BOMAG BW 216 DH-4 / PDH-4 Operation and Maintenance Manual – 2006 PDF

Description

BOMAG BW 216 DH-4 and BW 216 PDH-4 Operation and Maintenance Manual

This BOMAG BW 216 DH-4 / PDH-4 Operation and Maintenance Manual is the complete operating and maintenance instruction set for the BW 216 DH-4 and BW 216 PDH-4 single drum rollers, issued under BOMAG document number 00815971. It runs from the daily checks an operator performs before starting the engine through to the scheduled service intervals, adjustment values, tightening torques and fault-finding tables a workshop depends on. The document is written for operators and maintenance personnel on construction sites, and it covers both the smooth drum DH-4 and the padfoot PDH-4 variant, including the compaction measuring systems and the optional cabin equipment.

File Details

• Manual type: Operating instructions and maintenance instructions, with safety regulations and trouble shooting
• Brand: BOMAG
• Models covered: BW 216 DH-4, BW 216 PDH-4 (single drum roller)
• Machine serial numbers: 101 582 64, 101 582 65
• Document number: 00815971
• Publication date: 2006
• Language: English
• File format: PDF
• Page count: 146 pages

Chapters Covered

• Technical Data – dimensions, operating and axle weights, static linear load, travel characteristics and gradability, engine data, drive system, brakes, steering, vibration frequency and amplitude, tire size and pressure, filling capacities, noise and vibration values
• Safety Regulations – intended use and unintended use, who may operate the machine, conversions and alterations, loading, towing, checking the Roll Over Protection Structure, starting, driving, driving on slopes and gradients, parking, refuelling, fire protection, and the rules for working on hydraulic lines, the engine, electrical equipment, the battery, the fuel system, wheels and tires, and cleaning
• Indicators and Controls – ignition switch, LCD display unit and its warning lamps, heating and ventilation vents, travel lever control panel, vibration rotary switch, travel speed rotary switch, emergency stop switch, warning horn, engine speed and vibration frequency switches, lighting and hazard switches, fuse assignments, cabin control panels, the E_VIB display and the BTM display and control elements with line and bar diagram explanation
• Operation – tests before starting to operate, starting the engine, starting with jump wires, driving the machine, switching vibration on and off, operating the parking brake and stopping, shutting the engine down, changing the LCD display, emergency exit, adjusting the steering wheel and seat, operating the hood, towing in case of engine failure, transport, BTM 05 settings before start-up, measuring pass, finishing compaction of a track, printing measuring data, changing the paper roll and the printer ribbon
• Maintenance – general notes, fuels and lubricants, table of fuels and lubricants, running-in instructions, maintenance chart, engine oil level, water separator, fuel level, hydraulic oil level, coolant level, dust separator on the oil bath air filter, tire pressure, cooling fins on engine and hydraulic oil cooler, drive axle oil level, wheel hub oil level, axle reduction gear, drum reduction gear, vibration bearings, engine oil and oil filter cartridges, fuel filter cartridge, fuel tank sludge, battery service, fuel pre-filter cartridge, refrigerant compressor V-belt, air conditioning service, valve clearance, ribbed V-belt, engine mounts and pillow blocks, oil changes for drive axle, wheel hubs, axle reduction gear, drum reduction gear and vibration bearings, axle-to-frame fastening, wheel nuts, ROPS check, oil bath air filter cleaning, hydraulic oil and breather filter, hydraulic oil filter, coolant change, crank case pressure ventilation valve, injector replacement, combustion air filter service, scraper adjustment, parking brake adjustment, tire change, cabin fresh air filter, tightening torques and engine conservation
• Trouble Shooting – engine starting problems, poor starting and irregular running, excessive exhaust smoke, engine overheating, poor engine power, low engine oil pressure and charge control faults
• Cab Assembly Before Initial Start-up – general safety regulations for assembly, preparations, cabin assembly and final function tests and checks

What makes this BOMAG BW 216 manual unusually practical is the way operating instruction and maintenance instruction are bound into a single document. The controls chapter does not simply name the switches; it explains what each warning lamp on the fault monitoring board means and what the machine does when one of them triggers, including the automatic engine shutdown delays. The maintenance chapter carries the full maintenance chart with interval columns running from every 10 operating hours up to every 6000 operating hours, so the reader can see at a glance which task falls due and when, then turn to the numbered procedure for the torque value, oil grade or adjustment figure that task requires.

