This is the BOMAG Service Manual for the BW 216 DHC-4 and BW 216 PDHC-4 single drum rollers, covering machines from serial number ranges 101 583 21 and 101 583 22. It is the factory workshop book (OEM document 008 914 40), 1098 pages in English, delivered as a PDF download.
A service manual is written for the person doing the repair, not just the operator. It takes you through the roller's main systems, from the diesel engine and travel drive to the vibration drive and electrics, with the testing and adjustment work a shop needs to bring the machine back into spec.
When the roller quits mid lift and there is no dealer tech coming, this is the reference you work from. The file carries over 16,000 bookmarks, so you can jump straight from the fault to the system chapter instead of paging through a thousand sheets.
What's Inside This Bomag BW 216 DHC-4, BW 216 PDHC-4 Manual
| System | Pages | Key Topics |
|---|---|---|
| Front Matter and General | 1-32 | Fuel System, Hydraulic System, Air Conditioning System, Engine, Generator, Starter Motor, Ball and Roller Bearings |
| Technical Data, Maintenance and Connection Overview | 33-52 | Travel Pump, Drum Drive Motor, Axle Drive Motor, Vibration Pump, Vibration Motor, Steering Valve, Rear Axle |
| Tests and Adjustments | 53-68 | Travel Pump, Steering Cylinder, Vibration Motor, Steering/Charge Pump, Injection Line, Brake Solenoid Valve |
| Flushing and Bleeding | 69-104 | Filling and Filtering Unit, Flushing Filter, Drum Drive Motor, Axle Motor, Travel Pump, Hydraulic Oil Tank |
| Electrics | 105-176 | Service the Battery; S00, Ignition Switch; Understanding Circuit Diagrams; Structure; Potential Cross References; Relay Cross Reference |
| Dust Protection | 177-182 | Dust Protection Bag, Control Panel, Wiring Loom, Instrument Carrier, Fastening Screws, Spacers, Washers, Switches |
| Engine Electrics | 183-312 | EMR3 System Components; Engine Control Unit; Pin Assignment of Engine Control EDC16 / EMR3; Rotary Speed Sensor for Camshaft; Speed Sensor, B114; Rotary Speed Sensor for Crankshaft |
| Electronic Modules | 313-414 | Bem, BOMAG Evib-Meter; Electrics Module A68; Anti-Spin Control; Electric Module K04; Heating/Air Conditioning Control |
| Speedometer Module | 415-418 | Description of Function; Teaching the Module; Manual Testing of the Speedometer; Connect the Ground Cable (-).; BW24RH, BW27RH, C550H and C560H = Travel 18 Meters.; Disconnect the Cable Bridge From "Teach" to "15/ 54“. |
| Service Training | 419-482 | Service Training Decks: MESX Control, BEM/Evib-Meter, BTMplus, Variocontrol, BCM05mobile; Component Photos with Measuring-Value Tables (Captioned BW 216 D-4) |
| Engine | 483-540 | Check the Engine Oil Level; Changing Engine Oil and Oil Filter Cartridges; Change the Fuel Pre-Filter Cartridge; Change the Fuel Filter Cartridge; Check, Clean the Water Separator; Check the Coolant Level |
| Air Conditioning System | 541-584 | Checking, Replacing the Refrigerant Compressor V-Belt; Service the Air Conditioning; Physical Basics; a - Heat Absorption; Refrigerant R134a; General |
| Replacing the Cab Window Panes | 585-594 | Glass Panes, Fastening Element, Fixing Washer and Spacer, Washer, Hexagon Nut, Protective Cap, Locking Handle, Suction Lifter |
| Drum | 595-650 | Special Tools, Single Drum Rollers; Removing and Installing the Drum; Repairing the Drum; Removing the Travel Motor; Dismantling, Assembling the Change- Over Weights; Dismantling the Change-Over Weight |
| Articulated Joint, Hydraulic Steering | 651-674 | Articulated Joint, Hydraulic Steering, Oscillating Articulated Joint, Rocker Bearings, Steering Cylinder, Friction Bearing, Belleville Springs |
| Suppliers Documentation - Travel and Vibration Pump | 675-679 | Travel and Vibration Pump, Series 90 Pumps |
| Suppliers Documentation - Travel and Vibration Pump Repair | 680-830 | Full Supplier Repair Instructions: Sectional Drawings, Disassembly, Wear Limits, Reassembly and Setting |
| Suppliers Documentation - Travel Motor | 831-912 | Travel Motor: Sections, Repair Procedure, Seal and Bearing Data |
| Suppliers Documentation - Steering Valve | 913-946 | Steering Valve: Sections, Spool Identification, Service and Setting |
| Suppliers Documentation - Axle and Vibration Motor | 947-1056 | Axle and Vibration Motor: Sectional Views, Repair and Reassembly Data |
| Circuit Diagrams | 1057-1098 | Wiring Diagram 582 702 27, Component List (Bauteilliste), Terminal and Connector Overviews |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Deutz TCD 2013 L04 2V, Common Rail (DCR), EMR3 | p. 34 |
