00820764EN.g22-1

Operating Instruction
Maintenance Instruction
Original Operating Instructions
BW 212 D-5 SL
S/N 961 584 36 1001>
Single drum roller
008 207 64 EN © 07/2022

WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm.
Always start and operate the engine in a well-ventilated area.

If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING: Crude oil, gasoline, diesel fuel and other petroleum

products can expose you to chemicals including toluene and benzene,
which are known to the State of California to cause cancer and birth
defects or other reproductive harm.
These exposures can occur in and around oil fields, refineries, chemical
plants, transport and storage operations such as pipelines, marine
terminals, tank trucks and other facilities and equipment.
For more information go to www.P65Warnings.ca.gov/petroleum.
2
Table of contents
Table of contents
1 Introduction............................................................................................ 9
1.1 Foreword....................................................................................... 10
1.2 Machine type plate and engine type plate................................. 12
2 Technical data...................................................................................... 13
2.1 Noise and vibration data.............................................................. 17
2.1.1 Noise data................................................................................... 17
2.1.2 Vibration data.............................................................................. 17
3 Concerning your safety...................................................................... 19
3.1 Basic prerequisites...................................................................... 20
3.1.1 General........................................................................................ 20
3.1.2 Explanation of signal words used................................................ 21
3.1.3 Personal protective equipment.................................................... 22
3.1.4 Intended use................................................................................ 23
3.1.5 Improper use............................................................................... 24
3.1.6 Estimated service life of the machine.......................................... 24
3.2 Definition of responsible persons.............................................. 25
3.2.1 Operating company..................................................................... 25
3.2.2 Expert / qualified person.............................................................. 25
3.2.3 Driver / operator.......................................................................... 26
3.3 Basic safety regulations for safe operation............................... 27
3.3.1 Remaining dangers, remaining risks........................................... 27
3.3.2 Regular safety inspections.......................................................... 27
3.3.3 Modifications and alterations to the machine.............................. 27
3.3.4 Damage, defects, misuse of safety devices................................ 28
3.3.5 Roll Over Protection Structure (ROPS) and Fall On Protection
Structure (FOPS)......................................................................... 28
3.4 Handling fuels and lubricants..................................................... 30
3.4.1 Preliminary remarks.................................................................... 30
3.4.2 Safety regulations and environmental protection regulations for
handling diesel fuel...................................................................... 31
handling oil.................................................................................. 33
handling hydraulic oil................................................................... 34
BW 212 D-5 SL 3
Table of contents

handling coolants........................................................................ 36
handling battery acid................................................................... 38
3.5 Load/transport the machine........................................................ 40
3.6 Starting up the machine.............................................................. 42
3.6.1 Prior to commissioning................................................................ 42
3.6.2 Starting the engine...................................................................... 43
3.6.3 Starting the engine with jump leads............................................ 43
3.7 Driving the machine; working operation.................................... 45
3.7.1 Driving the machine..................................................................... 45
3.7.2 Driving up and down slopes........................................................ 46
3.7.3 Cross-slope................................................................................. 46
3.7.4 Working with vibration................................................................. 47
3.7.5 Parking the machine.................................................................... 47
3.8 Refuelling...................................................................................... 48
3.9 Emergency procedures............................................................... 49
3.9.1 Actuating the emergency stop switch.......................................... 49
3.9.2 Disconnecting the battery............................................................ 49
3.9.3 Towing the machine..................................................................... 49
3.10 Maintenance work...................................................................... 51
3.10.1 Preliminary remarks.................................................................. 51
3.10.2 Working on hydraulic lines........................................................ 51
3.10.3 Working on the engine.............................................................. 52
3.10.4 Maintenance work on electric components and battery............ 53
3.10.5 Working on the air conditioning................................................. 53
3.10.6 Working on wheels and tyres.................................................... 53
3.10.7 Cleaning work............................................................................ 54
3.10.8 Measures for longer shut-down periods.................................... 54
3.10.9 After maintenance work............................................................. 55
3.11 Repair.......................................................................................... 56
3.12 Signage....................................................................................... 57
3.13 Danger zones.............................................................................. 64
4 Indicators and control elements........................................................ 65
4.1 Driver’s stand............................................................................... 66
4 BW 212 D-5 SL
Table of contents
4.1.1 Instrument cluster........................................................................ 67

4.1.2 Starter switch............................................................................... 73
4.1.3 Operating console....................................................................... 74
4.1.4 Travel lever.................................................................................. 78
4.1.5 Driver’s seat................................................................................ 79
4.1.6 12 V DIN socket.......................................................................... 81
4.2 Cabin............................................................................................. 82
4.2.1 Control console cabin.................................................................. 83
4.2.2 Heating / air conditioning............................................................. 84
4.2.3 Fire extinguisher.......................................................................... 85
4.3 Outside of machine...................................................................... 86
4.3.1 Main battery switch...................................................................... 86
5 Checks prior to start up...................................................................... 87
5.1 Notes on safety............................................................................. 88
5.2 Visual inspections and function tests........................................ 90
5.3 Daily maintenance........................................................................ 91
5.3.1 Checking the engine oil level....................................................... 91
5.3.2 Checking the fuel level; topping up fuel....................................... 92
5.3.3 Checking the hydraulic oil level................................................... 94
5.3.4 Checking the coolant level.......................................................... 95
5.3.5 Checking the air filter................................................................... 96
5.3.6 Checking wheels and tyres......................................................... 97
6 Operation.............................................................................................. 99
6.1 Setting up the workplace........................................................... 100
6.2 Starting the engine..................................................................... 101
6.3 Travel mode................................................................................ 104
6.3.1 Preliminary remarks and safety notes....................................... 104
6.3.2 Driving the machine................................................................... 105
6.3.3 Applying the parking brake........................................................ 106
6.4 Working with vibration............................................................... 107
6.4.1 Preliminary remarks and safety notes....................................... 107
6.4.2 Switching the vibration on and off............................................. 108
6.5 ECONOMIZER............................................................................. 111
6.6 Parking the machine in secured condition.............................. 112
6.7 Operating the heating / air conditioning system..................... 114
BW 212 D-5 SL 5
Table of contents
6.8 Emergency procedures.............................................................. 115

6.8.1 Actuating the emergency stop switch........................................ 115
6.8.2 Disconnecting the battery.......................................................... 115
6.8.3 Emergency exit.......................................................................... 115
6.8.4 Towing the machine................................................................... 116
6.8.5 After towing................................................................................ 117
7 Loading / transporting the machine................................................. 119
7.1 Prepare for transport................................................................. 120
7.2 Loading the machine................................................................. 121
7.3 Lashing the machine to the transport vehicle......................... 123
7.4 Loading by crane........................................................................ 124
7.5 After transportation.................................................................... 126
8 Maintenance....................................................................................... 127
8.1 Preliminary remarks and safety notes..................................... 128
8.2 Preparations/concluding work.................................................. 130
8.2.1 Open and secure the engine hood............................................ 130
8.2.2 Engaging/releasing the articulation lock.................................... 131
8.3 Fuels and lubricants.................................................................. 133
8.3.1 Engine oil................................................................................... 133
8.3.2 Fuel........................................................................................... 135
8.3.3 Coolant...................................................................................... 136
8.3.4 Hydraulic oil............................................................................... 140
8.3.5 Gear oil SAE 75W-90................................................................ 141
8.3.6 Gear oil SAE 80W-140.............................................................. 141
8.4 List of fuels and lubricants........................................................ 142
8.5 Running-in instructions............................................................. 144
8.5.1 General information................................................................... 144
8.5.2 After the first 250 operating hours............................................. 144
8.5.3 After the first 500 operating hours............................................. 145
8.5.4 After the first 1000 operating hours........................................... 145
8.6 Maintenance Table..................................................................... 146
8.7 Every 250 operating hours........................................................ 149
8.7.1 Checking the rubber-bonded metal rails and rubber buffers..... 149
8.7.2 Cleaning the radiator module.................................................... 150
8.7.3 Checking the ribbed V-belt........................................................ 152
6 BW 212 D-5 SL
Table of contents
8.7.4 Checking, tensioning the V-belt of the air conditioning com-

pressor...................................................................................... 152
8.7.5 Checking the oil level in the drive axle...................................... 155
8.7.6 Checking the oil level in the wheel hubs................................... 155
8.7.7 Checking the oil level in the exciter housing............................. 156
8.7.8 Changing the fresh air filter in the cabin.................................... 158
8.7.9 Check the air intake lines.......................................................... 159
8.7.10 Checking radiator hoses and hose clamps............................. 159
8.7.11 Check the parking brake.......................................................... 160
8.8 Every 500 operating hours........................................................ 161
8.8.1 Change engine oil and oil filter cartridge................................... 161
8.8.2 Replacing the fuel filter; bleeding the fuel system..................... 163
8.8.3 Checking the anti-freeze concentration and the condition of the
coolant....................................................................................... 166
8.8.4 Checking the hydraulic lines...................................................... 167
8.8.5 Servicing the battery; checking the main battery shutoff........... 169
8.8.6 Servicing the air conditioning system........................................ 170
8.9 Every 1000 operating hours...................................................... 173
8.9.1 Checking, adjusting the valve clearance................................... 173
8.9.2 Replacing the ribbed V-belt....................................................... 175
8.9.3 Replacing the V-belt of the air conditioning compressor........... 176
8.9.4 Checking the engine mounts..................................................... 177
8.9.5 Replacing the hydraulic oil filter................................................. 178
8.9.6 Change the oil in the drive axle................................................. 180
8.9.7 Changing the oil in the wheel hubs........................................... 181
8.9.8 Change the oil in the exciter housing........................................ 183
8.9.9 Retightening the fastening of the axle on the frame.................. 185
8.9.10 Retightening the wheel nuts.................................................... 185
8.9.11 Checking the ROPS/FOPS...................................................... 185
8.9.12 Checking the travel lever control............................................. 186
8.9.13 Cleaning the circulation air filter of the heating....................... 187
8.10 Every 2000 operating hours.................................................... 188
8.10.1 Changing the hydraulic oil....................................................... 188
8.10.2 Changing the coolant.............................................................. 190
8.11 Every 3000 operating hours.................................................... 194
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Table of contents
8.11.1 Check the injection valves....................................................... 194

8.12 As required............................................................................... 195
8.12.1 Air filter maintenance............................................................... 195
8.12.2 Checking and cleaning the water separator............................ 199
8.12.3 Adjusting the scrapers............................................................. 200
8.12.4 Cleaning the machine.............................................................. 201
8.12.5 Filling the windscreen washer tank......................................... 202
8.12.6 Drain the fuel tank sludge........................................................ 202
8.12.7 Retightening the padfoot shell................................................. 203
8.12.8 Measures prior to extended shut-down period........................ 203
9 Troubleshooting................................................................................ 207
9.1 Preliminary remarks................................................................... 208
9.2 Starting the engine with jump leads......................................... 209
9.3 Fuse assignment........................................................................ 210
9.3.1 Notes on safety......................................................................... 210
9.3.2 Central electrics......................................................................... 210
9.3.3 Traffic lights............................................................................... 213
9.3.4 Main fuses................................................................................. 214
9.3.5 Control console cabin................................................................ 215
9.4 Fault code display...................................................................... 216
9.5 Engine faults............................................................................... 217
10 Disposal.............................................................................................. 221
10.1 Final shut-down of machine.................................................... 222
11 List of special tools........................................................................... 223
8 BW 212 D-5 SL
Introduction
1 Introduction
BW 212 D-5 SL 9
Introduction – Foreword
1.1 Foreword
BOMAG manufactures machines for earth,
asphalt and refuse compaction, stabilizers/
recyclers as well as planers and pavers.
BOMAG’s vast experience in connection
with state-of-the-art production and test
methods, such as lifetime tests of all impor-
tant components and highest quality
demands guarantee maximum reliability of
your machine.
These operating and maintenance instructions
are part of your machine.
They provide necessary information to operate
your machine safely and properly.
They also contain information on required oper-
ating, maintenance and repair measures.
Carefully read the operating and maintenance
instructions before taking your machine into
operation.
Please observe the safety regulations strictly
and follow all instructions to ensure safe opera-
tion.
If you are not yet acquainted with the indicators
and control elements on this machine, you
should thoroughly read the corresponding
chapter Ä Chapter 4 ‘Indicators and control
elements’ on page 65.
The description of the individual operating
steps including the notes on safety to be fol-
lowed can be found in chapter “Operation”
Ä Chapter 6 ‘Operation’ on page 99.
Before every start up, carry out all required
visual inspections and function tests Ä Chapter
5 ‘Checks prior to start up’ on page 87.
Ensure the compliance with the specified oper-
ating, maintenance and repair measures to
maintain the functional safety of your machine.
10 BW 212 D-5 SL
Introduction – Foreword
A description of all necessary maintenance

work, maintenance intervals as well as informa-
tion on fuels and lubricants can be found in the
chapter “Maintenance” Ä Chapter 8 ‘Mainte-
nance’ on page 127.
Do not service or repair your machine by your-
self to avoid harming persons or damaging
material or environment.
The machine must only be serviced and
repaired by qualified and authorised personnel.
Contact our customer service to carry out the
required maintenance work or necessary
repairs.
In case of operating errors, inadequate mainte-
nance or the use of unapproved fuels and lubri-
cants all warranty claims will become null and
void.
For your own personal safety you should only
use original parts from BOMAG.
For your machine we offer service kits to make
maintenance easier.
In the course of technical development, we
reserve the right to technical modifications
without prior notification.
These operating and maintenance instructions
are also available in other languages.
Apart from that, you can also order the spare
parts catalogue against the serial number of
your machine.
The above notes do not constitute an extension
of the warranty and liability conditions specified
in the general sales and delivery conditions of
BOMAG GmbH.
We wish you successful work with your
BOMAG machine.
BW 212 D-5 SL 11
Introduction – Machine type plate and engine type plate
1.2 Machine type plate and engine type plate

Please enter here:
Machine type (1):
Serial number (2):
Fig. 1: Machine type plate

(example)
Please enter here:

Engine type (1):
Engine number (2):
Fig. 2: Engine type plate

(example)
12 BW 212 D-5 SL
Technical data
2 Technical data
BW 212 D-5 SL 13
Technical data
Dimensions
B-584-0034
Fig. 3
A B D H H2 K L O1/2 S W
2975 2260 1500 2240 3053 530 5870 65 25 2130
(117) (89) (59) (88) (120) (20.9) (231) (2.6) (1.0) (84)
Dimensions in millimetres
(Dimensions in inches)
Weights
Max. operating weight 13610 kg
(30005) (lbs)
Operating weight 10980 kg
(24207) (lbs)
Operating weight with cabin 11490 kg
(25331) (lbs)
Axle load, drum 6900 kg
(15212) (lbs)
14 BW 212 D-5 SL
Technical data
Weights
Axle load, wheels 4590 kg
(10119) (lbs)
Static linear load 32.4 kg/cm
(181) (pli)
Travel characteristics
Travel speed (1) 0–6 km/h
(0–3.7) (mph)
Travel speed (2) 0–10 km/h
(0–6.2) (mph)
Max. gradeability without/with vibration (soil 45/43 %
and weather dependent)
Drive
Engine manufacturer Deutz
Type BF4M 2012 C
Cooling system Fluid
Number of cylinders 4
Rated power ISO 14396 98 kW
Rated power SAE J 1995 132 HP
Rated speed 2300 min-1
Electric system
Voltage 12 V
BW 212 D-5 SL 15
Technical data
Tyres
Tyre size 23.1-26 12PR
Air pressure, nominal value 1.1 bar
(16) (psi)
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Oscill.-articul.
Steering angle +/- 35 °
Oscillation angle +/- 12 °
Inner track radius 3677 mm
(145) (in)
Exciter system
Drive system hydrostatic
Frequency (1/2) 30/36 Hz
(1800/2160) (vpm)
Amplitude (1/2) 1.80/0.95 mm
(0071/0037) (in)
Centrifugal force (1/2) 236/170 kN
(53055/38218) (lbf)
Filling capacities
Fuel (diesel) 250 l
(66) (gal us)
16 BW 212 D-5 SL
Technical data – Noise and vibration data
2.1 Noise and vibration data

The following noise and vibration data were
determined in accordance with the following
guidelines under equipment specific conditions
and by using harmonized standards:
n EU Machine Directive edition 2006/42/EU
n Noise Emission Directive 2000/14/EU, Noise
Protection Directive 2003/10/EU
n Vibration Protection Directive 2002/44/EU
During operation these values may vary
because of the prevailing operating conditions.
2.1.1 Noise data

Sound pressure level at LpA = 82 dB(A), determined acc. to ISO 11201
the operator's stand and EN 500.
WARNING!
Loss of hearing caused by too
high noise burdens!
– Wear your personal protective
equipment (ear protection).
Guaranteed sound LWA = 109 dB(A), determined acc. to ISO 3744

power level and EN 500
2.1.2 Vibration data

Vibration of the entire The weighted effective acceleration value
body (driver’s seat) determined according to ISO 2631 is ≤ 0.5
m/s2.
Hand-arm vibration The weighted effective acceleration value

determined according to ISO 5349 is ≤ 2.5
m/s2.
BW 212 D-5 SL 17
Technical data – Noise and vibration data
18 BW 212 D-5 SL
Concerning your safety
3 Concerning your safety
BW 212 D-5 SL 19
Concerning your safety – Basic prerequisites
3.1 Basic prerequisites

