BOMAG BW 216 D-4 and BW 216 PD-4 Single Drum Roller Service Manual 008 911 83 (August 2007)

Description

BOMAG BW 216 D-4 and BW 216 PD-4 Single Drum Roller Service Manual 008 911 83 (August 2007)

This download is the BOMAG BW 216 D-4 and BW 216 PD-4 Single Drum Roller Service Manual 008 911 83 (August 2007), the bound workshop book printed under catalogue number 008 911 83 and dated 08/2007. It is written for trained mechanics working on the two title machines: the smooth-drum BW 216 D-4 and the padfoot BW 216 PD-4. The cover identifies the serial groups S/N 101 583 23…… and S/N 101 583 24…… Wiring sheets inside further pin those groups to 101 583 231 001 (BW 216 D-4) and 101 583 241 001 (BW 216 PD-4), with a later diagram set from 101 583 231 023 and 101 583 241 002.

A service-training insert bound into the same file also walks through related series-4 single drum rollers (BW 211 / 213 D-4 and BW 216 / 219 D-4). Treat that chapter as shared training material; the technical-data tables, tests, drum work, and machine-specific diagrams in this book are written around the BW 216 D-4 and BW 216 PD-4.

File Details

• Manual type: Service manual (workshop repair and diagnostics)
• Brand / models: BOMAG BW 216 D-4 and BW 216 PD-4 single drum rollers
• Language: English
• Page count: 974
• File format: PDF
• Catalogue / document number: 008 911 83
• Date: 08/2007 (August 2007)

Chapters Covered

• 1 General — introduction; safety regulations; general repair instructions; tightening torques
• 2 Maintenance — general notes; fuels and lubricants; table of fuels and lubricants; running-in instructions; maintenance chart
• 3 Technical data — dimensions, weights, travel, engine, brakes, steering, vibration, tires, filling capacities, component data
• 4 Connection overview — travel / vibration pump ports and test points
• 5 Tests and adjustments — special tools; travel-pump neutral; travel-circuit pressures; vibrator shaft speeds; vibration-circuit pressures; vibration-motor leakage; steering-circuit pressure
• 6 Flushing and bleeding — flushing tools; travel circuit (pump distribution and axle-motor distribution); vibration circuit; bleeding both circuits
• 7 Fundamental electrics — circuit-diagram reading; terminals; current, voltage, resistance; Ohm’s law; diodes, relays, fuses; batteries; three-phase generator; starter; Telemecanique switch; inductive proximity switches; angle sensor; Deutsch DT/DTM and spring-clamp connectors
• 8 Special tools, electrics
• 9 Electronic modules — BEM (BOMAG Evib-meter); seat contact module
• 10 Speedometer module
• 11 Service training machine — series-4 single drum roller training (BW 211 / 213 D-4 and BW 216 / 219 D-4)
• 12 Engine — TCD 2012 and TCD 2013 descriptions; lubrication, coolant and fuel circuits; Deutz Common Rail (DCR); sensors; EDC16 with EMR 3; EGR; instrument cluster; fault diagnosis and EMR3 fault codes; SerDia; troubleshooting chart; valve adjustment; ribbed V-belt; Deutz special tools
• 13 Air conditioning system — R134a circuit, compressor oil and clutch, evacuation, leak test, charging, troubleshooting, heating / A/C control
• 14 Replacing the cab window panes
• 15 Drum — special tools; repair overview; remove / install; drum repair; change-over weights; rubber buffers and pretension
• 16 Oscillating articulated joint — tools; repair overview; remove / install; dismantle and assemble
• 17 Suppliers documentation — Sauer travel pump series 90R; travel drive series 51; vibration pump 42R 041; vibration motor A10FM; transmission CR; axle DANA 193
• 18 Circuit diagrams — wiring diagram 582 702 14; wiring diagram 582 702 30; hydraulic diagram

Taken together, the book is a full workshop path: identify the machine, service it on a schedule, measure the hydrostatic circuits, overhaul the drum and articulation, diagnose the Deutz EMR 3 engine and the onboard electrics, then confirm the repair against the wiring and hydraulic sheets.

