Injection valve defective Have examined by a specialist
Engine oil pressure too low Engine oil level too low (control Top up oil
light "engine oil pressure" lights,
the warning buzzer sounds)
Leakages in the lubrication Shut the engine down immediately,
system check fittings on oil lines, lubrication
oil filter and oil cooler for leaks, if nec-
essary tighten the fittings.
The charge control light lights Generator speed too low Check the V-belt tension, replace the
during operation, the warning V-belt if necessary
buzzer sounds
The generator does not charge Have examined by a specialis
the battery, because generator or
regulator is defective

BW 216 D-40 / BW 216 PD-40 167

 Trouble shooting

168 BW 216 D-40 / BW 216 PD-40

 Cab assembly before initial start-up

8 Cab assembly before initial start-up

BW 216 D-40 / BW 216 PD-40 169

 Cab assembly before initial start-up

General safety regulations for When installing the cabin to your machine you must strictly
assembly comply with the valid accident prevention instructions or the
country specific regulations. However, dangers for persons
and property may still arise, if:
the lifting gear used has a too low bearing capacity
damaged or worn lifting tackle is used
unqualified personnel is entrusted with the installation
the safety instructions are not observed

Each person involved in the installation of the cabin must

therefore read and comply with these safety regulations. If
necessary, the customer must demand a written confirmation
with signature.
Moreover, the following instructions and regulations must obviously
also be complied with:
applicable accident prevention instructions
generally accepted safety and road traffic regulations
country specific safety regulations. It is the duty of the oper-
ator to be acquainted with these instructions and to apply
these accordingly. This applies also for local regulations con-
cerning different types of handling work. Should the recom-
mendations in these instructions be different from the regula-
tions valid in your country, you must comply with the safety
regulations valid in your country.

Changes and conversions to the Unauthorized changes to the cabin are prohibited for safety rea-
cabin/machine sons.
Original parts and accessories have been specially designed for
this machine. We wish to make explicitly clear that we have not
tested or approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse
effect on the active and/or passive driving safety.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.

Notes on safety in the assembly

instructions WARNING!
Paragraphs marked like this highlight possible dangers
for persons.

NOTICE!
Paragraphs marked like this highlight possible dangers
for machines or parts of the machine.

170 BW 216 D-40 / BW 216 PD-40

 Cab assembly before initial start-up

Paragraphs marked like this contains technical infor-

mation and hints for optimal assembly.

ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubricants
as well as replacement parts.
Strictly observe the national regulations for the protec-
tion of the environment.

Information and safety stickers/ Keep stickers/decals in good and legible condition (see spare parts
decals on the cabin catalogue) and comply with their meaning.
Replace damaged stickers/decals

Work on heating lines Before starting work on heating pipes relieve any pressure and let
them cool down - danger of scalding!
After completing work on the heating system of the machine check
all connections and fittings for leaks.

Working on electric parts of the Before starting to work on electric parts of the machine disconnect
machine the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not repair
fuses with a piece of wire. Fire hazard.

8.1 Preparations

WARNING!
Danger of accident!
For transport purposes the driver's seat must be tied
down with cable straps thus to operate the seat con-
tact switch. Before resuming operation of the machine
these cable straps must strictly be removed to ensure
safe and reliable function of the seat contact switch.
Check the 4 lifting eyes on the cabin roof for tight fit.
Fasten the lifting gear to all four lifting eyes.
Use lifting gear (chains or ropes) of sufficient load
bearing capacity. The minimum load bearing capacity
of the crane must be 1000 kg.
Do not stand or step under loads being lifted.

BW 216 D-40 / BW 216 PD-40 171

 Cab assembly before initial start-up

Make sure that all fastening screws, washers, spacers and

nuts to fasten the cabin are available Ä Fig. 211.

Fig. 211

Check whether rear rack, foot mat, step plate and fastening
kit are available.

Fasten the lifting gear to the four lifting eyes 1 Ä Fig. 212.
Loosen possible fastening on the transport pallet.

Fig. 212

Slowly list the crane with a crane.

WARNING!
Danger of accident!
Do not stand or step under loads being lifted.

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 Cab assembly before initial start-up

8.2 Cabin assembly

WARNING!
Danger of accident!
Use lifting gear (chains or ropes) of sufficient load
bearing capacity. The minimum load bearing capacity
of the crane must be 1000 kg.
Do not stand or step under loads being lifted.

Clean the operator's stand of dirt, oil and moisture.

Stick the supplied sealing tape 1 Ä Fig. 213 along the edge
of the operator's stand.

NOTICE!
Only unroll and stick the sealing tape on just before
mounting the cab to the operator's stand. The sealing
tape will swell a few minutes after being unrolled. In
this case the cabin can no longer be mounted!

Fig. 213

Stick the sealing tape 1 Ä Fig. 214 all around the operator's
stand.
Do not run the sealing tape across the front recess in the
operator's stand (2), since this is the air inlet for the cabin
ventilation.

Mount the cabin immediately after sticking on the

sealing tape, because the sealing tape will swell.
Fig. 214

Spray the sealing tape with soapsuds Ä Fig. 215, to be able

to slide the cabin on the operator's stand.

Fig. 215

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 Cab assembly before initial start-up

Slowly lower the cabin vertically to the operator's stand

Ä Fig. 216.