3.1.1 General
This 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 unprofes-
sional way,
n the safety instructions are not observed.
Each person involved in the operation, mainte-
nance and repair of the machine must there-
fore read and comply with these safety regula-
tions. If necessary, the operating company
must obtain the relevant signatures as confir-
mation.
Furthermore, the following obviously also
applies:
n applicable accident prevention instructions,
n generally accepted safety and road traffic
regulations,
n country/state specific safety regulations.
It is the duty of the operator to be acquainted
with the safety regulations and to apply these
accordingly. This also applies for local regula-
tions and regulations concerning different types
of handling activities. Should the recommenda-
tions in these instructions be different from the
regulations valid in your country, you must
comply with the safety regulations valid in your
country.
20 BW 212 D-5 SL
3.1.2 Explanation of signal words used
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indi-
cate an extremely dangerous situa-
tion that could lead to fatal or
severe injuries, if this warning is dis-
regarded.
WARNING!
Danger to life or danger of severe
injuries if failing to comply!
cate a dangerous situation that
could lead to fatal or severe injuries,
if this warning is disregarded.
CAUTION!
Danger of injury if failing to
comply!
cate a dangerous situation that
could lead to fatal or severe injuries,
if this warning is disregarded.
NOTICE!
Danger of material damage if
failing to comply!
cate possible dangers for machines
or components.
BW 212 D-5 SL 21

cate technical information or notes
on using the machine or its compo-
nents.
ENVIRONMENT!
Environmental damage if failing
to comply!
Paragraphs marked accordingly
indicate practices for safe and envi-
ronment-friendly disposal of fuels
and lubricants as well as replace-
ment parts.
3.1.3 Personal protective equipment

Depending on the work to be carried out, personal protective equip-
ment is required (to be provided by the operating company):
Working clothes Tight fitting working clothes with low tear
resistance, tight sleeves and without
any projecting parts protect against
being caught by moving components.
Safety shoes They protect against heavy falling parts

and slipping on slippery ground.
Protective gloves They protect the hands against scrapes,

punctures or deeper injuries, irritating
and caustic substances and burns.
Safety goggles They protect the eyes against airborne

particles and squirting fluids.
22 BW 212 D-5 SL
Face protection This protects the face against airborne

particles and squirting fluids.
Hard hat This protects the head against falling

parts and injuries.
Hearing protection This protects against extreme noise.
Fine dust mask For protection against particulate pollu-

tants.
Respiratory protection This protects the airways against sub-

stances or particles.
3.1.4 Intended use

This machine is intended for commercial use
only.
The machine must only be used for:
n Compaction during earthwork and for road
sub-base construction.
n Compaction of bituminous material, e.g.
road surface layers.
Intended use also includes compliance with the
specified operating, maintenance and repair
measures.
BW 212 D-5 SL 23
3.1.5 Improper use

Dangers may arise with the machine if it is
used other than for its intended purpose.
Any danger caused by improper use is the sole
responsibility of the operating company or
driver/operator; the manufacturer cannot be
held liable.
Examples of improper use are:
n Work with vibration on hard concrete, cured
bitumen layers or extremely frozen ground
n Driving on non-load-bearing subsoil or inad-
equate contact areas (danger of tilting)
n Using the machine for towing
n Using to pull down walls or demolish build-
ings
Transporting persons, except the machine
driver, is prohibited.
Starting and operating the machine in explo-
sive environments and in underground mining
is prohibited.
3.1.6 Estimated service life of the machine

If the following general conditions are met, the
service life of the machine is usually in the
range of several thousand operating hours:
n Regular safety inspections by an expert /
qualified person
n Performance of the prescribed maintenance
work within the specified time
n Immediate performance of necessary repair
work
n Exclusive use of original spare parts
24 BW 212 D-5 SL
Concerning your safety – Definition of responsible persons
3.2 Definition of responsible persons

3.2.1 Operating company
The operating company is the natural or jurid-
ical person who uses the machine or in who's
name the machine is used.
The operating company must make sure that
the machine is only used for the purpose it is
intended for and in strict compliance with the
safety regulations mentioned in these operating
and maintenance instructions.
The operating company must determine and
assess the danger in its company. It must then
take appropriate action to ensure health and
safety at work for its employees and point out
any remaining dangers.
The operating company must determine
whether there are special operational hazards
such as a toxic atmosphere or limiting soil con-
ditions. Such conditions require special, addi-
tional measures to remove or reduce the
hazard.
The operating company must make sure that
all users read and understand the information
concerning safety.
The operating company is responsible for the
planning and professional execution of regular
safety inspections.
3.2.2 Expert / qualified person

An expert / qualified person is a person who,
based on his/her professional education and
experience, has profound knowledge in the
field of construction equipment and the
machine in question in particular.
BW 212 D-5 SL 25
Concerning your safety – Definition of responsible persons
This person is acquainted with the applicable

governmental industrial safety regulations,
accident prevention instructions, guidelines and
generally acknowledged technical rules and
regulations (standards, directives, technical
rules of other member states of the European
Union or other contractual states concerning
the agreement about the European Economic
Area) in as far as is necessary to be able to
judge the safe condition of this machine.
3.2.3 Driver / operator

This machine must only be operated by
trained, instructed persons entrusted by the
operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for
driver or operator:
The driver or operator must:
n be instructed about his rights and obliga-
tions,
n wear protective equipment as appropriate
for the application,
n have read and understood the operating
instructions,
n have made himself familiar with the opera-
tion of the machine,
n be physically and psychologically able to
drive and operate the machine.
Persons under the influence of alcohol, medi-
cation or drugs are not allowed to operate,
service or repair the machine.
Maintenance and repair work requires specific
knowledge and must therefore only be per-
formed by trained specialists.
26 BW 212 D-5 SL
Concerning your safety – Basic safety regulations for safe operation
3.3 Basic safety regulations for safe operation

3.3.1 Remaining dangers, remaining risks
Despite careful work and compliance with
standards and regulations it cannot be ruled
out that further dangers may arise when
working with and handling the machine.
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 partic-
ular attention to the machine, so that they can
react immediately in case of a possible mal-
function, an incident or failure etc.
All persons remaining in the area of the
machine must be informed about the dangers
that arise from the operation of the machine.
3.3.2 Regular safety inspections

Have the machine inspected by an expert /
qualified person as required for the conditions
the machine is working under, but at least once
every year.
3.3.3 Modifications and alterations to the machine

Unauthorized changes to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been spe-
cially designed for this machine.
BW 212 D-5 SL 27
We wish to make explicitly clear that we have

not tested or approved any parts or accesso-
ries not supplied by us.
The installation and/or use of such products
may have an adverse effect on the active
and/or passive safety.
3.3.4 Damage, defects, misuse of safety devices

Machines which are not safe to operate or in
traffic must be immediately taken out of service
and shall not be used, until these deficiencies
have been properly rectified.
Safety installations and switches must neither
be removed nor must they be made ineffective.
3.3.5 Roll Over Protection Structure (ROPS) and Fall On Pro-

tection Structure (FOPS)
Machines with cabin already have

ROPS/FOPS as an integrated part
of the cabin.
The frame of the machine must not be warped,

bent or cracked in the area of the ROPS/FOPS
fastening.
The ROPS/FOPS must not have any rust,
damage, hairline cracks or open fractures.
The current machine weight must never
exceed the testing weight for the ROPS/FOPS.
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/FOPS must therefore also not be
straightened or repaired if it is damaged.
28 BW 212 D-5 SL
A defective ROPS/FOPS must always be

replaced with an original spare part in close
coordination with the manufacturer.
BW 212 D-5 SL 29
Concerning your safety – Handling fuels and lubricants
3.4 Handling fuels and lubricants

3.4.1 Preliminary remarks
The operating company must ensure that all
professional users have read and follow the
corresponding safety data sheets for the indi-
vidual fuels and lubricants.
Safety data sheets provide valuable informa-
tion about the following characteristics:
n name of substance
n possible dangers
n composition / information on constituents
n first-aid measures
n fire fighting measures
n measures in case of accidental release
n handling and storage
n limitation and monitoring of exposure / per-
sonal protective equipment
n physical and chemical properties
n stability and reactivity
n toxicological data
n environmental data
n notes on waste disposal
n information on transport
n legislation
n other data
30 BW 212 D-5 SL
3.4.2 Safety regulations and environmental protection regula-

tions for handling diesel fuel
WARNING!
Danger of burning by ignited
diesel fuel!
– Do not allow diesel fuel to come
into contact with hot compo-
nents.
– Smoking and open fire are pro-
Fig. 4 hibited!
equipment (protective gloves,
protective clothing).
CAUTION!
Health hazard caused by contact
with diesel fuel!
– Do not inhale any fuel fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled
diesel fuel!
– Immediately bind spilled diesel
fuel with an oil-binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally
hazardous substance!
– Always keep diesel fuel in proper
containers.
» Continued on the next page
BW 212 D-5 SL 31
– Immediately bind spilled diesel

fuel with an oil-binding agent and
dispose of properly.
– Dispose of diesel fuel and fuel fil-
ters according to regulations.
32 BW 212 D-5 SL

tions for handling oil
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come into con-
tact with hot components.
hibited!
Fig. 5 equipment (protective gloves,
CAUTION!
with oil!
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with
an oil-binding agent.
ENVIRONMENT!
Oil is an environmentally haz-
ardous substance!
– Always keep oil in proper con-
tainers.
– Dispose of oil and oil filter
according to regulations.
BW 212 D-5 SL 33

tions for handling hydraulic oil
WARNING!
Danger of injury caused by
escaping pressure fluid!
– Always depressurize the
hydraulic system before starting
work in the hydraulic system.
protective clothing, goggles).
Should hydraulic fluid penetrate the

skin, seek medical assistance
immediately.
WARNING!
Danger of burning by ignited
hydraulic oil!
– Do not allow hydraulic oil to
come into contact with hot com-
ponents.
hibited!
CAUTION!
with hydraulic oil!
– Do not inhale any oil vapours.
– Avoid contact.
34 BW 212 D-5 SL
CAUTION!
Danger of slipping on spilled oil!
ENVIRONMENT!
Oil is an environmentally haz-
ardous substance!
– Always keep oil in proper con-
tainers.
– Dispose of oil and oil filter
according to regulations.
BW 212 D-5 SL 35

tions for handling coolants
WARNING!
Danger of scalding by hot fluid!
– Open the compensation tank
only when the engine is cold.
Fig. 7
CAUTION!
with coolant and coolant addi-
tives!
– Do not inhale any fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled
coolant!
– Immediately bind spilled coolant
with an oil-binding agent.
ENVIRONMENT!
Coolant is an environmentally
hazardous substance!
– Always keep coolant and coolant
additives in proper containers.
» Continued on the next page
36 BW 212 D-5 SL
– Immediately bind spilled coolant

with an oil-binding agent and dis-
pose of it according to regula-
tions.
– Dispose of coolant according to
regulations.
BW 212 D-5 SL 37

tions for handling battery acid
WARNING!
Danger of cauterization with acid!
– Do not allow clothes, skin or
eyes to come into contact with
Fig. 8 acid.
– Rinse off spilled battery acid
immediately with lots of water.
Rinse acid off clothes, skin or eyes

immediately with lots of clean water.
Immediately call for medical advice
in case of cauterization.
WARNING!
exploding gas mixture!
– Remove the plugs when
recharging the battery.
– Ensure adequate ventilation.
hibited!
– Do not lay any tools or other
metal objects on the battery.
– Do not wear jewellery (watch,
bracelets, etc.) when working on
the battery.
38 BW 212 D-5 SL
ENVIRONMENT!
Battery acid is an environmen-
tally hazardous substance!
– Dispose of battery and battery
acid according to regulations.
BW 212 D-5 SL 39
Concerning your safety – Load/transport the machine
3.5 Load/transport the machine

Use only stable loading ramps of sufficient load
bearing capacity.
Loading ramps and transport vehicle must be
free of grease, oil, snow and ice.
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. The
instructing person must stand within the view of
the operator, but outside the danger area.
Secure the machine with the articulation lock
after driving it on the transport vehicle or before
loading it with a crane.
Do not use damaged or in any other way
impaired lashing points.
Always use appropriate lifting and lashing
means on the lifting and lashing points.
Use lifting and lashing gear only in the pre-
scribed direction of load application.
Lifting tackle must not be damaged by machine
components.
Secure the machine on the transport vehicle
against rolling, slipping and turning over.
Loads must only be attached and hoisted by an
expert / capable person.
Use only lifting gear and lifting tackle with suffi-
cient load bearing capacity for the weight to be
loaded.
Fasten the lifting gear only at the specified
lifting points.
Danger to the life of persons if they step or
stand under a suspended load.
When lifting the machine avoid uncontrolled
movements of the load. If necessary hold the
load with guide ropes.
40 BW 212 D-5 SL
Concerning your safety – Load/transport the machine
After the transport loosen the articulation lock

again, as otherwise the machine wouild not be
steerable.
BW 212 D-5 SL 41
Concerning your safety – Starting up the machine
3.6 Starting up the machine

3.6.1 Prior to commissioning
Only use machines which have been serviced
at regular intervals.
Become acquainted with the equipment, the
indicators and control elements, the working
principle of the machine and the working area.
Use your personal protective equipment (hard
hat, safety boots, if necessary also goggles
and ear protection).
Make sure that the machine is equipped with
the required lighting according to the require-
ments of the application.
Do not take any loose objects with you or
fasten them to the machine.
Before mounting the machine check whether:
n persons or obstructions are beside or under
the machine;
n the machine is free of oily and combustible
materials;
n all access steps, grips and platforms are free
of obstacles, grease, oils, fuel, dirt, snow
and ice;
n all safety elements are in place;
n all maintenance flaps and doors are closed
and locked.
Climb onto or off the machine only when the
machine is standing. Use the existing access
steps and grips.
When climbing on and off the machine use the
three-point support method: Always keep two
feet and one hand or one foot and two hands
on the machine.
Never jump off the machine.
Before commissioning, carry out all required
visual inspections and function tests.
42 BW 212 D-5 SL
If the tests reveal damage or other defects, the

machine must not be operated until these have
been rectified.
Do not operate the machine with defective indi-
cators and control elements.
3.6.2 Starting the engine

The machine must only be started and oper-
ated from the driver’s seat.
Before starting and moving the machine, make
sure that there is nobody in the danger zone.
To start, set all control levers to “neutral posi-
tion”.
Do not use any starting aids like start pilot or
ether.
The machine must not be operated with dam-
aged, missing or non-functional safety installa-
tions.
After starting check all display instruments.
Do not inhale exhaust fumes, because they
contain toxic substances, which could cause
damage to health, unconsciousness or even
death.
For operation in closed or partly closed rooms
ensure adequate ventilation.
3.6.3 Starting the engine with jump leads

Connect positive with positive and negative
with negative (ground cable) – always connect
the ground strap last and disconnect it first! A
wrong connection will cause severe damage in
the electric system.
BW 212 D-5 SL 43
Do not start the engine by shorting the electric

terminals on the starter motor, because the
machine may start to drive immediately.
44 BW 212 D-5 SL
Concerning your safety – Driving the machine; working operation
3.7 Driving the machine; working operation

3.7.1 Driving the machine
Always wear the seat belt when driving.
Only drive on load-bearing surfaces.
Do not drive on ice and snow.
If the machine has touched high-voltage power
lines:
n Do not leave the driver’s stand
n Warn others from coming close to or
touching the machine
n If possible, drive the machine out of the
danger zone
n Have the power switched off.
Operate the machine only from the driver’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.
Do not use the machine to transport persons.
In case of unusual noises and development of
smoke perform trouble shooting to determine
the cause and have the fault corrected.
Match the speed to the working conditions.
Do not make extreme steering movements
when driving at high speed: danger of tipping
over!
Always give way to loaded transport vehicles.
Switch the lights on if visibility is poor.
Always keep a safe distance to excavation pit
borders, embankments and edges.
Refrain from any work that could adversely
affect the stability of the machine.
BW 212 D-5 SL 45
Always keep a sufficient distance when

passing through subways, under bridges, tun-
nels, electric power lines, etc.
3.7.2 Driving up and down slopes

Do not drive on gradients or slopes exceeding
the maximum gradeability of the machine
Ä Chapter 2 ‘Technical data’ on page 13.
Drive extremely carefully on gradients and
always directly up or down the slope.
Soil conditions and weather influences impair
the gradeability of the machine.
Wet and loose soil considerably reduces trac-
tion of the machine on inclinations and slopes.
Increased danger of accident!
3.7.3 Cross-slope
The tipping angle was measured statically on
level, hard ground with the machine stopped
and without steering.
The max. permissible inclination of the
machine may be limited by the max. permis-
sible slanted position of the engine.
The specified angle must not be exceeded.
Fig. 9: Maximum cross- With loose soil, acceleration/deceleration, run-
slope ning vibration, steering or attached accessories
the tipping angle may be considerably lower.
Driving across slopes should therefore be
strictly avoided, because of the high risk of tip-
ping over and the related risk of severe or even
fatal accidents.
46 BW 212 D-5 SL
3.7.4 Working with vibration

When compacting with vibration you must
always check the effect of the vibration on
nearby buildings and underground supply lines
(gas, water, sewage, electric power). If neces-
sary stop compacting with vibration.
Do not activate the vibration on hard (frozen,
concrete) ground. Components may get dam-
aged.
3.7.5 Parking the machine