| Rated power (DIN ISO 3046) | 119 kW | p. 34 |
| Rated speed | 2200 rpm | p. 34 |
| Operating weight (CECE), BW 216 DHC-4 | 16450 kg | p. 34 |
| Operating weight (CECE), BW 216 PDHC-4 | 16850 kg | p. 34 |
| Drum axle load (CECE), DHC-4 / PDHC-4 | 11150 kg / 11550 kg | p. 34 |
| Static linear load (DHC-4) | 52.3 kg/cm | p. 34 |
| Travel speeds | 0...3.5 / 0...6.0 / 0...12.0 km/h | p. 34 |
| Overall length / width / height | 6128 / 2130 / 2268 mm | p. 34 |
| Fuel capacity | 340 l | p. 35 |
| Hydraulic oil capacity | 60 l | p. 35 |
| Coolant capacity | 16 l | p. 35 |
| Travel pump high pressure limitation | 400 + 26 bar | p. 35 |
| Travel pump charge pressure, high idle | 26 bar | p. 35 |
| Max. steering pressure | 175 + 26 bar | p. 36 |
| Tyres / pressure | 23.1-26/12 TL R3 at 1.4 bar | p. 35 |
| Oscillating articulated joint torques | 77 Nm / 90 Nm | p. 668 |
Bomag BW 216 DHC-4, BW 216 PDHC-4 Common Problems This Manual Covers
No vibration or weak amplitude
The drum turns but will not shake, or compaction drops off in high amplitude. The vibration chapter walks through the exciter drive circuit so you can isolate whether the fault sits in the pump, the drum drive motor, or the switching side.
Manual Section: VibrationRoller will not travel or creeps
A closed-loop travel circuit that has lost charge pressure will leave the machine dead on the lift or barely crawling uphill. The travel drive section covers testing the pump and motor circuit and setting pressures back to specification.
Manual Section: Travel driveEngine cranks but will not start
Fuel supply, shutdown circuit, and starting system faults all present the same way at the key. The engine chapter gives the checks to separate a fuel problem from an electrical one before parts get thrown at it.
Manual Section: EngineElectrical faults and dead circuits
Gauges drop out, the vibration switch does nothing, or the machine dies when a relay gives up. The electrics section covers the machine's circuits so you can trace a fault with a meter instead of guessing at the harness.
Manual Section: ElectricsSteering slow or wandering
Play in the articulated joint or a tired steering circuit shows up as wander on the pass and hard turning at the end of it. The steering chapter covers the hydraulic circuit and the joint area so the fault can be pinned down.
Manual Section: SteeringHydraulic oil running hot
Overheating oil on long passes usually points to internal leakage or a circuit held near relief. The hydraulics coverage gives the test points and pressure values needed to find which circuit is dumping heat into the tank.
Manual Section: HydraulicsFrequently Asked Questions
Which machines does this manual cover?
The BOMAG BW 216 DHC-4 and BW 216 PDHC-4 single drum rollers, serial number ranges 101 583 21 and 101 583 22. Check the serial on your machine's type plate against those ranges before buying.
Is this a service manual or an operator's book?
It is the factory Service Manual (OEM document 008 914 40), written for repair and workshop use: testing, adjustment, and troubleshooting of the machine's systems, not just daily operation.
Does it help diagnose vibration and travel drive problems?
Yes. The Vibration and Travel drive sections cover the drive circuits for the drum and the closed-loop travel system, which is where most no-vibration and no-travel complaints on a single drum roller end up.
What engine is fitted to the Bomag BW 216 DHC-4 and BW 216 PDHC-4?
A Deutz TCD 2013 L04 2V with common rail injection (DCR) and EMR3 engine management, rated at 119 kW at 2200 rpm. The specification table on page 34 lists the same engine for both the DHC-4 and the PDHC-4.
What are the fluid capacities for the Bomag BW 216 DHC-4?
Page 35 gives 340 litres of fuel, 60 litres of hydraulic oil and 16 litres of coolant. Have those quantities on hand before a full service so you are not part way through a change with an empty drum.
How much does the Bomag BW 216 PDHC-4 weigh compared with the DHC-4?
Page 34 lists a CECE operating weight of 16850 kg for the PDHC-4 and 16450 kg for the DHC-4. Drum axle load runs 11550 kg on the PDHC-4 against 11150 kg on the DHC-4, which matters when you are booking transport.
How do I get the manual after paying?
It is a direct PDF download, about 59 MB, available immediately after checkout. No shipping, no waiting on a printed copy.
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