Machine Coverage in Detail

The technical data section covers both variants side by side. The BW 216 DH-4 and BW 216 PDH-4 share the same Deutz TDC 2012 L06 2V six-cylinder water-cooled engine rated at 150 kW at 2200 rpm, a 12 V electrical system, hydrostatic drive and hydrostatic service brake, articulated hydrostatic steering and a 340 litre fuel tank. Where the two machines differ, the manual gives separate figures – operating weight, axle load distribution, static linear load, drum amplitude and gradability. The DH-4 runs a 2.0 / 1.0 mm amplitude pair, the PDH-4 runs 1.84 / 0.94 mm, and both work at 31 / 36 Hz. Filling capacities for engine oil, coolant, hydraulic oil, drive axle, wheel hubs, axle and drum reduction gears and the vibration bearings are all listed with their approved oil grades, and the machine fills its tires with water and calcium chloride or magnesium chloride ballast in the quantities stated.

The Safety Content

Safety is handled as a standalone regulation chapter rather than scattered notes. It sets out the intended use of the machine – compaction of bituminous materials and medium to heavy earthwork compaction – and the operations it must not be used for, such as vibratory work on hard concrete, cured concrete layers or heavily frozen ground. It states the operator age and training requirements, bans operation under the influence of alcohol, medication or drugs, and rules on unauthorised conversions. The towing limits, the 1 km/h maximum towing speed and 500 m maximum towing distance, the ROPS inspection criteria and the emergency exit through the right-hand cabin window are all specified here. Later chapters repeat the relevant warnings inside each procedure, so the reader meets the hazard warning at the point where the work is actually carried out.

Diagnostics and Measuring Systems

For machines fitted with the compaction measuring equipment, the manual documents the display and control elements in full, including the meaning of each field on the screen, the rotary switches for nominal value presetting, the START, STOP, PRINT and DELETE buttons, and the fault light. The line diagram and bar diagram are each explained item by item – pass number, travel direction, amplitude, maximum, minimum and mean values, change in percent, track length and the raster divisions – so the operator can read a printed compaction record correctly. The jump operation symbols, which warn of excessive drum jumping or tumbling, are covered with the instruction to select a smaller amplitude.

Put the BW 216 DH-4 Manual to Work

With this manual on hand, a technician or operator can carry out the complete scheduled maintenance programme on a BW 216 DH-4 or PDH-4 roller, from the daily engine oil and coolant level checks up to the 2000 hour oil changes in the drive axle, wheel hubs, axle reduction gear, drum reduction gear and vibration bearings. Valve clearance adjustment on the Deutz engine, parking brake adjustment, scraper setting on both the smooth drum and the padfoot drum, wheel nut and axle fastening torques, combustion air filter servicing and the annual air conditioning and ROPS checks are all covered with the values needed to do the job correctly. Working from the specified tightening torques and adjustment clearances rather than from guesswork is what keeps a vibrating drum roller reliable on site, protects the vibration bearings from overfilling damage and prevents the expensive repeat repairs that follow an incorrect setting.

Engine faults are handled in a dedicated trouble shooting section that pairs each symptom with its likely cause and the remedy, covering starting failures, poor starting and irregular running, excessive exhaust smoke, overheating, loss of power, low oil pressure and charge control warnings. The cab assembly chapter makes the document useful beyond routine servicing, since it documents the assembly steps, sealing tape procedure, fastening sequence and 578 Nm cabin fastening torque together with the function tests that must follow.

IMAGES PREVIEW

This BOMAG BW 216 DH-4 / PDH-4 Operation and Maintenance Manual is delivered as an instant PDF download. There is no shipping and no waiting for a physical book to arrive. Open it on a laptop, tablet or phone in the workshop or on site, print the pages you need for the job in front of you, and keep the complete document available for every future service interval for the life of the machine.