Park the machine on horizontal, level, firm
ground.
Before leaving the machine:
n Shift all control levers to “neutral position”,
“Off” or “0”;
n apply the parking brake,
n Switch off the engine and remove the igni-
tion key;
n Switch off and pull out the main battery
switch;
n Secure the machine against unauthorised
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.
When parking on ascents or descents use
appropriate means to secure the machine
against rolling.
BW 212 D-5 SL 47
Concerning your safety – Refuelling
3.8 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.
Static charges may be generated in the fuel as
it passes through the filling system. The dis-
charge of these charges in the presence of
combustible vapours can cause fire or an
explosion.
Ultra-low sulphur diesel fuel poses a higher risk
of combustion caused by the static charging
than diesel fuel with a higher sulphur content.
You should therefore always make sure that
the filling system is properly grounded and that
there is equipotential bonding to the machine. If
necessary use a connecting cable between
filling system and vehicle ground.
Monitor the entire refuelling process.
Do not spill any fuel. Collect leaking 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 tank cap; if necessary,
replace immediately.
48 BW 212 D-5 SL
Concerning your safety – Emergency procedures
3.9 Emergency procedures

3.9.1 Actuating the emergency stop switch
In events of emergency and in case of danger
actuate the emergency stop switch immedi-
ately.
The machine is braked immediately, the engine
is shut down.
Restart the machine only after the danger that
caused the actuation of the emergency stop
switch has been eliminated.
In case of frequent use the wear on the multi-
discs brakes will be very high, you should
therefore never use the emergency stop switch
as a service brake.
3.9.2 Disconnecting the battery

In event of emergency, e.g. in case of a cable
fire, disconnect the battery from the vehicle
network.
Turn off and pull out the main battery switch or
lift off the battery pole to do so.
3.9.3 Towing the machine

Tow the machine only in a case of emergency
or to avoid an accident.
Before releasing the parking brake apply suit-
able measures to secure the machine against
unintended rolling.
Use a tractor vehicle with sufficient traction and
braking power for the unbraked towed load.
If no tow bar is used, towing is only permitted
uphill.
BW 212 D-5 SL 49
Concerning your safety – Emergency procedures
Before starting towing operations make sure

that the fastening means are able to withstand
the load and are fastened at the points pro-
vided for this purpose.
Before removing the towing facility apply
appropriate measures to secure the machine
against unintended rolling.
50 BW 212 D-5 SL
Concerning your safety – Maintenance work
3.10 Maintenance work

3.10.1 Preliminary remarks
Always carry out the prescribed maintenance
work and maintenance measures on time in
order to maintain the safety, operational readi-
ness and long service life of the machine.
The machine must only be serviced by quali-
fied personnel authorised by the operating
company.
3.10.2 Working on hydraulic lines

Before the hydraulic system can be depressur-
ized, machine parts with hydraulic movement
must be safely set down or secured to prevent
them from falling.
Relieve hydraulic pressures before working on
hydraulic lines. Hydraulic oil escaping under
pressure can penetrate the skin and cause
severe injury. Immediately call for medical
assistance if injured by hydraulic oil.
Do not step in front of or behind the machine
when performing 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 collected and dis-
posed of in an environmentally friendly way.
Always collect and dispose of hydraulic oils
separately.
Do not start the engine after draining off the
hydraulic oil. Once all work is completed (with
the system still depressurized!) check all con-
nections and fittings for leaks.
BW 212 D-5 SL 51
Hydraulic hoses must be visually inspected at

regular intervals.
Do not mix up hoses by mistake.
Only genuine replacement hydraulic hoses
ensure that the correct hose type (pressure
range) is used at the right location.
3.10.3 Working on the engine

Do not work on the fuel system while the
engine is running. Danger to life due to high
pressures!
Wait until the engine has stopped, then wait
approx. another 15 minutes.
Keep out of the danger zone during the initial
test run.
In case of leaks return to the workshop immedi-
ately.
Drain the engine oil at operating temperature.
Danger of scalding!
Wipe off spilled oil, collect leaking oil and dis-
pose of it in an environmentally friendly way.
Store used filters and other oil contaminated
materials in a separate, specially marked con-
tainer and dispose of them in an environmen-
tally friendly way.
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.
Engine and exhaust system work at high tem-
peratures. Keep combustible materials away
and do not touch any hot surfaces.
Check and change coolant only when the
engine is cold. Collect coolant and dispose of it
in an environmentally friendly way.
52 BW 212 D-5 SL
3.10.4 Maintenance work on electric components and battery

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.
When working on the battery, smoking and
open fire are prohibited!
Do not lay any tools or other metal objects on
the battery.
Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.
Connection cables of the battery must not
touch or rub against machine parts.
3.10.5 Working on the air conditioning

Faults on the air conditioning should only be
remedied by authorized service personnel.
Do not perform welding work in the vicinity of
the air conditioning. Danger of explosion!
Do not release refrigerant into the atmosphere,
but dispose of it in line with environmental reg-
ulations.
3.10.6 Working on wheels and tyres

Explosion-like bursting of tyres or parts of tyres
and rims can cause most severe or even fatal
injuries.
Do not drive with damaged wheels or tyres.
Install the tyres only if you are sufficiently expe-
rienced and with the right tools at hand. If nec-
essary have the tyres assembled in a qualified
workshop.
BW 212 D-5 SL 53
Always ensure the correct tyre pressure and do

not exceed the specified maximum pressure.
When checking the tyre pressure stand in the
extended path of the tyre track. Use an at least
6-meter-long air hose, so that you can keep a
safe distance to the tyre.
Always consider the heavy weight of a wheel
during disassembly and assembly. Use a crane
or forklift truck equipped with suitable claws or
belts on the hoisting device.
3.10.7 Cleaning work

Do not perform cleaning work while the motor
is running.
Allow the engine to cool down before starting
cleaning work on engine and exhaust system.
Never use gasoline or other easily inflammable
substances for cleaning.
When cleaning with a high pressure cleaner, do
not subject electrical parts and insulation mate-
rial to the direct jet of water, or cover them
beforehand.
Do not guide the water jet into the exhaust pipe
and into the air filter.
3.10.8 Measures for longer shut-down periods

If the machine is taken out of operation for a
longer period of time, various conditions must
be met and maintenance work must be carried
out both before and after shut-down Ä Chapter
8.12.8 ‘Measures prior to extended shut-down
period’ on page 203.
It is not necessary to define a maximum
storage period if these measures have been
performed.
54 BW 212 D-5 SL
3.10.9 After maintenance work

Reassemble all guards and protective devices.
Close all maintenance flaps and maintenance
doors again.
BW 212 D-5 SL 55
Concerning your safety – Repair
3.11 Repair
Identify a defective machine with a warning
sign.
Only operate the machine after it has been
repaired.
Repairs must only be performed by an expert/
qualified person.
When replacing safety relevant components,
only original spare parts must be used.
56 BW 212 D-5 SL
Concerning your safety – Signage
3.12 Signage
Keep stickers and signage in good and legible
condition and comply with their meaning.
Replace damaged and illegible stickers or sig-
nage immediately.
B-584-0040
Fig. 10
BW 212 D-5 SL 57
Engine Coolant
Spec.: • MB 325.5
• Deutz DQC CC-14
Part No.: 009 940 03 (20 l)
Diesel
Hydraulic Oil
B-584-0033
Fig. 11
58 BW 212 D-5 SL
B-586-0400
Fig. 12
Warning sticker - Danger of crushing
Fig. 13
Warning sticker - Follow operating instructions
Fig. 14
BW 212 D-5 SL 59
Prohibition sticker - High pressure cleaning
Fig. 15
Instruction sticker - Always wear your seat belt
Fig. 16
Information sticker - Emergency exit
Fig. 17
Information sticker - Lashing point
Fig. 18
60 BW 212 D-5 SL
Information sticker - Lifting point
Fig. 19
Information sticker - Hydraulic oil drain
B-DEC-0210
Fig. 20
Information sticker - Engine oil drain
B-DEC-0211
Fig. 21
Information sticker - Coolant drain
B-DEC-0212
Fig. 22
BW 212 D-5 SL 61
Information sticker - Filler opening for hydraulic

Hydraulic Oil oil
B-DEC-0214
Fig. 23
Information sticker - Filler opening for diesel
Diesel
B-DEC-0215
Fig. 24
Information sticker - Vehicle voltage 12 V
Fig. 25
Information sticker - Coolant
Engine Coolant
Spec.: • MB 325.5
• Deutz DQC CC-14
Part No.: 009 940 03 (20 l)
B-DEC-0221
Fig. 26
62 BW 212 D-5 SL
Machine type plate (example)
Fig. 27
BW 212 D-5 SL 63
Concerning your safety – Danger zones
3.13 Danger zones
3m 3m
B-584-0012
Fig. 28
The area around the machine is a danger

zone.
Before starting the machine and during opera-
tion, the driver / operator must ensure that
nobody is in the danger zone.
Give warning signals, if necessary. Stop work
immediately if persons are in the danger zone.
64 BW 212 D-5 SL
Indicators and control elements
4 Indicators and control elements
BW 212 D-5 SL 65
Indicators and control elements – Driver’s stand
4.1 Driver’s stand
1 2
7
4
6
5
B-584-0002
Fig. 29
1 Instrument cluster
2 Starter switch
3 Operating console
4 Travel lever
5 Driver’s seat
6 Socket
7 Steering wheel
66 BW 212 D-5 SL
4.1.1 Instrument cluster

Overview
3
5 6 7 8
4
9 10 B-DIS-0678
Fig. 30
1 Control and warning lights
2 INFO 3 display field
5 Fuel level gauge
6 Not assigned
7 Engine speedometer
8 Not assigned
9 [F1] button
10 [F2] button
BW 212 D-5 SL 67
Control and warning

lights
Designation Note
Exhaust gas after- Not assigned
treatment system
warning light
AdBlue®/DEF Not assigned
warning light
Regeneration Not assigned

warning light
Exhaust gas tem- Not assigned

perature warning
light
Air filter warning Not assigned
light
Water in fuel Lights up when there is excessive water con-

warning light tent in the fuel pre-filter. Warning buzzer
sounds.
Clean the water separator.
Preheating control Lights up during pre-heating.
light
Warning light for Lights up if the engine oil temperature is too

engine oil tempera- high. Warning buzzer sounds.
ture Run the engine at idle speed or, if necessary,
shut it down and clean the radiator; if neces-
sary, repair the engine.
Flashes if the engine oil temperature continues
to rise (engine overheating). Warning buzzer
sounds.
The engine will be shut down after a short
while.
Coolant level Not assigned
warning light
68 BW 212 D-5 SL
Designation Note
Engine oil pressure Lights up if the engine oil pressure is too low.
warning light The engine will be shut down after a short
while.
Check the engine oil level; if necessary, repair
the engine.
Central warning light Flashes in case of system faults, warnings and
for information purposes.
Charge control light Lights up if the battery is not being charged.

Check the belt drive, if necessary, repair the
generator.
Warning light for Not assigned
hydraulic system
Engine control light Lights up in case of a fault in the engine control

unit.
Take note of the fault codes and inform our
Customer Service Department.
Driver’s seat Lights up when the driver’s seat is not occu-
warning light pied. If the machine is travelling, the warning
buzzer will sound and the machine is deceler-
ated after 3 seconds.
To continue driving, occupy the driver's seat
and shift the travel lever again to the desired
travel direction through the parking brake posi-
tion.
Precision spreader Not assigned
control light
Water level warning Not assigned

light
Parking brake Lights up when the parking brake is applied.

warning light
BW 212 D-5 SL 69
Designation Note
Crabwalk control Not assigned
light
Indicator control
light
Neutral position indi- Not assigned

cator
INFO 1 display field

Each actuation of the [F1] button switches
between:
n Operating hours
n Coolant temperature
n Battery voltage
n Vibration frequency (optional equipment)
B-DIS-0735
Fig. 31
INFO 2 display field
Each actuation of the button [F2] switches
between:
n Travel speed
n ECONOMIZER (optional equipment)
n EVIB value (optional equipment)
n Travel speed and EVIB value (optional equip-
B-DIS-0736 ment)
Fig. 32 n Fault code display
n Overview of operating values
70 BW 212 D-5 SL
INFO 2 display field Description

1 (1) Travel speed
(2) Pre-selected speed limitation (depending
2 on the position of the rotary switch for travel
ranges)
Compaction status Ä Chapter 6.5 ‘ECONO-
MIZER’ on page 111
1
(1) EVIB value
(2) Pre/selected EVIB value (only for
2 machines with Variocontrol)
(1) EVIB value

1 2
(2) Travel speed
(1)
1 n DTC: Fault code
2 n OC: Frequency of fault
n HLO: Operating hour when fault last
occurred
(2) Fault code index/total of incoming fault
codes
n Diesel particulate filter soot load
(Only on machines with exhaust gas after-
treatment system)
n Coolant temperature
n Vibration frequency
(Only on machines with corresponding
measuring technology (optional equip-
ment))
n Battery voltage
n Fuel consumption
n Engine speed
BW 212 D-5 SL 71
After 5 seconds, the view of the

INFO 2 display field is automatically switched
over to full screen mode.
B-DIS-0747
Fig. 33
The view can be changed with the [F1] button:
Press briefly Return to the view with three

display fields.
After 5 seconds, the view
switches back to full screen
B-DIS-0735
mode again.
Fig. 34 Press long. Returns to the view with
three display fields perma-
nently.
Press long Permanent view appears in
again. full screen mode after
5 seconds.
72 BW 212 D-5 SL
4.1.2 Starter switch

Position “0” Switch the ignition off
Ignition key can be removed
Position “I” Ignition on
All control and warning lights
light up for a moment (test
function)
At low temperatures the pre-
Fig. 35 heating control light lights up
Position “II” Turn further against spring
pressure, the engine starts
Turn the ignition key back to
position “I” when the engine
starts
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.
BW 212 D-5 SL 73
4.1.3 Operating console
1 2 3 4 5
9 8 7 6
B-584-0035
Fig. 36
1 Emergency stop switch
2 Rotary switch for amplitude pre-selection
3 Rotary switch for working lights (optional equipment)
4 Rotary switch for engine speed
5 Push button for warning horn
6 Rotary switch for direction indicators (optional equipment)
7 Push button for hazard light system (optional equipment)
8 Rotary switch for lighting (optional equipment)
9 Rotary switch for travel speed ranges
74 BW 212 D-5 SL
4.1.3.1 Emergency stop switch

press In events of emergency and
in case of danger actuate the
emergency stop switch
immediately by pressing it
fully down. It automatically
locks in end position.
The machine will be braked
immediately. The engine is
Fig. 37 shut down.
switch off/ Turn the Emergency Stop
unlock switch clockwise and let it
go.
NOTICE!
In case of frequent use the wear
on the multi-discs brakes will be
very high.
– Do not use the emergency stop
switch as service brake!
4.1.3.2 Rotary switch for amplitude pre-selection

Position “Left” low amplitude, high fre-
quency
Position Vibration off
“Middle”
Position “Right” high amplitude, low fre-
quency
Fig. 38
BW 212 D-5 SL 75
4.1.3.3 Rotary switch for working lights

Position “Left” Working lights off
Position “Right” Working lights on
Optional equipment
Fig. 39
4.1.3.4 Rotary switch for engine speed

Position “Left” Idle speed position (MIN)
Position ECO -mode
“Middle” The engine speed automati-
cally adapts to the power
requirements. This enables
economical operation.
Position “Right” Full load position (MAX)
Fig. 40
4.1.3.5 Push button for warning horn

Press. Warning horn sounds
Fig. 41
76 BW 212 D-5 SL
4.1.3.6 Rotary switch for direction indicators

Position Direction indicators off
“Middle”
Position “left or Front and rear direction indi-
right” cators on the corresponding
side are flashing
Optional equipment
Fig. 42
4.1.3.7 Push button for hazard light system

Press Hazard light system on
Press again. Hazard light system off
Optional equipment
B-SWI-2205
Fig. 43
4.1.3.8 Rotary switch for lighting

Position "Left" Light off
Position Side light on
“Middle”
Position "Right" Travel light on
Optional equipment
Fig. 44
BW 212 D-5 SL 77
4.1.3.9 Rotary switch for travel ranges

Position “Left” Travel speed range 1
Position “Right” Travel speed range 2
B-SWI-1624
Fig. 45
4.1.4 Travel lever

Shift forward Forward travel
Pull back Backward travel
Position Service brake position
“Middle”
Position “Middle Parking brake position
B-ELE-0138
right”
Fig. 46
Push button for vibration
Press Vibration on
Press again Vibration off
B-ELE-0139
Fig. 47
78 BW 212 D-5 SL
4.1.5 Driver’s seat

4.1.5.1 Standard driver’s seat
3 2
B-SEA-0023
Fig. 48
Pos. Control element Setting Description

1 50 kg Driver’s weight Press down the handle
until the correct driver’s
130 kg weight has been set.
Press down the handle
against the end stop,
the weight adjustment
automatically switches
back to the top position.
2 Length adjust- Pull the lever up and
ment push the seat forward or
back.
3 Backrest inclina- Relieve the backrest

tion and pull the lever up.
BW 212 D-5 SL 79
4.1.5.2 Comfort driver’s seat
Optional equipment
5
3
2
4
1
B-SEA-0034
Fig. 49

1 Driver’s weight Check weight setting in
90 kg the window.
Fold out and turn the
handle until the correct
driver’s weight has been
set.
2 Length adjust- Pull the lever up and
ment push the seat forward or
back.
3 Seat height Lift up the seat until it

locks at the appropriate
height.
When lifting the seat
completely it will sink
down to lowest position.
80 BW 212 D-5 SL

4 Backrest inclina- Relieve the backrest
tion and pull the lever up.
5 Backrest exten- Adjust the backrest

sion extension by pulling or
pushing it in.
4.1.6 12 V DIN socket

Permanent current, loadable up to 20 A.
Fig. 50
BW 212 D-5 SL 81
Indicators and control elements – Cabin
4.2 Cabin
ROPS cabin with
heating / air conditioning
1 2
3 4 5 6
B-584-0004
Fig. 51
1 Control console cabin
2 Sun visor
3 Rotary switch for air distribution
4 Rotary switch for cabin temperature
5 Rotary switch for fan
6 Rotary switch for air conditioning
82 BW 212 D-5 SL
4.2.1 Control console cabin
1 2 3 4 5 6 7 8
17 9
16 15 14 13 12 11 10
B-SWI-0497
Fig. 52
Pos. Designation Note