Machines, serial groups, and published specifications

Both title machines share the same basic envelope. Length is 5808 mm, wheelbase 2960 mm, drum diameter 1500 mm, width 2130 mm, and height to the cab roof 2972 mm. Drum shell thickness differs: 35 mm on the BW 216 D-4 and 25 mm on the BW 216 PD-4. Operating weight with ROPS and cabin is 15700 kg (D-4) and 16200 kg (PD-4). Drum axle load is 10400 kg versus 10900 kg; rear axle load is 5300 kg on both. Static linear load on the smooth drum is 48.8 kg/cm.

Travel is hydrostatic on two driven axles, with four ranges: 0–4, 0–5, 0–7 and 0–11 km/h. Maximum gradability is given as 45 % (D-4) and 48 % (PD-4), soil dependent. Service braking is hydrostatic; parking is hydraulic-mechanical. Steering is articulated and hydrostatic. Vibration is a single hydrostatic drum at 30/36 Hz, with amplitudes 1.8/0.95 mm on the D-4 and 1.64/0.82 mm on the PD-4. Tires are 23.1-26/12 TL R3 at 1.4 bar. Ambient operating range is −20 °C to +50 °C. Electrical system voltage is 12 V.

The engine listed for both machines is a water-cooled 4-cylinder Deutz TCD 2013 L04 2V rated 119 kW at 2200 rpm (DIN ISO 3046). Additional engine figures in the same chapter include 4-stroke diesel combustion, low idle 700–800 rpm, high idle 2200–2250 rpm, specific fuel consumption 226 g/kWh, valve clearance 0.4 mm intake / 0.6 mm exhaust, and injection opening pressure DRC / 1600 bar. Filling capacities published with the machine data are engine oil 15 litres (the fuels table lists approx. 15.5 litres including filter), fuel 340 litres, hydraulic oil 60 litres, and coolant 16 litres. Vibration bearings take 2 × 0.8 litres of SAE 15W/40; the drive axle about 11 litres of SAE 90 API GL5; wheel hubs 2 litres per side; axle reduction gear 1.9 litres; drum drive gear 3.2 litres. Air-conditioning charge is 1400 g of R134a.

Hydraulic hardware the tests refer to

Travel pump: Sauer 90R 075 axial-piston swash-plate unit, 75 cm³/rev, 163.65 l/min maximum flow, high-pressure limitation 400 + 26 bar, charge pressure at high idle 26 bar. Drum reduction gear CR 31 at 45.6:1. Drum drive motor Sauer 51C 110 (110 / 55 cm³/rev stages). Axle drive motor Sauer 51D 110 bent-axle unit (110 / 69 cm³/rev). Vibration pump Sauer 42R 041, 41 cm³/rev, start-up 345 + 26 bar, operating pressure around 100 bar depending on soil. Vibration motor Bosch-Rexroth A10FM 45, 45 cm³/rev. Steering / charge pump HY/ZFFS11/16 gear pump, 16 cm³/rev, maximum steering pressure 175 + 26 bar, with a Danfoss OSPC 500 ON steering valve. Rear axle Dana CHC 193/66LD with No-Spin differential, 100 % locking, reduction 65.08.

Chapter 4 maps every port on the combined pump stack — high-pressure A/B, charge, leak-oil L / L1 / L2, frequency solenoids, multi-function valves, and the mechanical neutral setscrews — so a technician can hang gauges without guessing. Chapter 5 then uses those ports: set travel-pump neutral, read charge and high pressure in both directions, check vibrator shaft speed at high and low amplitude, measure vibration start-up and operating pressure, quantify vibration-motor leak-off, and stall-steer to confirm maximum steering pressure.

Maintenance, fuels, and running-in

Approved engine oils are listed under Deutz DQC II-05 with ACEA E3/E5/E7 or E4/E6 and API CG-4/CH-4/CI-4 families. Oil-change interval at those qualities is 500 operating hours, or at least once per year, halved when fuel sulphur exceeds 0.5 % or ambient temperature stays below −10 °C. Hydraulic oil is HV 46 (ISO), HVLP per DIN 51524 Part 3, viscosity index at least 150; ester-based Panolin HLP Synth. 46 is noted as a factory-fill option on request. Drive-axle oil is API GL5 SAE 90. Grease is lithium EP, penetration 2. Diesel specifications include DIN/EN 590, DIN 51 601, BS 2869, ASTM D 975 1-D/2-D and several NATO codes. BOMAG does not approve RME biodiesel; the text still records the consequences if it is used (power loss, paint attack, halved oil interval).