NOTICE!
The cabine must be lowered vertically onto the opera-
tor's stand.

Fig. 216

NOTICE!
Take care that none of the hoses and electric cables
become squashed Ä Fig. 217.

Fig. 217

Run cables and hoses from inside the cabin through the
operator's stand to the outside.

Turn both fastening screws Ä Fig. 218 at the rear of the

cabin in handtight.

Fig. 218

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 Cab assembly before initial start-up

If the bores do not match the cabin can be moved into

position by means of a crow bar Ä Fig. 219.

Fig. 219

Tighten the bottom fastening screw on the access side

Ä Fig. 220 with 578 Nm.

Fig. 220

Loosen both fastening screws Ä Fig. 221 at the rear of the

cabin again.

The cabin will now slide into final assembly position.

Fig. 221

Tighten both fastening screws Ä Fig. 221 at the rear of the

cabin with 578 Nm.

BW 216 D-40 / BW 216 PD-40 175

 Cab assembly before initial start-up

Tighten the rear lateral fastening screw on the left hand side
with 578 Nm Ä Fig. 222.

Fig. 222

Tighten the rear lateral fastening screw on the right hand side
with 578 Nm Ä Fig. 223.

Fig. 223

Tighten the rear inside fastening screw on the right hand side
with 578 Nm Ä Fig. 224.

Fig. 224

Turn nuts with washers onto both studs and tighten with 200
Nm Ä Fig. 225.

Fig. 225

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 Cab assembly before initial start-up

Tighten the front lateral fastening screw on the right hand

side with 578 Nm Ä Fig. 226.

Fig. 226

Tighten the front lateral fastening screw on the left hand side
with 578 Nm Ä Fig. 227.

Fig. 227

Cover all lateral fastening screws with plastic caps

Ä Fig. 228.

Fig. 228

Insert the foot mat 1 Ä Fig. 229.

Fig. 229

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 Cab assembly before initial start-up

Attach the step plate 1 Ä Fig. 230 and tighten the three fas-
tening screws (2).

Fig. 230

Insert the dashboard and fasten it with four fastening screws

Ä Fig. 231.

Fig. 231

Insert the rear rack and knock both plastic fasteners carefully
into the bores with a hammer Ä Fig. 232.

Fig. 232

Connect the feed 1 Ä Fig. 233 and the return flow (2) for the
air conditioning system with quick release couplings.
Connect the feed (4) and the return flow (3) of the heating.
(Observe the marks on the hoses).

Run the connecting lines for the heating parallel to

each other (do not cross).

Fig. 233

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 Cab assembly before initial start-up

Check the function of air conditioning and heating

within the scope of the function test.
Observe identical hose diameters when connecting.

Plug on both connecting plugs for the washing water pumps

Ä Fig. 234.

Fig. 234

Plug on the hoses for the washing water supply to front and
rear windscreens 1 Ä Fig. 235.

Check the function of the washing water system within

the scope of the function test.

Fig. 235

Insert the plug 1 Ä Fig. 236 into the socket (2).

Close the bayonet catch by turning the corrugated cap nut in
clockwise direction against the stop.

WARNING!
Before starting to work on electric parts of the machine
disconnect the battery and cover it with insulating
material.
Fig. 236

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 Cab assembly before initial start-up

Connect the plug connection of the air conditioning system

Ä Fig. 237.

Fig. 237

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 Cab assembly before initial start-up

8.3 Final function tests and checks

NOTICE!
Make sure that all screws have been tightened with the
specified torque.

After the cabin assembly the following tests must be

performed to assure that all cables and lines are cor-
rectly connected.

Insert the ignition key and turn clockwise to position "1".

Operate the switches for headlights, direction indicators and
interior light to check their function.
Operate the switches for front and rear windscreen washer
system and check their correct function.

If the function of the windscreen washer system is

reversed, the two washing water hoses must be inter-
changed.

Start the engine.

Switch the air conditioning on by the switch. After a five

minute operation the cabin must become noticeably cooler.
Switch the air heater on by the switch. After a five minute
operation the cabin must become noticeably warmer.

Function of the seat contact switch.

NOTICE!
The machine must not be operated if the seat contact
switch is not functioning correctly.

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 Cab assembly before initial start-up

182 BW 216 D-40 / BW 216 PD-40

 Disposal

9 Disposal

BW 216 D-40 / BW 216 PD-40 183

 Disposal

9.1 Final shut-down of machine

If the machine can no longer be used and needs to be finally shut
down you must carry out the following work and have the machine
disassembled by an officially recognized specialist workshop.

WARNING!
Danger of cauterisation ! Danger of explosion!
When working on the battery do not use open fire, do
not smoke!
The battery contains acid. Do not let acid come in con-
tact with skin or clothes!
Wear protective clothing!

Remove the batteries and dispose of in compliance with legal

regulations.

ENVIRONMENT!
Catch all fuels and lubricants, do not let them seep into
the ground and dispose of in compliance with legal
regulations.

Empty the fuel tank.

Drain the hydraulic oil tank.
Drain coolant from engine and cooling system.
Drain off engine and transmission oil

WARNING!
Danger of explosion!
Parts that previously contained combustible fluids must
not be cut with a cutting torch.

184 BW 216 D-40 / BW 216 PD-40