1 Not assigned
2 Not assigned
3 Not assigned
4 Not assigned
5 Not assigned
6 Not assigned
7 Not assigned
8 Not assigned
9 Rear windscreen wiper Interval/on/off
10 washer nozzles for rear wind-
screen
11 Rear windscreen heating The rear windscreen heating is
switched off after three minutes.
12 Rear working lights
13 Cabin light
14 Front working lights
BW 212 D-5 SL 83
Pos. Designation Note

15 Flashing beacon
16 Washer nozzles for front wind-
screen
17 Front windscreen wiper Interval/on/off
4.2.2 Heating / air conditioning

4.2.2.1 Rotary switch for air distribution
Position "Top" Air flow to windscreen
Position Air flow to body
"Middle"
Position Air flow to body and footwell
"Bottom"
Fig. 53
4.2.2.2 Rotary switch for cabin temperature

Position "Top" max. temperature
Position min. temperature
"Bottom"
Fig. 54
84 BW 212 D-5 SL
4.2.2.3 Rotary switch for fan

Position “0” Fan off
Position “1” to Fan stages of different
“3” strengths
Fig. 55
4.2.2.4 Rotary switch for air conditioning system

Position "Top" Air conditioning on
Position Air conditioning off
"Bottom"
Optional equipment
Fig. 56 The air conditioning system only

works when the engine is running
and the fan is switched on.
4.2.3 Fire extinguisher
Optional equipment
NOTICE!
Components may get damaged!
– When retrofitting a fire extin-
guisher, install it only in this posi-
Fig. 57
tion.
BW 212 D-5 SL 85
Indicators and control elements – Outside of machine
4.3 Outside of machine

4.3.1 Main battery switch
Position “on” Main battery switch locked.
Normal position, operation.
Turn anticlock- Main battery switch can be
wise pulled out.
Disconnects the batteries
from the on-board electrics,
B-584-0005
e.g. to prevent unauthorised
Fig. 58 use.
Individual control units may
still be connected to the
board electrics despite the
main battery switch being
pulled out.
86 BW 212 D-5 SL
Checks prior to start up
5 Checks prior to start up
BW 212 D-5 SL 87
Checks prior to start up – Notes on safety
5.1 Notes on safety

If the following tests reveal damages or other
defects, the machine must not be operated,
until these deficiencies have been corrected.
Do not operate the machine with defective indi-
cators and control elements.
Safety installations must not be removed or
made ineffective.
Do not change any fixed settings.
WARNING!
Health hazard caused by fuels
and lubricants!
– Safety regulations and environ-
mental protection regulations
must be followed when handling
fuels and lubricants Ä Chapter
3.4 ‘Handling fuels and lubri-
cants’ on page 30.
WARNING!
rotating parts!
– Before starting work on the
machine make sure that the
engine can not be started.
CAUTION!
Danger of being injured by the
engine hood dropping down!
– Always secure an opened engine
hood.
Park the machine safely Ä Chapter 6.6

‘Parking the machine in secured condition’
on page 112.
88 BW 212 D-5 SL
Checks prior to start up – Notes on safety
Open and secure the engine hood Ä Chapter

8.2.1 ‘Open and secure the engine hood’
on page 130.
Close the engine hood again after work is com-
pleted.
BW 212 D-5 SL 89
Checks prior to start up – Visual inspections and function tests
5.2 Visual inspections and function tests

1. Check the hydraulic oil tank and lines for
condition and leaks.
2. Check the fuel tank and lines for condition
and leaks.
3. Check the cooling system for contamina-
tion, damage and leaks.
4. Check the bolted connections are tight and
secure.
5. Check the engine and exhaust system for
leaks.
6. Check the belt drive for damage.
7. Check the machine for contamination and
damage.
8. Check function of steering.
9. Check function of brake.
10. Check emergency stop function.
11. Check function of backup alarm system.
12. Check the mirror settings and condition.
13. Check function of seat contact switch.
90 BW 212 D-5 SL
Checks prior to start up – Daily maintenance
5.3 Daily maintenance

5.3.1 Checking the engine oil level
NOTICE!
Danger of engine damage!
– If the engine is warm, shut it
down and check the oil level after
five minutes. With a cold engine
the oil level can be checked
immediately.
– Use only oil of the permitted
specification Ä Chapter 8.3.1
‘Engine oil’ on page 133.
Protective equip- n Working clothes

ment: n Safety shoes
n Protective gloves
1. Pull the dipstick out, wipe it off with a lint-
free, clean cloth and reinsert it to the end
stop.
2. Pull the dipstick out again.
ð The oil level must be between the “MIN”
and “MAX” marks.
B-582-0079
3. For topping up, clean the area around the
Fig. 59 filling port.
4. Unscrew the cap and fill with engine oil up
to the “MAX” mark.
5. Close the cap.
BW 212 D-5 SL 91
5.3.2 Checking the fuel level; topping up fuel

5.3.2.1 Checking the fuel level
1. Check the filling level on the fuel gauge.
1
ð Depending on the filling level, the fuel
level warning light appears (1):
n Warning light lights up =
filling level 7% - 12%
n Warning light flashes =
B-DIS-0812 filling level < 7%
Fig. 60 2. Refuel as necessary, when doing so,
always shut down engine and auxiliary
heating.
5.3.2.2 Refuelling
NOTICE!
– Never run the fuel tank empty, as
otherwise the fuel system needs
to be bled.
– Monitor the entire refuelling
process.
– Contaminated fuel can cause
malfunction or even damage of
the engine. If necessary, fill in
fuel through a screen filter.
– Use only fuel of the permitted
‘Fuel’ on page 135.
92 BW 212 D-5 SL

n Protective gloves
Diesel
1. Clean the area around the filling port.
2. Unscrew the cap and fill with fuel.
3. Close the cap.
B-586-0407
Fig. 61
BW 212 D-5 SL 93
5.3.3 Checking the hydraulic oil level
NOTICE!
– Check the hydraulic oil level at
room temperature (approx. 20 °C
(68 °F)).
– 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.
‘Hydraulic oil’ on page 140.

n Protective gloves
1. Check the oil level in the inspection glass.
Normal level approx. 3 cm (1.2 in)
below the top edge of the
sight glass
Minimum level Middle of inspection glass
B-587-0045
filling port.
Fig. 62
3. Unscrew the cover and fill in hydraulic oil.
4. Close the cap.
94 BW 212 D-5 SL
5.3.4 Checking the coolant level
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.
– Use only coolant of the permitted
‘Coolant’ on page 136.
A coolant level which is too low is indicated by

the coolant level warning light.
B-SYM-1007
Fig. 63
n Protective gloves
n Safety goggles
1. Check the coolant level in the compensa-
tion tank.
WARNING!
Danger of scalding by hot fluid!
– Open the compensation tank
B-586-0372
only when the engine is cold.

filling port.
BW 212 D-5 SL 95
3. Unscrew the cover and fill in coolant up to

the “MAX” mark.
4. Close the cap.
5.3.5 Checking the air filter

n Protective gloves
1. Check the air filter maintenance indicator.
2. If the yellow pin has reached the red area
(1), service the air filter Ä Chapter 8.12.1
‘Air filter maintenance’ on page 195.
B-584-0013
Fig. 65
96 BW 212 D-5 SL
5.3.6 Checking wheels and tyres
WARNING!
Danger of being injured by
bursting tyres!
equipment (safety shoes, gloves,
goggles, hard hat).
– When checking the tyre pressure
stand in the extended path of the
tyre track.
– Use an air hose with a length of
min. 6 meters.
– Never exceed the permitted max-
imum pressure.
The tire pressure can be adapted to

the operating conditions within the
specified limits.
A reduced tire pressure improves
the traction especially 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.

n Protective gloves
n Safety goggles
n Hard hat
BW 212 D-5 SL 97
1. Move the machine so that the tyre valve is

in top position.
2. Park the machine safely Ä Chapter 6.6
bar on page 112.
psi 3. Check the wheels and tyres for cuts,
B-586-0086 bulges, damaged rims, missing wheel
studs or nuts.
Fig. 66
4. Have damaged wheels or tyres replaced
immediately.
5. Unscrew the valve caps and check the
front and rear tyre pressure, correct if nec-
essary.
Ensure equal pressure in all tyres.
Tyre pressure nominal value

Ä Chapter 2 ‘Technical data’
on page 13
6. Screw the valve caps back on again.
98 BW 212 D-5 SL
Operation
6 Operation
BW 212 D-5 SL 99
Operation – Setting up the workplace
6.1 Setting up the workplace

on page 112.
2. If necessary, adjust the driver's seat
Ä Chapter 4.1.5 ‘Driver’s seat’ on page 79.
100 BW 212 D-5 SL

Operation – Starting the engine
6.2 Starting the engine
WARNING!
Loss of hearing caused by too
high noise burdens!
equipment (ear protection).
Protective equip- n Hearing protection

ment:
Prerequisites:
n Main battery switch is switched on.
n Emergency stop switch is unlocked.
n The travel lever is in “Middle right” position
(parking brake closed).
1. Turn the rotary switch for amplitude pre-
selection to “Middle” position.
B-SWI-1084
Fig. 67
2. Turn the rotary switch for engine speed to
“Middle” position (ECO mode).
B-SWI-1089
Fig. 68
BW 212 D-5 SL 101

3. Turn the ignition key to position “I”.

ð All control and warning lights in the
instrument cluster light up for a moment.
B-ELE-0081
Fig. 69
4. If the pre-heating control light lights up,
wait until it goes out before starting the
engine.
B-SYM-1142
Fig. 70 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.
NOTICE!
– Run the starting process for max-
imum 20 seconds without inter-
ruption and pause for a minute
between starting attempts.
– If the engine has not started after
two attempts, determine the
cause.
5. Turn the ignition key to position “II”.

ð The starter cranks the engine.
B-ELE-0082
Fig. 71
102 BW 212 D-5 SL

NOTICE!
– Warm up engine for a short while
before starting work. Do not
operate the engine immediately
under full load.
BW 212 D-5 SL 103

Operation – Travel mode
6.3 Travel mode

6.3.1 Preliminary remarks and safety notes
Driving up and down
slopes DANGER!
Danger to life caused by the
machine turning over!
– Never drive across a slope.
– Always drive straight up or down
a slope.
Do not drive on gradients exceeding the max-

imum gradeability of the machine Ä Chapter 2
‘Technical data’ on page 13.
Soil conditions and weather influences impair
the gradeability of the machine.
Wet and loose soil considerably reduces trac-
tion of the machine on inclinations and slopes.
Increased danger of accident!
Leaving the seat while

travelling
If the operator leaves his seat while travelling,
the driver's seat warning light lights up.
The warning buzzer sounds.
After approx. 3 seconds, the machine brakes to
Fig. 72 a standstill.
Before being able to drive again, the travel
lever must first be shifted to the right into the
parking brake position.
104 BW 212 D-5 SL

6.3.2 Driving the machine

1. Fasten your seat belt.
2. Pre-select the desired travel speed range.
The travel speed range can

also be switched over while
driving.
B-SWI-1624
Fig. 73
“Middle” position (ECO mode).
B-SWI-1089
Fig. 74
4. Shift the travel lever to the left out of
parking brake position to disengage.
5. Shift the travel lever slowly in the desired
travel direction.
ð The further the travel lever is moved for-
wards or backwards, the faster the
B-ELE-0138 machine will travel.
Fig. 75
BW 212 D-5 SL 105

6. Set the travel lever to “Middle” position to

stop the machine.
ð The machine decelerates to a standstill.
7. Always apply the parking brake when stop-
ping on inclinations or slopes.
B-ELE-0142
Fig. 76
6.3.3 Applying the parking brake

1. Shift the travel lever to “Middle” position.
ð The machine decelerates to a standstill.
2. Engage the travel lever to the right (parking
brake position).
ð The parking brake warning light lights
up.
B-ELE-0143
Fig. 77
106 BW 212 D-5 SL

Operation – Working with vibration
6.4 Working with vibration

6.4.1 Preliminary remarks and safety notes
NOTICE!
Possible damage to neigh-
bouring buildings!
– When compacting with vibration
you must always check the effect
of the vibration on nearby build-
ings and underground supply
lines (gas, water, sewage, elec-
tric power).
– If necessary stop compacting
with vibration.
NOTICE!
Machine parts may get damaged!
– Do not activate the vibration on
hard (frozen, concrete) ground.
Vibration at standstill causes transverse marks:

n Switch the vibration on only after shifting the
travel lever in the desired travel direction.
n Switch the vibration off before stopping the
machine.
BW 212 D-5 SL 107

6.4.2 Switching the vibration on and off

1. Turn the rotary switch for travel speed
ranges to “Left” position.
B-SWI-1624
Fig. 78
“Middle” position (ECO mode) or “Right”
position (MAX).
B-SWI-1089
Fig. 79
Pre-selecting the vibra-
tion
3. Pre-select the desired amplitude with the
rotary switch for amplitude pre-selection.
B-SWI-1083
Fig. 80
108 BW 212 D-5 SL

Switching the vibration

on
4. Shift the travel lever slowly in the desired
travel direction.
B-ELE-0138
Fig. 81
5. Actuate the vibration push button.
ð Vibration is switched on.
B-ELE-0139
Fig. 82
Switching the vibration
off
6. Press the push button once again to switch
off vibration.
ð Vibration is switched off.
B-ELE-0139
Fig. 83
BW 212 D-5 SL 109

7. After finishing work, turn the rotary switch

for amplitude pre-selection back to position
“0”.
B-SWI-1084
Fig. 84
110 BW 212 D-5 SL

Operation – ECONOMIZER
6.5 ECONOMIZER
Optional equipment
The ECONOMIZER continuously informs the

driver about the compaction status of the layer
being compacted and enables the detection
and targeted post-compaction of local weak
spots.
The acceleration sensor on the drum measures
the reaction of the road subbase.
n With the vibration switched on, the meas-
uring value for the soil stiffness is shown on
a scale (1–10).
n Intermediate steps are displayed as a
hatched area on the scale.
1 n If the display value does not increase any
further, no further compaction can be ach-
B-DIS-0821
ieved with this machine. The maximum dis-
Fig. 85 play value (10) is not always reached.
n If the drum is in jump operation, the display
(1) flashes.
In order to achieve the desired soil stiffness,
one must always perform a suitable reference
measurement before compaction is started.
The reference measurement is used to deter-
mine which display value of the ECONOMIZER
corresponds with the measuring value for soil
stiffness.
BW 212 D-5 SL 111

Operation – Parking the machine in secured condition
6.6 Parking the machine in secured condition

1. Drive the machine onto level, firm ground.
2. To stop the machine return the travel lever
to the middle position and shift it to the
right to lock (parking brake position).
ð The parking brake warning light lights
up.
B-ELE-0143
Fig. 86
“Left” position (MIN).
NOTICE!
– Do not shut down the engine all
B-SWI-1469
of a sudden from full load speed,
but let it idle for about two
Fig. 87 minutes.
4. Turn the ignition key to position “0” and pull

it out.
B-ELE-0080
Fig. 88
112 BW 212 D-5 SL

Operation – Parking the machine in secured condition
5. Turn the main battery switch anticlockwise

and pull it out.
B-SWI-0169
Fig. 89
BW 212 D-5 SL 113

Operation – Operating the heating / air conditioning system
6.7 Operating the heating / air conditioning system
NOTICE!
The function of the heating / air
conditioning system may be
affected!
– Always keep the air inlet slots on
the cabin free of snow, foliage
etc.
Fig. 90 – Switch the air conditioning on
every month for about ten
a Adjust the air distribu-
minutes.
tion
b Regulate the cabin tem-
perature
c Air conditioning on/off
d Set the fan speed
Heating the interior 1. Close all windows completely.
2. Adjust the desired air distribution.
3. Switch on the fan.
4. Regulate the cabin temperature.
Cooling the interior 1. Close all windows completely.

2. Adjust the desired air distribution.
3. Switch on the fan.
4. Switch the air conditioning on.
5. Regulate the cabin temperature.
Reducing the humidity 1. Direct the air distribution to the windscreen.