The maintenance chart runs from daily dipstick, water-separator, fuel, hydraulic and coolant checks through 250 / 500 / 1000 / 2000 / 3000 / 6000 hour tasks: engine oil and filters, fuel filters, valve clearance, axle and hub oils, vibration-bearing oil, hydraulic oil and filters (at least every two years), coolant, crankcase ventilation valve, EMR injector test, and combustion-air filter service. Running-in adds a 30-minute V-belt retighten and a 250-hour first oil set plus wheel-nut and mount retighten.

Engine, EMR 3, and air conditioning

Chapter 12 treats series-4 Deutz engines as a family: 4- or 6-cylinder TCD 2013, or 6-cylinder TCD 2012, water-cooled in-line units with two-valve heads, turbocharger, intercooler, internal or timed EGR for EPA/COM Tier/Stage III, and Deutz Common Rail (DCR) under EDC16 / EMR 3. For the BW 216 D-4 / PD-4 the rating table stays on the TCD 2013 L04 2V. The chapter still gives component callouts, lubrication and coolant flow, rail and speed sensors, the instrument cluster, the diagnostic button, the EMR3 fault-code list, SerDia service software notes, a general troubleshooting chart, valve-adjustment angles with and without EGR, and the ribbed fan belt. Special-tool lists for TCD 2012 2V and TCD 2013 2V are included so injector, rail-sensor and wear-gauge work can be done with the published kit numbers.

The A/C chapter is a complete R134a service path: physical basics, compressor oil, magnetic clutch, V-belt, evacuation, leak test, charging, a refrigerant-circuit troubleshooting diagram, an R134a steam table, and heating / air-conditioning control. Lines are to be opened only by instructed personnel; the text states that plainly.

Drum, oscillating joint, electrics, and supplier books

Drum work covers lift-out of the frame (side-plate off, or drum lifted up through the yoke), hose marking, buffer replacement and pretension, and dismantling of the change-over weights. The repair overview drawing calls out silicone oil 47V 1000 cSt, SAE 15W/40 in the vibrator, Loctite 270, and 120 Nm fasteners. The oscillating articulated joint chapter supplies its own tool list plus remove, strip, and rebuild sequences — required before any work in the articulation area, which the safety chapter insists must be locked.

Electrics start from first principles so a mechanic can read the later sheets, then document generator, starter, proximity and angle sensors, and the Deutsch DT/DTM and spring-clamp connectors used on the machine. Module chapters cover the BEM Evib-meter, the seat-contact module, and the speedometer module. Two wiring sets are bound in: 582 702 14 (from the serials above) and 582 702 30 (later serials), indexed for supply/start, Deutz EMR III, brake and backup alarm, speed ranges / seat switch / vibration, indicators, Variocontrol, BCM, anti-theft, lighting, cabin equipment, and heater / A/C. A full hydraulic schematic closes the book. Supplier reprints for the Sauer 90R and series 51 units, the 42R 041 vibration pump, the A10FM motor, the CR transmission, and the Dana 193 axle sit in front of those diagrams so pump or axle work can follow the component maker’s procedures without leaving the file.

What you can do with this manual

With the BOMAG BW 216 D-4 and BW 216 PD-4 Single Drum Roller Service Manual 008 911 83 (August 2007) a workshop can schedule the machine from the printed chart, set travel-pump neutral and prove charge and high-pressure values, flush and bleed travel and vibration loops after a component change, time the vibrator, measure motor leak-off, overhaul the drum and oscillating joint, service the TCD 2013 L04 2V and its EMR 3 control, charge the R134a system, and trace faults on the 582 702 14 / 582 702 30 wiring sheets and the hydraulic diagram. Using the published pressures, clearances, oil grades, and tightening data is what keeps a 15–16 tonne hydrostatic roller from destroying a pump, a rail system, or an articulation bearing during the next shift.

The file is delivered as an instant PDF after payment. There is no printed shipment to wait for. Open it on a workshop PC, tablet, or phone and print the pages you need at the bench.