2. Switch the fan to stage “3”.
3. Set the cabin temperature to “Max”.
114 BW 212 D-5 SL

Operation – Emergency procedures
6.8 Emergency procedures

6.8.1 Actuating the emergency stop switch
1. In events of emergency and in case of
danger actuate the emergency stop switch
immediately.
ð The engine is shut down and the parking
brake is closed.
Fig. 91
6.8.2 Disconnecting the battery

1. In events of emergency, e.g. in case of a
cable fire, disconnect the battery from the
vehicle network. For this purpose turn the
main battery switch anticlockwise and pull
it out or pull the battery terminal off the bat-
tery.
Fig. 92
6.8.3 Emergency exit

If a machine has turned over and the cabin
door is jammed, the cabin windows can be
used as emergency exits.
1. Take the emergency hammer out of its
bracket and smash the cabin window.
Fig. 93
BW 212 D-5 SL 115

6.8.4 Towing the machine

Tow the machine only in case of emergency or
to prevent an accident.
Towing distance max. 500 m (1600 ft), towing
speed max. 1 km/h (55 ft/min).
Before towing make sure that:
n the tractor vehicle has sufficient traction and
braking power for the non-braking towed
load;
n lifting tackle is of sufficient strength to with-
stand the load and is fastened at the points
provided for this purpose.
If no tow bar is used, towing is only permitted
uphill.
n Protective gloves
WARNING!
uncontrolled machine movement!
– Always secure the machine
1. Fasten the towing device reliably to the

towing points.
2. Open and secure the engine hood
Ä Chapter 8.2.1 ‘Open and secure the
engine hood’ on page 130.
B-584-0015
Fig. 94
116 BW 212 D-5 SL

Travel pump
3. Remove the caps from the two high pres-
2 3 sure limiting valves (1).
4. For bypass switching, loosen the counter
nuts (3).
5. Tighten the socket head cap screws (2)
1 until the screw touches the spring cup
B-584-0014 (increased resistance).
Fig. 95 6. Tighten the socket head cap screws
another half turn.
7. Tighten the counter nuts, tightening torque:
22 Nm (16 ft·lbf).
8. Press the emergency operation button
completely in.
9. Insert a suitable pump lever extension and
operate the pump, until the brake is
released.
ð The machine can now be towed.
B-GEN-0126
Fig. 96
6.8.5 After towing
WARNING!
uncontrolled machine movement!
– Always secure the machine
BW 212 D-5 SL 117

1. After towing, park the machine in a safe

place and secure it against accidentally
rolling away.
2. If the engine cannot be started, pull the
emergency operation button completely out
after towing.
After starting the engine the

emergency operation button is
pushed out by hydraulic pres-
B-GEN-0127
sure.
Fig. 97
3. Loosen the counter nuts (3) on the high
2 3 pressure limiting valves of the travel pump.
4. Unscrew the socket head cap screws (2)
against the end stop.
5. Tighten the counter nuts, tightening torque:
1 22 Nm (16 ft·lbf).
B-584-0014
Fig. 98
118 BW 212 D-5 SL

Loading / transporting the machine
7 Loading / transporting the machine
BW 212 D-5 SL 119

Loading / transporting the machine – Prepare for transport
7.1 Prepare for transport

1. Close all doors, windows and flaps.
2. Remove all loose objects from the machine
or from the operator's stand or fasten them
reliably.
120 BW 212 D-5 SL

Loading / transporting the machine – Loading the machine
7.2 Loading the machine

bearing capacity.
The ramp inclination must be less than the gra-
deability of the machine.
Make sure that any persons keep a safety dis-
tance of at least 2 metres while the machine is
driven onto or down from the transport vehicle.
The instructing person should not be inside the
travel range of the machine.
Centre-of-gravity posi-
tion
H
L B-584-0011
Fig. 99
Distance from middle of drum Height

1204 mm 929 mm
47.4 in 36.6 in
DANGER!
machine slipping or turning over!
– Make sure that no persons are in
the danger zone.
BW 212 D-5 SL 121

Loading / transporting the machine – Loading the machine

ranges to position “Left”.
2. Drive the machine carefully onto the trans-
port vehicle.
3. Observe the centre of gravity.
4. Switch off the engine and remove the igni-
B-SWI-1624
tion key.
Fig. 100 5. Engage the articulation lock Ä Chapter
8.2.2.1 ‘Engaging the articulation lock’
on page 131.
122 BW 212 D-5 SL

Loading / transporting the machine – Lashing the machine to the transport vehicle
7.3 Lashing the machine to the transport vehicle

Do not use lashing points that are damaged or
impaired in any way.
Always use appropriate lashing tackle at the
lashing points.
Use lashing tackle only in the specified loading
direction.
Lashing tackle must not be damaged by
machine parts.
1. Fasten the lashing tackle at the marked
lashing points.
2. Lash the machine securely to the transport
vehicle.
B-584-0006
Fig. 101
BW 212 D-5 SL 123

Loading / transporting the machine – Loading by crane
7.4 Loading by crane

Loads may only be attached and hoisted by an
expert/qualified person.
Do not use lashing points that are damaged or
impaired in any way.
Only use lifting and lashing tackle with suffi-
cient load bearing capacity for the weight to be
loaded. Minimum load bearing capacity of the
lifting tackle: see max. operating weight
Ä Chapter 2 ‘Technical data’ on page 13.
Always use appropriate lashing tackle at the
lashing points.
Use lashing tackle only in the specified loading
direction.
Lashing tackle must not be damaged by
machine parts.
When lifting the machine avoid uncontrolled
movements of the load. If necessary, hold the
load steady with guide ropes.
1. Shut down the engine.
2. Engage the articulation lock Ä Chapter
8.2.2.1 ‘Engaging the articulation lock’
on page 131.
3. Fasten the lashing tackle at the marked
lifting points.
4. Adjust the length of the lifting tackle so that
the crane hook is vertically above the
centre of gravity of the machine.
5. Use a suitable crossbar to prevent the
B-584-0007 machine from being damaged.
Fig. 102
124 BW 212 D-5 SL

Loading / transporting the machine – Loading by crane
DANGER!
Danger to life caused by sus-
pended loads!
– Do not step or stand under sus-
pended loads.
6. Lift the machine carefully and set down

again at the intended location.
BW 212 D-5 SL 125

Loading / transporting the machine – After transportation
7.5 After transportation

bearing capacity.
The ramp inclination must be less than the gra-
deability of the machine.
Make sure that any persons keep a safety dis-
tance of at least 2 metres while the machine is
driven onto or down from the transport vehicle.
The instructing person should not be inside the
travel range of the machine.
1. Loosen the articulation lock Ä Chapter

8.2.2.2 ‘Disengaging the articulation lock’
on page 132.
ranges to “Left” position.
3.
DANGER!
machine slipping or turning
over!
B-SWI-1624
– Make sure that no persons

Fig. 103 are in the danger zone.
Drive the machine carefully off the trans-

port vehicle.
126 BW 212 D-5 SL

Maintenance
8 Maintenance
BW 212 D-5 SL 127

Maintenance – Preliminary remarks and safety notes
8.1 Preliminary remarks and safety notes
DANGER!
Danger to life caused by an
operationally unsafe machine!
– The machine must only be serv-
iced by qualified and authorized
personnel.
– Follow the safety regulations for
maintenance work Ä Chapter
3.10 ‘Maintenance work’
on page 51.
WARNING!
and lubricants!
CAUTION!
Danger of being injured by the
engine hood dropping down!
– Always secure an opened engine
hood.
Wear your personal protective equipment.

Park the machine on horizontal, level, firm
ground.
Keep unauthorised persons away from the
machine.
Perform maintenance work only with the
engine shut down.
128 BW 212 D-5 SL

Maintenance – Preliminary remarks and safety notes
Make sure that the engine cannot be acciden-

tally started during maintenance work.
Do not touch hot components.
Thoroughly clean the machine and engine
before starting maintenance work.
Before mounting the machine, check whether
all access steps, grips and platforms are free of
obstacles, grease, oils, fuel, dirt, snow and ice.
Use only the intended access steps and grips
to mount the machine.
For overhead maintenance work use the
access steps and working platforms provided
or other secure means.
Do not step on machine parts which are not
intended for this purpose.
Always attach the articulation lock when
working in the area of the articulated joint.
Do not leave any tools or other objects, that
could cause damage, in or on the machine.
After maintenance work has been completed,
dispose of fuels and lubricants, filters, sealing
elements and cleaning cloths in line with envi-
ronmental regulations.
After maintenance work is completed reinstall
all protective devices.
Close all maintenance flaps and doors after
maintenance work has been completed.
The terms right/left are always in

relation to the travel direction.
BW 212 D-5 SL 129

Maintenance – Preparations/concluding work
8.2 Preparations/concluding work

Certain maintenance tasks require prepara-
tions and concluding activities.
This includes e.g. opening and closing mainte-
nance flaps and maintenance doors as well as
securing certain components.
After this work close all maintenance flaps and
doors again and return all components to their
operating condition.
8.2.1 Open and secure the engine hood

Opening the engine
hood
1. Unlock the lock.
2. Press the button.
3. Swing the engine hood upwards by the
handle.
B-584-0008
Fig. 104
4. Secure the engine hood into its uppermost
position with a split pin (1).
B-586-0131
Fig. 105
130 BW 212 D-5 SL

8.2.2 Engaging/releasing the articulation lock

8.2.2.1 Engaging the articulation lock
WARNING!
Danger of crushing by the articu-
lating machine!
– Do not step into the articulation
area of the machine while the
engine is running.
1. Move the steering to middle position and

stop the machine.
2. Switch off the engine and remove the igni-
tion key.
3. Pull the split pin out of the locking bolt for
the articulation lock.
4. Lift up the articulation locking bolt and
swivel it by 180°.
B-586-0415
Fig. 106
5. Engage the articulation locking bolt and
secure it with the split pin.
B-586-0416
Fig. 107
BW 212 D-5 SL 131

8.2.2.2 Disengaging the articulation lock
WARNING!
Danger of crushing by the articu-
lating machine!
– Do not step into the articulation
area of the machine while the
engine is running.
1. Pull the split pin out of the locking bolt for

the articulation lock.
2. Lift up the articulation locking bolt and
swivel it by 180°.
B-586-0416
Fig. 108
3. Engage the articulation lock in the holding
fixture and secure it with the split pin.
B-586-0415
Fig. 109
132 BW 212 D-5 SL

Maintenance – Fuels and lubricants
8.3 Fuels and lubricants

8.3.1 Engine oil
8.3.1.1 Oil quality
Engine oils for use in DEUTZ engines are clas-
sified in DEUTZ Engine Oil Quality Classes
(DQC).
The following engine oil specifications are

permitted:
DEUTZ ACEA API DHD
DQC II-10 E3-96 CH-4 DHD-1
E4-12 CI-4
E5-02 CI-4 Plus
E7-12
DQC III-10 - - -
DQC - - -
IV-10
Avoid mixing of engine oils.
The list of approved engine oils is also

available on the Internet under the following
address:
www.deutz.com
de SERVICE \ Maintenance \ Betriebs-
stoffe \ Öle \ DEUTZ Quality Class \
DQC Freigabeliste
en SERVICE \ Maintenance \ Operating
Liquids\ Oils \ DEUTZ Quality Class \
DQC Release List
BW 212 D-5 SL 133

8.3.1.2 Oil viscosity

Since engine 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).
Only use multi-purpose oils.
The temperature indications of the SAE-class
always refer to fresh oils. In travel operation
engine oil ages because of soot and fuel resi-
dues. This adversely affects the properties of
the engine oil, especially under low ambient
temperatures.
Optimal operating conditions can be achieved
by using the oil viscosity chart as a reference.
Fig. 110: Oil viscosity dia-

gram
8.3.1.3 Oil change intervals

If the oil change intervals are not reached over
a period of one year, the oil change should be
performed at least 1 x per year, irrespective of
the operating hours reached.
The oil change interval must be halved if at
least one of the following conditions applies:
n Permanent ambient temperatures below
-10 °C (14 °F)
n Engine oil temperatures below 60 °C
(84 °F).
n Sulphur content in fuel exceeding 0.5 %
134 BW 212 D-5 SL

8.3.2 Fuel
8.3.2.1 Fuel quality
You should preferably use commercial diesel
fuel with a sulphur content of less than 0.5 %.
When using a diesel fuel with a high sulphur
content of 0.5 % to 1.0 % the oil change inter-
vals must be halved.
Fuels with a sulphur content of more than
1.0 % are not permitted.
In order to fulfil national emission regulations
one must strictly use the legally required fuels
(e.g. sulphur content).
The following fuel specifications are recom-
mended:
n EN 590
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
8.3.2.2 Winter fuel

For winter operation use only winter diesel fuel,
to avoid clogging because of paraffin separa-
tion.
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.
BW 212 D-5 SL 135

NOTICE!
– The admixture of petroleum and
the addition of “flow enhancing
additives” (fuel additives) is not
permitted.
8.3.2.3 Storage
Even traces of zinc, lead and copper can cause
deposits in the injection nozzles, especially in
modern Common-Rail injection systems.
Zinc and lead coatings in refuelling systems
and fuel lines are not permitted.
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.
8.3.3 Coolant
8.3.3.1 General
For fluid cooled engines the cooling fluid must
be prepared by admixing a cooling system pro-
tection agent to the fresh water and should be
checked within the specified maintenance inter-
vals.
This prevents damage caused by corrosion,
cavitation, freezing and overheating.
136 BW 212 D-5 SL

8.3.3.2 Water quality

The correct quality of water is highly important
when preparing coolant. Clear and clean water
within the boundaries of the following analysis
values should generally be used.
Analysis values
pH-value at 20 °C (68 6.5 - 8.5
°F)
Chlorine-ion content max. 100 mg/l
Sulphate ion content max. 100 mg/l
Water hardness (ion max. 3.56 mmol/l
content of calcium and max: 356 mg/l (ppm)
magnesium )
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 sol-
ution.
Water hardness - Mix with soft, distilled or
too high fully demineralized water
Chlorides and/or - Mix with distilled or fully
sulphates too demineralized water
high
BW 212 D-5 SL 137

NOTICE!
– Another analysis must be made
after the fresh water has been
prepared.
8.3.3.3 Cooling system protection agent

As a protection against frost, corrosion and
boiling, anti-freeze agents must be used in 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 using our
BOMAG cooling system protection 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 on the internet under the following
link:
www.deutz.com
de SERVICE \ Maintenance \ Betriebs-
stoffe \ Kühlsystemschutz
en SERVICE \ Maintenance \ Operating
Liquids \ Coolant
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 C.
138 BW 212 D-5 SL

NOTICE!
– 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 cor-
rosion protection.
The mixing ratio must not be below or

exceed the following value:
Cooling Fresh water Protection
system pro- against cold
tection 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!
– A proportion of more than 50% of
cooling system protection agent
results in reduced cooling power.
– The use of corrosion protection
oils as cooling system protection
agents is not permitted.
BW 212 D-5 SL 139

8.3.4 Hydraulic oil

8.3.4.1 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).
When refilling or changing oil, use only
hydraulic oil type HVLP according to DIN
51524, part 3, or hydraulic oil type HV
according to ISO 6743/4.
The viscosity index must be at least 150
(observe information of manufacturer).
8.3.4.2 Bio-degradable hydraulic oil

The hydraulic system can also be operated
with a synthetic ester based biodegradable
hydraulic oil.
The biodegradable hydraulic oil
Panolin HLP Synth. 46 or Plantohyd 46 S
meets all the requirements of a mineral oil
based hydraulic oil according to DIN 51524.
In hydraulic systems filled with biodegradable
hydraulic oil, always use the same oil to top up
and do not mix oil types.
When changing from mineral oil based
hydraulic oil to an ester-based, biologically
degradable hydraulic oil, you should consult
the lubrication oil service of the oil manufac-
turer, or our customer service for details.
140 BW 212 D-5 SL

NOTICE!
Danger of damage to the
hydraulic system!
– After the changeover check the
hydraulic oil filters increasingly
for contamination.
– Have regular oil analyses per-
formed regarding the water con-
tent and mineral oil.
– Replace the hydraulic oil filter at
the latest after 500 operating
hours.
8.3.5 Gear oil SAE 75W-90

Use a fully synthetic gear oil in accordance with
SAE 75W-90, API GL5 with a kinematic vis-
cosity of at least 16 mm2/s at 100 °C (212 °F).
8.3.6 Gear oil SAE 80W-140

Use a fully synthetic gear oil in accordance with
SAE 80W-140, API GL5 with a kinematic vis-
cosity of at least 20 mm2/s at 100 °C (212 °F).
It is a hypoid lubricant of highest quality class
for transmissions under extreme strain.
BW 212 D-5 SL 141

Maintenance – List of fuels and lubricants
8.4 List of fuels and lubricants

Assembly Fuel or lubricant Spare Filling
group parts quantity
Summer Winter number Observe
the level
mark!
Engine oil SAE 10W-40 009 920 06 8.5 l
Specification: Ä Chapter 8.3.1 20 l (2.2 gal us)
‘Engine oil’ on page 133
SAE 15W-40
SAE 10W-30
SAE 30 SAE 10W
Fuel Diesel Winter diesel 250 l
fuel (66 gal us)
Specification: Ä Chapter 8.3.2
‘Fuel’ on page 135
Coolant Mixture of water and anti-freeze 009 940 03 14 l
agent 20 l (3.7 gal us)
Specification: Ä Chapter 8.3.3
‘Coolant’ on page 136
Hydraulic Hydraulic oil (ISO), HVLP 46 009 930 09 75 l
system Specification: Ä Chapter 8.3.4.1 20 l (20 gal us)
‘Mineral oil based hydraulic oil’
on page 140
or ester based biodegradable
hydraulic oil
Specification: Ä Chapter 8.3.4.2
‘Bio-degradable hydraulic oil’
on page 140
Exciter housing Gear oil SAE 75W-90 009 925 05 1.2 l each
Specification: Ä Chapter 8.3.5 20 l (0.32 gal
‘Gear oil SAE 75W-90’ us)
on page 141
142 BW 212 D-5 SL

Maintenance – List of fuels and lubricants
Assembly Fuel or lubricant Spare Filling

group parts quantity
Summer Winter number Observe
the level
mark!
Drum drive Gear oil SAE 80W-140 009 925 07 6.5 l
reduction gear Specification: Ä Chapter 8.3.6 20 l (1.7 gal us)
‘Gear oil SAE 80W-140’
on page 141
Drive axle Gear oil SAE 80W-140 009 925 07 11 l
Specification: Ä Chapter 8.3.6 20 l (2.9 gal us)
on page 141
Axle reduction Gear oil SAE 80W-140 009 925 07 1.9 l
gear Specification: Ä Chapter 8.3.6 20 l (0.50 gal
on page 141
Wheel hubs Gear oil SAE 80W-140 009 925 07 1.4 l each
Specification: Ä Chapter 8.3.6 20 l (0.37 gal
on page 141
Tyres Water + calcium chloride 295 l + 100
kg
(80 gal us
+ 220 lbs)
or water + magnesium chloride 308 l + 87
kg
(81 gal us
+ 192 lbs)
Air conditioning Refrigerant R134a 1500 g
(3.3 lbs)
BW 212 D-5 SL 143

Maintenance – Running-in instructions
8.5 Running-in instructions

8.5.1 General information
When commissioning new machines, the run-
ning-in instructions listed in this chapter must
be carried out after the specified operating
hours.
The maintenance work listed must be carried
out in addition to the regular maintenance inter-
vals.
8.5.2 After the first 250 operating hours

1. Tighten all bolted connections on air intake,
exhaust, oil sump and engine mounts.
2. Retighten the bolted connections on the
machine.
3. Retighten the wheel nuts Ä Chapter 8.9.10
‘Retightening the wheel nuts’ on page 185.
4. Oil and filter change on diesel engine
Ä Chapter 8.8.1 ‘Change engine oil and oil
filter cartridge’ on page 161.
5. Oil change in drive axle Ä Chapter 8.9.6
‘Change the oil in the drive axle’
on page 180.
6. Oil change in wheel hubs Ä Chapter 8.9.7
‘Changing the oil in the wheel hubs’
on page 181.
7. Exciter unit oil change. Ä Chapter 8.9.8
‘Change the oil in the exciter housing’
on page 183
144 BW 212 D-5 SL

Maintenance – Running-in instructions

1. Oil and filter change diesel engine.
Ä Chapter 8.8.1 ‘Change engine oil and oil
filter cartridge’ on page 161
on page 183

1. Oil change in drive axle. Ä Chapter 8.9.6
‘Change the oil in the drive axle’
on page 180
2. Oil change in wheel hubs Ä Chapter 8.9.7
‘Changing the oil in the wheel hubs’
on page 181
on page 183
4. Retighten the wheel nuts. Ä Chapter
8.9.10 ‘Retightening the wheel nuts’
on page 185
BW 212 D-5 SL 145

Maintenance – Maintenance Table
8.6 Maintenance Table

No. Maintenance works Page
Daily maintenance
5.3.1 Checking the engine oil level 91
5.3.2 Checking the fuel level; topping up fuel 92
5.3.3 Checking the hydraulic oil level 94
5.3.4 Checking the coolant level 95
5.3.5 Checking the air filter 96
5.3.6 Checking wheels and tyres 97
Every 250 operating hours
8.7.1 Checking the rubber-bonded metal rails and rubber 149
buffers
8.7.2 Cleaning the radiator module 150
8.7.3 Checking the ribbed V-belt 152
8.7.4 Checking, tensioning the V-belt of the air condi- 152
tioning compressor
8.7.5 Checking the oil level in the drive axle 155
8.7.6 Checking the oil level in the wheel hubs 155
8.7.7 Checking the oil level in the exciter housing 156
8.7.8 Changing the fresh air filter in the cabin 158
8.7.9 Check the air intake lines 159
8.7.10 Checking radiator hoses and hose clamps 159
8.7.11 Check the parking brake 160
8.8.1 Change engine oil and oil filter cartridge 161
8.8.2 Replacing the fuel filter; bleeding the fuel system 163
8.8.3 Checking the anti-freeze concentration and the con- 166
dition of the coolant
8.8.4 Checking the hydraulic lines 167
146 BW 212 D-5 SL


8.8.5 Servicing the battery; checking the main battery 169
shutoff
8.8.6 Servicing the air conditioning system 170
8.9.1 Checking, adjusting the valve clearance 173
8.9.2 Replacing the ribbed V-belt 175
8.9.3 Replacing the V-belt of the air conditioning com- 176
pressor
8.9.4 Checking the engine mounts 177
8.9.5 Replacing the hydraulic oil filter 178
8.9.6 Change the oil in the drive axle 180
8.9.7 Changing the oil in the wheel hubs 181
8.9.8 Change the oil in the exciter housing 183
8.9.9 Retightening the fastening of the axle on the frame 185
8.9.10 Retightening the wheel nuts 185
8.9.11 Checking the ROPS/FOPS 185
8.9.12 Checking the travel lever control 186
8.9.13 Cleaning the circulation air filter of the heating 187
8.10.1 Changing the hydraulic oil 188
8.10.2 Changing the coolant 190
8.11.1 Check the injection valves 194
As required
8.12.1 Air filter maintenance 195
8.12.2 Checking and cleaning the water separator 199
8.12.3 Adjusting the scrapers 200
8.12.4 Cleaning the machine 201
8.12.5 Filling the windscreen washer tank 202
BW 212 D-5 SL 147


8.12.6 Drain the fuel tank sludge 202
8.12.7 Retightening the padfoot shell 203
8.12.8 Measures prior to extended shut-down period 203
148 BW 212 D-5 SL

Maintenance – Every 250 operating hours
8.7 Every 250 operating hours

8.7.1 Checking the rubber-bonded metal rails and rubber buf-
fers
n Protective gloves
1. Drive the machine onto horizontal, level,
firm ground.
Make sure there is sufficient

space to drive the machine for
at least one full turn of the
drum.

Checking the rubber-
bonded metal rails
3. Check the rubber-bonded metal rails on the
left-hand side for a tight fit, cracks and tear-
offs.
4. Have damaged any rubber-bonded metal
rails replaced immediately by our Customer
Service Department.
B-584-0036
Fig. 111
BW 212 D-5 SL 149

Checking the rubber buf-

fers To check the rubber buffers on the
right-hand side, the drum has to be
moved one revolution in three
steps.
5. Check the rubber buffers that are visible for

a tight fit, cracks and tear-offs.
Then start the engine and move the
machine forward approx. 1.50 m (5 ft).
Shut the engine down and perform the
check once again.
B-584-0037
6. Repeat these activities until the drum has
Fig. 112 been moved one revolution.
7. Have any damaged rubber buffers
replaced immediately by our Customer
Service Department.
8.7.2 Cleaning the radiator module
NOTICE!
– Dirt on fan blades and oil coolers
reduce the cooling effect. Dirt
deposits in these areas are sub-
stantially 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 radiator
and clean the cooling fins after.
– Do not damage any cooling fins
on the cooler core when
cleaning.
150 BW 212 D-5 SL

Cleaning with com- Protective equip- n Working clothes

pressed air ment: n Protective gloves
n Safety goggles
on page 112.
2. Allow the engine to cool down.
LUFT 3.
CAUTION!
AIR Danger of eye injuries caused
by particles flying around!
– Wear your personal protec-
tive equipment (protective
gloves, protective clothing,
B-586-0134
goggles).
Fig. 113
Blow the radiator out with compressed air
from the air discharge side.
4. Blow the radiator out with compressed air
from the air supply side.
Cleaning with cold

cleansing agent NOTICE!
Electric components can be dam-
aged by water entering into the
system!
– Protect electrical equipment such
as generator, regulator and
starter against the direct water
jet.
1. Spray engine and radiator with a suitable

cleansing agent, e.g. cold cleansing agent,
let it soak in for a while and spray it off with
a strong water jet.
2. Warm up the engine for a while to avoid
corrosion.
BW 212 D-5 SL 151

8.7.3 Checking the ribbed V-belt

n Protective gloves
on page 112.
3. Check the entire circumference of the belt
for damage and cracks.
4. Replace damaged ribbed V-belts.
Check dimension “a” between the

tongue of the moveable and the end
B-DEU-0042
stop of the fixed part of the idler
pulley.
Fig. 114
5. Check dimension “a” on the idler pulley.
ð The dimension must be min.
3 mm (0.12 in).
If the dimension is smaller, replace the
a ribbed V-belt.
B-DEU-0041
Fig. 115
8.7.4 Checking, tensioning the V-belt of the air conditioning

compressor
1. Park the machine in secured condition
Ä Chapter 6.6 ‘Parking the machine in
secured condition’ on page 112.
152 BW 212 D-5 SL

8.7.4.1 Checking the condition of the V-belt

n Protective gloves
1. Check the entire circumference of the belt
for damage and cracks.
2. Replace a damaged or torn V-belt
Ä Chapter 8.9.3 ‘Replacing the V-belt of
the air conditioning compressor’
on page 176.
B-586-0538
Fig. 116
8.7.4.2 Checking the V-belt tension

ment: n Protective gloves
Tool: n Belt tension tester
1. Press the indicator arm (a) of the tester into
the gap of the measuring scale.
2. Place the meter in the middle between the
V-belt pulleys on the back of the belt.
Fig. 117
BW 212 D-5 SL 153

3. Actuate the push button (b) evenly with a

finger under a right angle to the belt, until
the pressure spring disengages audibly
and noticeably.
ð The indicator arm remains in the meas-
ured position.
4. Take the measuring unit carefully off,
without moving the indicating arm.
Fig. 118
5. Read the belt tension where the upper
edge of the indicating arm intersects with
the measuring scale.
Belt tension nominal value
during initial 400 N (90 lbf) (cold)
assembly (new belt)
after a running-in 300 N (67 lbf)
time, in case of
Fig. 119
reassembly
6. Tighten the belt, if necessary.
8.7.4.3 Tensioning the V-belt

n Protective gloves
1. Loosen the screws (2, 3, 4) on the com-
1 2
pressor.
2. Turn the tensioning screw (1) to tighten the
V-belt to the specified value.
4 3. Tighten screws (2, 3, 4) again.
3
B-586-0133
Fig. 120
154 BW 212 D-5 SL

8.7.5 Checking the oil level in the drive axle
NOTICE!
– Use only gear oil of the permitted
on page 141.

n Protective gloves
on page 112.
2. Clean the area around the oil level inspec-
tion plug and unscrew the plug.
A second oil level inspection plug is located
on the opposite side.
3. Make sure the oil level is up to the bottom
edge of the bore; top up oil if necessary.
B-582-0047
4. Screw the oil level inspection plug back in
Fig. 121 tightly.
8.7.6 Checking the oil level in the wheel hubs
NOTICE!
on page 141.
BW 212 D-5 SL 155


1. Move the machine until the oil level inspec-
tion plug is in horizontal position.
3. Clean the area around the level inspection
plug and unscrew the plug.
Fig. 122 4. The oil level must reach the bottom edge of
the bore, top up oil if necessary.
5. Turn the level inspection plug tightly back
in.
6. Change the oil in both wheel hubs.
8.7.7 Checking the oil level in the exciter housing
NOTICE!
on page 141.
156 BW 212 D-5 SL


1. Before checking the oil level, run the
machine warm with vibration for about 1/2
hour.
2. Move the drum, until the oil level inspection
plug is in bottom position.
4. Clean the area around the level inspection
plug and unscrew the plug.
Fig. 123 ð The oil level must reach the bottom
edge of the level bore.
5. Clean the area around the filler plug and
unscrew the filler plug.
6. Fill in oil through the filler bore, until it starts
to run out through the level inspection bore.
8. Retighten the filler and level inspection
plugs.
9. Repeat this inspection on the other side.
Fig. 124
10. If a loss of oil is found, perform trouble
shooting, repair the drum if necessary.
BW 212 D-5 SL 157

8.7.8 Changing the fresh air filter in the cabin

2. Pull the fastening pins out of the left cover
and remove the cover.
Fig. 125
3. Loosen the fastening screw.
4. Also remove the cover from the right hand
side and loosen the fastening screw.
Fig. 126
5. Tilt the console towards the front screen
and hold it.
Fig. 127
158 BW 212 D-5 SL

6. Take out the filter.

7. Insert the new filter and fold the console
down again.
8. Tighten the left and right fastening screws
and reinstall the covers.
Fig. 128
8.7.9 Check the air intake lines

3. Check the condition and tight fit of all air
intake lines and hose clamps.
4. If fuel lines or hose clamps are found to be
damaged, the corresponding parts must be
immediately replaced.
8.7.10 Checking radiator hoses and hose clamps

n Protective gloves
on page 112.
3. Check the condition and tight fit of all radi-
ator hoses and hose clamps.
BW 212 D-5 SL 159

4. If a radiator hose is swollen, hardened or

cracked, the hose and hose clamps must
be replaced immediately.
8.7.11 Check the parking brake

This work must only be performed by
authorized service personnel.
160 BW 212 D-5 SL


8.8.1 Change engine oil and oil filter cartridge
Perform this maintenance work at

the latest after one year.
NOTICE!
– Change the oil only with the
engine at operating temperature.
‘Engine oil’ on page 133.
– Filling quantity: Ä Chapter 8.4
‘List of fuels and lubricants’
on page 142
BW 212 D-5 SL 161


n Protective gloves
on page 112.
WARNING!
Danger of burning on hot compo-
nents!
– Avoid touching hot components.
2. Unscrew the drain plug and collect any oil

running out.
3. Screw the drain plug back in tightly.
B-586-0390
Fig. 129
4. Thoroughly clean the outside of the oil filter
cartridge.
5. Unscrew the oil filter cartridge using an
appropriate strap wrench.
6. Remove any dirt from the sealing face of
the filter carrier.
B-586-0417
7. Thinly apply oil to the rubber seal of the
Fig. 130 new oil filter cartridge.
8. Screw on the new oil filter cartridge tightly
by hand.
162 BW 212 D-5 SL

9. Fill with new engine oil.

10. After a short test run check the oil level on
the dipstick; if necessary, top up to the top
dipstick mark.
11. Check oil filter cartridge and drain plug for
leaks.
B-586-0408
12. Dispose of the oil and oil filter cartridge in
Fig. 131 line with environmental regulations.
8.8.2 Replacing the fuel filter; bleeding the fuel system

8.8.2.1 Preliminary remarks
NOTICE!
– Ensure strict cleanliness! Thor-
oughly clean the area around the
fuel filters.
– Air in the fuel system causes
irregular running of the engine, a
drop in engine power, stalls the
engine and makes starting
impossible.
– After work on the fuel system
bleed the system, perform 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 manda-
tory.

BW 212 D-5 SL 163

8.8.2.2 Replacing the fuel filter


n Protective gloves
1. Loosen and unscrew the fuel filter cartridge
using an appropriate strap wrench.
2. Remove any dirt from the sealing face of
the filter carrier.
3. Slightly oil the rubber seal on the new filter
cartridge.
B-586-0418
4. Screw the new filter cartridge on by hand
Fig. 132 until the seal fits closely.
5. Tighten the filter cartridge by another half
turn.
8.8.2.3 Replacing the fuel pre-filter

164 BW 212 D-5 SL


n Protective gloves
1. Pull the plug-in connection off the sensor
on the water separator.
2. Place a collecting vessel under the drain
bore.
B-584-0043
Fig. 133
3. Unscrew the drain plug and collect the
escaping fuel.
B-584-0044
Fig. 134
4. Unscrew and remove the fuel pre-filter
using a suitable strap wrench.
5. Unscrew the water separator from the filter
cartridge.
6. Apply a thin coat of oil to the rubber seal of
the water separator.
B-584-0042
7. Screw the water separator to the new fuel
Fig. 135 pre-filter by hand, until the seal fits closely,
then tighten hand-tight.
8. Slightly oil the rubber seal on the new fuel
pre-filter.
9. Screw the fuel pre-filter on by hand until
the seal contacts; then tighten hand-tight.
10. Push the plug-in connection onto the
sensor on the water separator.
BW 212 D-5 SL 165

11. Dispose of fuel and filter in line with envi-

ronmental regulations.
8.8.2.4 Bleeding the fuel system

n Protective gloves
1. Open the bleeding screw on the fuel pre-
filter for one turn.
2. Operate the fuel hand pump manually, until
fuel flows out of the bleeding screw without
air bubbles.
3. Tighten the bleeding screw.
B-584-0045
4. Start the engine and run it for 5 minutes at
Fig. 136 idle speed.
5. Check the fuel pre-filter for leaks.
8.8.3 Checking the anti-freeze concentration and the condition

of the coolant
n Protective gloves
n Safety goggles
on page 112.
166 BW 212 D-5 SL

3. Unscrew the cap and check the anti-freeze

concentration with a conventional tester.
4. Check the condition of the coolant.
5. Thoroughly flush the cooling system if the
coolant is contaminated by corrosion resi-
dues or other suspended matter Ä Chapter
B-586-0376 8.10.2 ‘Changing the coolant’ on page 190.
Fig. 137 6. Close the cap.
8.8.4 Checking the hydraulic lines

This work must only be performed by an
expert / qualified person!
BW 212 D-5 SL 167


2. Check all hydraulic lines.
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 or for-
mation of cracks in the hose material,
n the hose shows deformation in pressur-
ized and depressurized condition, which
do not comply with the genuine shape of
the hydraulic hose (e.g. layer separa-
tion, formation of blisters, crushed spots,
buckling),
n leaks on hose, socket or fitting,
n the hydraulic hose has separated from
the fitting,
n fittings are damaged or deformed,
whereby the function and strength of the
hose - fitting connection is impaired,
n the fitting shows corrosion that impairs
both function and strength,
n incorrect installation (squeezing,
shearing or chafing points),
n paint covered hydraulic hoses (no detec-
tion of identifications or cracks),
n shelf life and service life exceeded.
3. Replace damaged hydraulic hoses immedi-
ately, fasten these properly and avoid
chafing.
4. Only operate the machine after it has been
repaired.
168 BW 212 D-5 SL

8.8.5 Servicing the battery; checking the main battery shutoff

8.8.5.1 Battery service
Maintenance free batteries also

need care. Maintenance free only
means that the fluid level does not
need to be checked.
Every battery has a self-discharge,
which may, if not checked occasion-
ally, even cause damage to the bat-
tery as a result of exhaustive dis-
charge.
Exhausted batteries (batteries with
formation of sulphate on the plates)
are not covered under warranty!

n Protective gloves
n Safety goggles
on page 112.
2. Remove the battery and clean the battery
compartment.
3. Clean the outside of the battery.
4. Clean the battery poles and terminals and
grease them with pole grease (Vaseline).
5. Install the battery and check the battery
B-584-0027
fastening.
Fig. 138 6. On serviceable batteries check the acid
level, if necessary top up to the filling mark
with distilled water.
BW 212 D-5 SL 169

8.8.5.2 Checking the main battery shutoff

1. Turn the main battery switch counter-clock-
wise and pull it out.
2. Check by turning the ignition key, whether
the battery is disconnected from the elec-
tric system of the machine.
Fig. 139
8.8.6 Servicing the air conditioning system

8.8.6.1 Cleaning the condenser
n Safety goggles
on page 112.
The air conditioning condenser is

located in front of the radiator.
LUFT 3.
CAUTION!
AIR Danger of eye injuries caused
by particles flying around!
– Wear your personal protec-
tive equipment (protective
gloves, protective clothing,
B-586-0134
goggles).
Fig. 140
Clean the condenser fins with compressed
air or water.
170 BW 212 D-5 SL

8.8.6.2 Air conditioning function test

1. Start the engine.
2. Switch the fan to the highest stage.
3. Choose the lowest cabin temperature.
5. Direct the air flow into the cabin and check,
that the flowing out air is considerably
cooler.
ð If the outflowing air is considerably
Fig. 141 cooler, the air conditioning system is in
a Adjust the air distribu- good working order.
tion
b Regulate the cabin tem-
perature
c Air conditioning on/off
d Fan on/off
8.8.6.3 Checking the condition of the drier/collector unit
Have the drier/collector unit

replaced by our customer service
once every year before the oper-
ating season.
1. Check the drier/collector unit for mechan-

ical damage or rust.
2. In case of mechanical damage or rust,
have the drier/collector unit immediately
replaced by our customer service.
3. Start the engine.
B-920-0067
Fig. 142
BW 212 D-5 SL 171

5. Check the moisture indication pearl inside

the inspection glass of the drier/collector
unit.
orange The degree of moisture in
the drying agent is correct.
colourless Moisture level of drying
B-920-0068 agent too high
Fig. 143 6. If the moisture level of the drying agent is
too high, have the drier/collector unit
7. Check the white floating ball inside the
inspection glass of the drier/collector unit.
Ball floats right on The refrigerant level
top is correct.
Ball floats at bottom The refrigerant level
is not correct.
B-920-0069
8. If the refrigerant level is too low, have the

Fig. 144 air conditioning system inspected by our
customer service.
172 BW 212 D-5 SL


8.9.1 Checking, adjusting the valve clearance
NOTICE!
We recommend to have this work
carried out by trained personnel or
our after sales service.
– Before checking the valve clear-
ance let the engine cool down for
at least 30 minutes. The engine
oil temperature must be below
80 °C (176 °F).
Valve clearance
Intake valve (I) 0.3 mm
(0.012 in)
Exhaust valve (E) 0.5 mm
(0.02 in)
n Protective gloves
on page 112.
BW 212 D-5 SL 173

3. Remove the valve cover.
B-DEU-0043
Fig. 145
4. Turn the crankshaft, until the valves on
cylinder 1 are overlapping.
ð The valves marked black can be
checked and adjusted.
B-DEU-0044
Fig. 146
5. Turn the crankshaft, until the valves on
cylinder 4 are overlapping.
ð The valves marked black can be
checked and adjusted.
B-DEU-0045
Fig. 147
174 BW 212 D-5 SL

Checking the valve clear-

ance
6. Check valve clearance between rocker arm
and valve with a feeler gauge. The feeler
gauge must fit through the gap with little
resistance.
7. If the gap is too narrow or too wide for the
feeler gauge, adjust the valve clearance.
B-DEU-0046
Fig. 148
Adjusting the valve
clearance
8. Slightly slacken the counter nut (2).
1
9. Adjust the setscrew (1) with a screwdriver,
until the feeler gauge can be inserted and
2
pulled out with little resistance after retight-
ening the counter nut.
10. Install the cylinder head cover with a new
B-DEU-0047 seal.
Fig. 149 11. After a short test run, check the engine for
leaks.
8.9.2 Replacing the ribbed V-belt

n Protective gloves
on page 112.
BW 212 D-5 SL 175

3. Unscrew fastening screws and push the

impeller forward.
4. Remove the V-belt of the air conditioning
compressor Ä Chapter 8.9.3 ‘Replacing
the V-belt of the air conditioning com-
pressor’ on page 176.
B-584-0046
Fig. 150
5. Swing the idler pulley back and remove the
ribbed V-belt.
6. Check the condition of tensioning device
and belt pulleys (e.g. excessively worn
bearings of tensioning device, idler pulley
and deflection pulleys as well as the profile
wear on the belt pulleys).
B-DEU-0039
7. Replace any damaged parts.

Fig. 151
8. Install the new ribbed V-belt.
9. Swing the idler pulley back and align the
ribbed V-belt.
10. Slowly release the tensioning element.
11. Check the correct seat of the ribbed V-belt
on the V-belt pulleys.
12. Assemble the V-belt of the air conditioning
compressor Ä Chapter 8.9.3 ‘Replacing
the V-belt of the air conditioning com-
B-DEU-0040 pressor’ on page 176.
Fig. 152 13. Tighten the impeller again.
8.9.3 Replacing the V-belt of the air conditioning compressor

the latest after two years.
176 BW 212 D-5 SL


n Protective gloves
on page 112.
3. Loosen the screws (2, 3, 4) on the com-
1 2
pressor.
4. Relieve the V-belt with the tensioning
screw (1) and take it off.
4 5. Install the new V-belt.
3 6. Turn the tensioning screw (1) to tighten the
B-586-0133
V-belt to the specified value Ä Chapter
Fig. 153 8.7.4.2 ‘Checking the V-belt tension’
on page 153.
7. Tighten screws (2, 3, 4) again.
8.9.4 Checking the engine mounts

3. Check air intake and exhaust manifold fas-
tenings for tight fit.
4. Check sockets and clamps between air
filter, exhaust turbocharger and charge air
line as well as the engine oil lines for tight
fit and leaks.
5. Check fastening screws on the engine oil
sump and engine mounts for tight fit.
BW 212 D-5 SL 177

6. Check condition and tight fit of engine

pillow blocks.
8.9.5 Replacing the hydraulic oil filter

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
housing again.
– Apart from the normal oil change
intervals, the filter element must
also be changed after major
repairs in the hydraulic system.

n Protective gloves
on page 112.
178 BW 212 D-5 SL

3. Unscrew the filter housing (3).

1
NOTICE!
Negligence may cause destruc-
2
tion to the entire hydraulic
system!
3 B-HYD-0013
– Visible dirt may be an early sign
for the failure of system compo-
Fig. 154 nents and indicate the possible
failure of components.
– In this case determine the cause
and replace or repair the defec-
tive components, if necessary.
– Do not clean or reuse the filter
element.
4. Take out the filter element (1) and clean the

filter housing.
5. Clean the thread on the filter housing.
6. Reassemble the filter housing with a new
filter element and a new O-ring (2).
7. Tighten the filter housing; tightening torque
max. 35 Nm (max. 26 ft·lbf).
8. After a short test run check the filter for
max. 35 Nm leaks.
max. 26 ft·lbf
9. Dispose of the oil and filters in line with
environmental regulations.
B-HYD-0015
Fig. 155
BW 212 D-5 SL 179

8.9.6 Change the oil in the drive axle
NOTICE!
– Drain gear oil only at operating
temperature.
on page 141.
on page 142.

n Protective gloves
on page 112.
WARNING!
nents!
2. Clean the area around all drain plugs and

oil level inspection plugs
3. Unscrew the drain plugs and oil level
inspection plugs and collect any oil running
out.
4. Turn the drain plugs tightly back in.
B-582-0052
Fig. 156
180 BW 212 D-5 SL

5. Fill in fresh gear oil through the oil level

inspection bores, until it has reached the
bottom edge of the bore.
A second oil level inspection

plug is located on the opposite
side.
B-582-0047
Fig. 157 6. After filling with oil, wait until the oil has
evenly distributed itself inside the axle, if
necessary fill with some more oil.
7. Turn the oil level inspection plugs tightly
back in.
8. Dispose of oil in line with environmental
regulations.
8.9.7 Changing the oil in the wheel hubs
NOTICE!
temperature.
on page 141.
on page 142.

BW 212 D-5 SL 181


1. Move the drum, until the oil level inspection
plug is in bottom position.
tion plug.
Fig. 158
WARNING!
nents!
4. Unscrew the level inspection plug and

catch any oil running out.
5. Move the drive wheel, until the oil level
inspection plug is in horizontal position.
6. Fill in oil through the inspection bore, until it
starts to run out through the level inspec-
tion bore.
7. Turn the level inspection plug tightly back
in.
Fig. 159 8. Change the oil in both wheel hubs.
9. Dispose of oil in an environmentally friendly
way.
182 BW 212 D-5 SL

8.9.8 Change the oil in the exciter housing
NOTICE!
temperature.
on page 141.
on page 142.


1. Before changing the oil level run the
machine warm for about 1/2 hour with
vibration.
2. Move the drum, until the drain plug is in
bottom position.
4. Clean the area around the drain plug.
Fig. 160
BW 212 D-5 SL 183

WARNING!
nents!
5. Unscrew the drain plug and catch any oil

running out.
6. Turn the drain plug tightly back in.
tion plug.
8. Unscrew the oil level inspection plug.
Fig. 161
9. Unscrew the oil filler plug and fill in new oil
through the oil filler bore, until oil starts to
drip out through the inspection bore.
10. Retighten the filler and level inspection
plugs.
11. Change the oil on both sides.
12. Dispose of oil in an environmentally friendly
Fig. 162 way.
184 BW 212 D-5 SL

8.9.9 Retightening the fastening of the axle on the frame

1. Check all fastening nuts on axle mounting
bolts for tight fit, retighten if necessary,
tightening torque: 650 Nm (480 ft·lbf).
Fig. 163
8.9.10 Retightening the wheel nuts

1. Tighten the wheel nuts cross-wise, tight-
ening torque: 550 Nm (405 ft·lbf).
Fig. 164
8.9.11 Checking the ROPS/FOPS
If the cabin is assembled, ROPS/

FOPS is already integrated as part
of the cabin.
All bolted connections must comply with the

specifications and should be absolutely tight
(observe the tightening torques).
Screw and nuts must not be damaged, bent or
deformed.
BW 212 D-5 SL 185

Unusual movements and noises (vibrations)

during operation are signs for damage or loos-
ened fastening elements.
1. Inspect the cabin, especially the ROPS/
FOPS structure, for cracks, corrosion,
damage and missing fastening parts.
2. Check the fastening screws for the cabin
(ROPS/FOPS) to the driver’s stand for tight
fit.
3. Check the rubber buffers of the operator’s
platform suspension for condition and tight
fit.
4. Check the condition and fastening of the
seat belts.
8.9.12 Checking the travel lever control

on page 112.
2. Move the travel lever forwards, backwards
and to parking brake position. Check the
function, for ease of movement, clearance
and damage.
3. In case of malfunction, determine the
cause and have the relevant components
B-ELE-0138
Replace broken travel lever only com-

Fig. 165 pletely.
4. Only operate the machine after it has been
repaired.
186 BW 212 D-5 SL

8.9.13 Cleaning the circulation air filter of the heating

n Protective gloves
on page 112.
2. Loosen the locks and remove the cover.
3. Take out the filter.
4. Clean the filter, replace if necessary.
5. Insert the filter and reinstall the cover.
B-GEN-0073
Fig. 166
BW 212 D-5 SL 187


8.10.1 Changing the hydraulic oil

The hydraulic oil must also be changed after

major repairs in the hydraulic system.
Always replace the hydraulic oil filter after each
hydraulic oil change. Change the hydraulic oil
filter only after the hydraulic oil change and
after the test run.
hydraulic oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths for cleaning.
When changing from mineral oil based
hydraulic oil to an ester-based, biologically
degradable hydraulic oil, you should consult
the lubrication oil service of the oil manufac-
turer, or our customer service for details.
NOTICE!
Risk of damage!
– Perform the oil change when the
hydraulic oil is warm.
– Use only hydraulic oil of the per-
mitted specification Ä Chapter
8.3.4 ‘Hydraulic oil’ on page 140.
on page 142.
188 BW 212 D-5 SL


n Protective gloves
on page 112.
2. Clean the area around the filling port and
remove the cap.
WARNING!
nents!
B-586-0105
Fig. 167 protective clothing).
3. Unscrew the plug.

4. Drain off and collect all hydraulic oil.
5. Turn the plug tightly back in.
We recommend to use our filling

and filtering unit with fine filter to fill
B-586-0392 the system. This ensures finest fil-
tration of the hydraulic oil, prolongs
Fig. 168
the lifetime of the hydraulic oil filter
and protects the hydraulic system.
6. Fill in new hydraulic oil.
BW 212 D-5 SL 189

7. Check the oil level in the inspection glass.

Normal level Approx. 3 cm (1.2 in)
below the top edge of the
sight glass
Minimum level Middle of inspection glass
B-587-0045
8.
The breather filter for the
Fig. 169 hydraulic oil tank is integrated in
the cap, you must therefore
replace the complete cap.
Close the tank with a new cap.

9. Dispose of oil in line with environmental
regulations.
8.10.2 Changing the coolant


coolant.
In case of lubrication oil entering into the
cooling system or if a suspicious turbidity
caused by corrosion residues or other sus-
pended matter occurs, the coolant must be
drained off and the complete cooling system
needs to be cleaned.
Oil can damage the sealing materials used in
the cooling system.
If oil has entered, add a cleansing agent in
order to remove any residues from the system.
Follow the instructions of the manufacturer! If in
doubt, consult your Customer Service or the
engine manufacturer.
190 BW 212 D-5 SL

When changing the coolant without any signs

of contamination, cleaning the cooling system
is not necessary.
NOTICE!
– Use only coolant of the permitted
‘Coolant’ on page 136.
– Do not mix different coolants and
additives of any other kind.
on page 142

n Protective gloves
on page 112.
3. Unscrew the cap from the compensation
tank.
B-586-0376
Fig. 170
BW 212 D-5 SL 191

4. Unscrew the plug.

5. Drain off and collect all coolant.
6. Turn the plug tightly back in.
7. Check the condition of the coolant.
8. Thoroughly flush the cooling system if the
B-586-0391
coolant is contaminated by corrosion resi-
dues or other suspended matter.
Fig. 171
9. Remove the thermostat.
10. Fill with clean water.
11. Start the engine and run to operating tem-
perature.
12. Allow the engine to cool down to approx.
50 °C (122 °F).
13. Drain off all water.
14. If using a cleaning agent repeat the
flushing process twice with clear water.
15. Reinstall the thermostat.
NOTICE!
The anti-freeze concentration (addi-
tive) must be at least 35 Vol% and
maximum 45 Vol%.
16. Fill up coolant.

17. Close the cap.
B-586-0372
Fig. 172
192 BW 212 D-5 SL

18. Set maximum cabin temperature.
B-SWI-0031
Fig. 173
19. Set maximum fan speed.
20. Start the engine Ä Chapter 6.2 ‘Starting
the engine’ on page 101.
21. Run the machine with idle speed until oper-
ating temperature has been reached and
the thermostat opens.
B-SWI-0035
22. As soon as the thermostat has opened, run
Fig. 174 the engine for approx. 1 minute at high
speed.
25. Check the coolant level again when the
engine has cooled down; top up if neces-
sary.
26. Dispose of coolant in line with environ-
mental regulations.
BW 212 D-5 SL 193


8.11.1 Check the injection valves
This work must only be performed by
authorized service personnel.
194 BW 212 D-5 SL

Maintenance – As required
8.12 As required
8.12.1 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 element.
– After cleaning, the air filter must
be inspected for damage using a
torch.
– Do not continue to use a dam-
aged 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.
BW 212 D-5 SL 195


n Fine dust mask
n Safety goggles
Carry out the air filter maintenance when the
yellow pin of the maintenance indicator has
1 reached the red area (1), but after one year at
the latest.
on page 112.
B-GEN-0053

Fig. 175
3. Loosen both locking hooks on the housing
cover and take the cover off.
4. Clean housing cover and dust discharge
valve.
Fig. 176
5. Pull out the air filter with light turning move-
ments.
Fig. 177
196 BW 212 D-5 SL

CAUTION!
Danger of eye injuries caused by
particles flying around!
CAUTION!
Danger due to fine dust pollution!
– Wear a fine dust mask.
6. Blow the air filter out with dry compressed

air (max. 2.1 bar (30 psi)) from inside to
outside by moving the gun up and down
inside the element, until it is free of dust.
Fig. 178
7. Examine the air filter with a torch for cracks
and holes in the paper bellows.
8. In case of damage replace the air filter and
the safety element.
Fig. 179
BW 212 D-5 SL 197

9. Slide the air filter carefully into the housing.
NOTICE!
– The dust discharge valve must
point vertically downwards.
– Make sure that the cover locks
engage correctly.
Fig. 180
10. Reassemble the housing cover.
11. Press the reset button (1) for the yellow
piston on the maintenance indicator.
1
B-GEN-0054
Fig. 181
8.12.1.1 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 one year.
– if the air filter warning light
comes on again after the air filter
has been cleaned.
198 BW 212 D-5 SL

1. Remove the housing cover and pull the air

filter element off.
2. Pull the safety element out by turning it
lightly.
3. Push in a new safety element.
4. Insert the air filter and reassemble the
housing cover.
Fig. 182
8.12.2 Checking and cleaning the water separator
The service intervals for the water

separator depend on the water con-
tent in the fuel and can therefore
not be determined precisely.
After taking the engine into opera-
tion you should check for signs of
water and dirt initially every day.

n Protective gloves
on page 112.
2. Loosen the drain plug and drain the fluid
until pure diesel fuel starts to run out.
3. Collect the escaping fluid.
4. Screw the drain plug back in tightly. Check
for leaks; if necessary, use a new seal ring.
ð Once the water separator is empty, the
B-584-0044
warning light for water in fuel must go
Fig. 183 out.
BW 212 D-5 SL 199

8.12.3 Adjusting the scrapers

Smooth drum scraper
n Protective gloves
1. Check the condition of the scraper plate.
2. Replace worn scraper plate.
3. Check the scraper setting.
ð The distance to the drum should be
approx. 1 mm (0.04 in).
4. To readjust the scrapers, loosen the fas-
tening screws on both sides and push the
scraper to the drum until the correct dis-
B-584-0039 tance is reached.
Fig. 184 5. Fasten the fastening screws again.
Scraper on smooth drum

with padfoot shell
n Protective gloves
1. Check the condition of the scraper teeth.
2. Replace worn teeth.
3. Check the scraper setting.
ð The distance to the drum should be
approx. 25 mm (1.0 in).
4. To readjust the scrapers, loosen the fas-
tening screws on both sides and swivel the
scraper until the correct distance is
B-584-0038 reached.
Fig. 185 5. Fasten the fastening screws again.
200 BW 212 D-5 SL

8.12.4 Cleaning the machine

Clean the machine thoroughly at least once a
week.
If necessary, clean the machine daily
for example when used on highly cohesive
soils or cement.
Do not climb on the machine to clean it.
WARNING!
falling off the platform!
– Always ensure safe standing.

n Safety goggles
3. When cleaning with a high pressure
cleaner, do not subject electrical parts and
insulation material to the direct jet of water,
or cover them beforehand.
4. If necessary, clean the windows using a
telescopic rod.
BW 212 D-5 SL 201

8.12.5 Filling the windscreen washer tank

1. Open the flap under the driver's seat on the
left hand side.
2. Check the fluid level in the provision con-
tainer, top up if necessary.
3. If there is a risk of frost, you may also fill
the provision container with an anti-freeze
mixture.
Fig. 186
8.12.6 Drain the fuel tank sludge

2. Unscrew the drain plug and drain off and
catch approx. 5 litres of fuel.
3. Turn the drain plug tightly back in.
4. Dispose of fuel environmentally.
Fig. 187
202 BW 212 D-5 SL

8.12.7 Retightening the padfoot shell

n Protective gloves
After the installation of the padfoot shell seg-
ments, all fastening screws must be retight-
ened.
1. Run an approx. two minute test drive with
vibration.
on page 112.
3. Retighten all fastening screws.
4. After approx. 60 minutes work, retighten all
Fig. 188 fastening screws again.
8.12.8 Measures prior to extended shut-down period

8.12.8.1 Measures before shutting down
If the machine is shut down for a longer period
of time, e.g. winter season, the following work
must be carried out:
1. Clean the machine thoroughly.
2. After shutting down store the machine
under cover in a dry and well ventilated
room.
3. Grease the bare piston rods of all hydraulic
cylinders well and pull them in as far as
possible.
4. Spray a thin oil film onto to all lever joints
and bearing points without lubrication.
5. Repair damaged paint; preserve bare
areas thoroughly with anti-corrosive agent.
6. Clean the water separator.
BW 212 D-5 SL 203

7. Fill the fuel tank with diesel fuel to prevent

the formation of condensation water in the
tank.
8. Change engine oil and oil filter if the oil has
been changed more than 300 hours ago, or
if the oil is older than 12 months.
9. Check the anti-freeze concentration and
the coolant level.
10. Disconnect the ground strap from the bat-
tery (this avoids self-discharge caused by
closed-circuit consuming devices).
8.12.8.2 Battery service during prolonged machine downtimes
WARNING!
exploding gas mixture!
– Remove the plugs when
recharging the battery.
– Ensure adequate ventilation.
hibited!
– Do not lay any tools or other
metal objects on the battery.
– Do not wear jewellery (watch,
bracelets, etc.) when working on
the battery.
204 BW 212 D-5 SL


n Safety goggles
1. Switch off all consuming devices (e.g. igni-
tion, light).
2. Measure the open-circuit voltage of the
battery at regular intervals (at least 1x per
month).
ð Reference values: 12.6 V = fully
charged; 12.3 V = discharged to 50%.
3. Recharge the battery immediately after an
open-circuit voltage of 12.25 V or less is
reached. Do not perform fast charging.
ð The open-circuit voltage of the battery
occurs approx. 10 hours after the last
charging process or one hour after the
last discharge.
4. Switch off the charging current before
removing the charging clamps.
5. After each charging process allow the bat-
tery to rest for one hour before taking it into
service.
6. For standstill periods of more than one
month you should always disconnect the
battery. Do not forget to perform regular
open-circuit voltage measurements.
8.12.8.3 Measures before restarting

1. Replace the fuel filter.
2. Replace the air filter.
3. Change engine oil and oil filter.
4. Check the coolant level.
BW 212 D-5 SL 205

5. Check the charge condition of the bat-

teries, recharge if necessary. Check the
battery fluid level before and after charging.
6. Connect the ground straps to the batteries.
7. Check the function of the electric system.
8. Check cables, hoses and lines for cracks
and leaks.
9. Check the service life of hydraulic hoses
and replace if necessary.
10. Start the engine and run it for 15 to 30
minutes with idle speed.
11. While the engine is running keep an eye on
the gauges for engine oil pressure and
coolant temperature.
12. Check the oil levels.
13. Check the function of electric system,
steering and brakes.
14. Clean the machine thoroughly.
15. Vent and refill the air conditioning system.
206 BW 212 D-5 SL

Troubleshooting
9 Troubleshooting
BW 212 D-5 SL 207

Troubleshooting – Preliminary remarks
9.1 Preliminary remarks

Malfunctions are frequently caused by incorrect
operation of the machine or insufficient mainte-
nance. Whenever a fault occurs you should
therefore thoroughly read these instructions on
correct operation and maintenance.
If you cannot locate the cause of a fault or rec-
tify it yourself by following the trouble shooting
chart, you should contact our customer service
department.
208 BW 212 D-5 SL

Troubleshooting – Starting the engine with jump leads
9.2 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.
1. Connect the plus pole of the external bat-

tery first with the plus pole of the vehicle
battery using the first jump lead.
2. 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 bat-
tery as possible.
Fig. 189 3. Start the engine Ä Chapter 6.2 ‘Starting
the engine’ on page 101.
NOTICE!
Danger of damage to the elec-
tronic system!
If no powerful consuming device is
switched on, voltage peaks may
occur when separating the con-
necting cables between the bat-
teries, which could damage elec-
trical components.
4. Once the engine is running switch on a

powerful consumer (working light, etc.).
5. After starting disconnect the negative poles
first and the positive poles after.
6. Switch off the consumer.
BW 212 D-5 SL 209

Troubleshooting – Fuse assignment
9.3 Fuse assignment

9.3.1 Notes on safety
WARNING!
Danger of injury by fire in the
machine!
– Do not use fuses with higher
ampere ratings and do not bridge
fuses.
9.3.2 Central electrics

The power board for central electrics is located
in the battery compartment.
1. Release the clamps and take off the cover.
B-584-0024
Fig. 190
Fuse Amperage Designation

F05 20 A 12-V socket
F13 10 A Starter switch
F18 15 A Working head lights, front
F22 15 A Working head lights, rear
F23 15 A Warning horn
F24 10 A Instrument cluster
F31 10 A Cabin fan
F39 50 A Main fuse for cabin
F40 30 A Heating, air conditioning
210 BW 212 D-5 SL


F41 10 A Flashing beacon
F67 20 A Control (potential 30)
F68 15 A Reserve (potential 30)
F91 5A Sensors
F109 10 A Windscreen wiper, washer
F122 10 A Engine control unit
F124 25 A Fuel pre-heating
F148 2A Control (potential 15)
F157 30 A Starter
F169 5A Start current
F180 5A Sensors
F182 5A Sensors
F243 7.5 A BOMAG TELEMATIC (potential 30)
F244 5A BOMAG TELEMATIC (potential 15)
F375 10 A Interface diagnostics (potential 30)
F376 10 A Interface diagnostics (potential 15)
F387 10 A Interface for measuring technology (potential
30)
F388 10 A Interface for measuring technology (potential
15)
F415 5A Acceleration transducer
BW 212 D-5 SL 211

Checking fuses
The power board for central electrics has a test
device (Fuse Test) that enables continuity
testing for flat fuses.
1. Insert the two plugs of the fuse into the
1
recesses (1).
ð If the fuse is OK, the LED (2) lights up.
FX
Fuse Test
DX
2
B-584-0028
Fig. 191
212 BW 212 D-5 SL

9.3.3 Traffic lights

The power board for the traffic lights is located
in the battery compartment.
Optional equipment
1. Release the clamps and take off the cover.
B-584-0029
Fig. 192

F07 15 A Hazard light
F09 5A Parking and tail light, left
F10 5A Parking and tail light, right
F66 15 A Head lights, front
F70 5A Direction indicators
F82 10 A Parking and tail light
F85 10 A Head lights, front
BW 212 D-5 SL 213

9.3.4 Main fuses

The main fuse box is located in the battery
compartment.
1. Open and remove the cover.
OPEN
CLOSE
B-584-0025
Fig. 193
F00
F156
F95
B-584-0047
Fig. 194

F00 100 A Main fuse
F95 23 A Engine control unit
F156 60 A Traffic lights
214 BW 212 D-5 SL

9.3.5 Control console cabin
Fig. 195
Posi- Fuse Amperage Designation

tion
1 F17 5A Radio
2 F264 10 A BCM
3 F271 10 A BCM net
4 F150 5A GPS
5 F266 10 A Radio/Tachograph
6 F143 20 A Rear windscreen heating
7 F28 15 A Rear windscreen wiper
8 F27 15 A Front windscreen wiper
9 F279 15 A Spare
10 F272 5A Control console cabin
BW 212 D-5 SL 215

Troubleshooting – Fault code display
9.4 Fault code display

If the warning buzzer sounds and the central
warning light lights up or flashes, read out the
fault code and inform our Customer Service
Department.
1. Press the [F2] button on the instrument
cluster until the ‘Fehlercode-Anzeige’
appears.
B-DIS-0736
Fig. 196
2. Read out and note the fault code (1).
1
3. If necessary, read out and note further fault
codes.
ð If there are other incoming fault codes,
these will also be shown in the
INFO 2 display field (2).
2
B-DIS-0809
In this case, the display will automati-
Fig. 197 cally switch to the next fault code after
approx. 4 seconds.
4. Inform our Customer Service Department.
216 BW 212 D-5 SL

Troubleshooting – Engine faults
9.5 Engine faults

Fault Possible cause Remedy
Engine does Fuel tank empty Refuel, bleed the fuel system
not start or Temperature below starting Check
starts poorly limit
Cold starting facility Check, replace if necessary
Engine oil with wrong SAE Change the engine oil
viscosity class
The fuel quality does not Change the fuel
meet the requirements
Battery defective or not Check
charged
Cable to starter loose or oxi- Check cable connection
dized
Starter defective or pinion Check starter
does not engage
Air filter clogged / exhaust Check, replace if necessary
turbocharger defective
Air in the fuel system Bleed the fuel system
Compression pressure too Check
low
Exhaust gas counter pres- Check
sure too high
Injection line leaking Check
Engine does Engine electronics prevent Check fault by fault code,
not start and starting repair as necessary
diagnostic
lamp is
flashing
Engine starts, Exhaust gas counter pres- Check
but runs irreg- sure too high
ularly or mis- Compression pressure too Check
fires low
Cold starting facility Check, replace if necessary
BW 212 D-5 SL 217


Air in the fuel system Bleed the fuel system
Fuel pre-cleaner soiled Check, clean the water sepa-
rator, replace the fuel pre-
cleaner
Injector defective Replace
Speed Engine electronics detected a Check fault by fault code,
changes are system fault and activates a repair as necessary
possible and substitute speed
central
warning lamp
lights
The engine Ventilation line to the coolant Clean
overheats, the compensation tank clogged
coolant tem- Engine oil with wrong SAE Change the engine oil
perature viscosity class
warning lamp
lights Engine oil cooler defective Check, replace if necessary
Engine oil filter dirty Replace
Engine oil level too low or too Check, top up or drain off as
high necessary
Radiator soiled Clean
Coolant pump defective (V- Check, whether torn or loose
belt torn or loose)
Lack of coolant Check the coolant level, top
up if necessary.
Resistance in cooling system Check the cooling system
too high / flow quantity too
low
Charge air pipe leaking Check
Intercooler soiled Clean
218 BW 212 D-5 SL


Fan defective / V-belt torn or Check fan / V-belt, replace if
loose necessary
Exhaust gas counter pres- Check
sure too high
Insufficient Engine oil level too high Check, top up or drain off as
engine power necessary
Fuel intake temperature too Check the system
high
Fan defective / V-belt torn or Check fan / V-belt, replace if
loose necessary
Intercooler soiled Clean
Resistance in cooling system Check the cooling system
too high / flow quantity too
low
Insufficient Engine electronics reduces Check fault by fault code,
engine power the power repair as necessary
and diagnos-
tics lamp
lights
Engine does Injection line leaking Check
not work with Injection valve defective Check, replace if necessary
all cylinders
Engine oil level too high Check, drain off if necessary
BW 212 D-5 SL 219


Engine has Engine oil level too low Check, top up or drain off as
too low or no necessary
oil pressure Engine oil with wrong SAE Change the engine oil
viscosity class
Engine has Engine oil level too high Check, drain off if necessary
excessive oil Crankcase ventilation Check, replace if necessary
consumption
Blue engine Engine oil level too high Check, drain off if necessary
exhaust
smoke
White engine Temperature below starting Check
exhaust limit
smoke Cold starting facility Check, replace if necessary
Injector defective Check, replace if necessary
Black engine Air filter clogged / exhaust Check, replace if necessary
exhaust turbocharger defective
smoke
220 BW 212 D-5 SL

Disposal
10 Disposal
BW 212 D-5 SL 221

Disposal – Final shut-down of machine
10.1 Final shut-down of machine

After the machine has reached the end of its
service life, the individual components of the
machine must be disposed of properly.
Observe national regulations!
Carry out the following work and have the
machine dismantled by a state-approved recy-
cling company.
WARNING!
and lubricants!

n Protective gloves
n Safety goggles
1. Remove the batteries.
2. Empty the fuel tank.
3. Drain the hydraulic oil tank.
4. Drain the coolant from the cooling system
and engine.
5. Drain off engine oil.
6. Drain off gear oil.
222 BW 212 D-5 SL

List of special tools
11 List of special tools
BW 212 D-5 SL 223

List of special tools
Belt tension tester

BOMAG No. 079 947 09
Fig.
224 BW 212 D-5 SL

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Operating Instruction

S/N 961 584 36 1001>

Single drum roller

008 207 64 EN © 07/2022

Always start and operate the engine in a well-ventilated area.

For more information go to www.P65warnings.ca.gov/diesel.

WARNING: Crude oil, gasoline, diesel fuel and other petroleum

For more information go to www.P65Warnings.ca.gov/petroleum.

3.4.5 Safety regulations and environmental protection regulations for

4.1.1 Instrument cluster........................................................................ 67

6.8 Emergency procedures.............................................................. 115

8.7.4 Checking, tensioning the V-belt of the air conditioning com-

8.11.1 Check the injection valves....................................................... 194

A description of all necessary maintenance

1.2 Machine type plate and engine type plate

Fig. 1: Machine type plate

Please enter here:

Fig. 2: Engine type plate

2.1 Noise and vibration data

2.1.1 Noise data

Guaranteed sound LWA = 109 dB(A), determined acc. to ISO 3744

2.1.2 Vibration data

Hand-arm vibration The weighted effective acceleration value

3 Concerning your safety

3.1 Basic prerequisites

3.1.2 Explanation of signal words used

Sections marked accordingly indi-

3.1.3 Personal protective equipment

Safety shoes They protect against heavy falling parts

Protective gloves They protect the hands against scrapes,

Safety goggles They protect the eyes against airborne

Face protection This protects the face against airborne

Hard hat This protects the head against falling

Hearing protection This protects against extreme noise.

Fine dust mask For protection against particulate pollu-

Respiratory protection This protects the airways against sub-

3.1.4 Intended use

3.1.5 Improper use

3.1.6 Estimated service life of the machine

3.2 Definition of responsible persons

3.2.2 Expert / qualified person

This person is acquainted with the applicable

3.2.3 Driver / operator

3.3 Basic safety regulations for safe operation

3.3.2 Regular safety inspections

3.3.3 Modifications and alterations to the machine

We wish to make explicitly clear that we have

3.3.4 Damage, defects, misuse of safety devices

3.3.5 Roll Over Protection Structure (ROPS) and Fall On Pro-

Machines with cabin already have

The frame of the machine must not be warped,

A defective ROPS/FOPS must always be

3.4 Handling fuels and lubricants

3.4.2 Safety regulations and environmental protection regula-

– Immediately bind spilled diesel

3.4.3 Safety regulations and environmental protection regula-

3.4.4 Safety regulations and environmental protection regula-

Should hydraulic fluid penetrate the

3.4.5 Safety regulations and environmental protection regula-

– Immediately bind spilled coolant