bw216dh 3 bw225d 3 Service Training PDF

Training Manual
Single Drum Rollers
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3
Part-No. 008 098 29 4/2000

Service Training
Table of contents
Foreword A1
Documentation A2
General A4
List of components B1
Technical data B2
Maintenance C1
Maintenance table C2
DEUTZ Diesel engine D1

Service side D2
Starter side D3
Lubrication oil circuit D4
Coolant circuit D5
Checking and adjusting the valve clearance D6
Plug-in injection pump D8
Travel system E1
Travel pump E4
Servo control E 15
Multi-function valves E 17
Charge pressure relief valve E 20
Axle drive motor E 21
Drum drive motor with reduction gear E 23
Flushing valve E 26
Trouble shooting travel system ETr 1
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3
Service Training
Vibration F1
Vibration pump F4
Control F8
High pressure protection F8
Charge pump F8
Vibration motor F9
Trouble shooting vibration FTr 1
Steering G1
Steering pump G3
Steering valve G5
Articulated joint G7
Trouble shooting steering GTr 1
Electrical system H1
Power supply H2
Ignition and starter circuit H4
Fault monitoring board H7
Brakes H 11
Speed range selector H 14
Anti Spin Control (ASC) H 18
Vibration H 20
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3
Service Training
Foreword
This training manual was specifically written for the new single drum rollers BW 216 D-3, BW 216 DH-
3/PDH-3, BW 219 DH-3/PDH3 and BW 225 D-3/PD-3 of generation 3. This range of single drum rollers
is the consequent further development of the machine range of heavy single drum rollers of generation
2 and is also an adaptation to the presently most modern status of technology.
Single drum rollers of this product ranges are today needed on construction sites all over the world. Rol-
lers of this size are mainly used in earth construction and for the preparation and sealing of sanitary
landfill sites.
During the development of this new generation of single drum rollers the requirements and demands of
our customers, operators and maintenance personnel were the main aspects which were taken into
consideration.
Since we would like to increase the benefit for our customers also in the future, we ask you kindly to
inform us about your ideas and suggestions.
The introduction of new or improved products on the market is not possible without thorough training of
all persons responsible for the efficient after sales service for all these products.
This is the reason why this document was prepared on the basis of the training material for the new ran-
ge of single drum rollers of generation 3. This material will help the trainer to transfer the necessary
knowledge to the participants in the training session in an easy to understand way.
This manual is by no means complete. Technical data and details, which were not available at the date
of release of this manual, or which have changed since the release of this manual, require special at-
tention of the respective trainer during the training course.
These training documents are not subjected to a regular updating service. All important changes to the
machine will, however, be worked in during the revision of this training manual.
The chapter "Documentation“ contains information about other documents for this machine. The latest
operating and maintenance instructions and the up-to-date electric and hydraulic diagrams are part of
this training manual.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -A1-
Service Training
Documentation
For the single drum rollers BW 216 D-3, BW 216 DH-3/PDH-3, BW 219 DH-3/PDH3 and BW 225 D-3/
PD-3 the following documents are additionally available:
1. Operating and maintenance instructions

Machine type Catalogue No.: from serial no. to serial no.
BW 216 D-3 008 140 61 101 580 40 0101
BW 216 DH-3 008 140 61 101 580 42 0101
BW 216 PDH-3 008 140 61 101 580 43 0101
BW 219 DH-3 008 140 61 101 580 50 0101
BW 219 PDH-3 008 140 61 101 580 51 0101
BW 225 D-3 008 140 61 101 580 60 0101
BW 225 PD-3 008 140 61 101 580 61 0101
2. Spare parts catalogue

Machine type Catalogue No.: from serial no. to serial no.
BW 216 D-3 008 153 40 101 580 40 0101
BW 216 DH-3 008 153 42 101 580 42 0101
BW 216 PDH-3 008 153 43 101 580 43 0101
BW 219 DH-3 008 153 50 101 580 50 0101
BW 219 PDH-3 008 153 51 101 580 51 0101
BW 225 D-3 008 153 60 101 580 60 0101
BW 225 PD-3 008 153 61 101 580 61 0101
3. Wiring diagram*
Drawing No.: from serial number to serial number
582 700 38 for single drum rollers with new monitoring board
4. Hydraulic diagram*
Machine type Drawing No.: from serial number to serial number
BW 216 D-3 581 201 26 101 580 40 0101
BW 216 DH-3 581 201 26 101 580 42 0101
BW 216 PDH-3 581 201 26 101 580 43 0101
BW 219 DH-3 581 201 27 101 580 50 0101
BW 219 PDH-3 581 201 27 101 580 51 0101
BW 225 D-3 581 201 28 101 580 61 0101
BW 225 PD-3 581 201 28 101 580 61 0101
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -A2-
Service Training
5. Repair instructions
Catalogue No.: Component Part-No.
6. Service Information
Comment:
* These documents are part of the training manual
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -A3-
Service Training
General
The new single drum rollers BW 216 D-3, BW 216 DH-3/PDH-3, BW 219 DH-3/PDH3 and BW 225 D-
3/PD-3 from BOMAG are mainly further developments of the preceding models BW 219 D-2 and BW
219 DH-2.
These machines have been successfully used over years on construction sites all over the world, espe-
cially in earth work and for the construction of sanitary landfill sites.
High compaction performance and extremely good traction are properties, which are of utmost im-
portance for machines of this type.
All components used in these machines are series production products and are permanently subjected
to stringent quality checks. This ensures a high level of reliability and safety.
As on many other BOMAG products and here particularly on the large single drum rollers of the new
generation, we have also with these machines made a decision in favour of the approved drive system
with diesel engine (water cooled) and hydrostatic drive. Hydrostatic drives transfer the output power of
the diesel engine directly to the drum, the drive wheels and the steering cylinder.
Drum and drive wheels are driven by fast rotating hydraulic motors and reduction gear (drum) or axle
(drive wheels).
On construction equipment the work place of the operator is of utmost importance. Under such operating
conditions the health and safety of the operator must be treated with top priority.
The cabin is very spacious and clearly layed out. The operator's seat is very comfortable and can be
individually adjusted for every operator, even to the weight.
All controls and gauges are within the reach and the field of vison of the operator.
A monitoring board with light emitting diodes and easy to understand pictograms informs the operator
about any faults occurring during operation. The operator is therefore always informed about the condi-
tion of the machine.
The generously dimensioned windows in the cabin with windscreen wiper and washer systems for front
and rear windscreens allow excellent view to all directions.
• strong ROPS/FOPS according to SAE standard
• wear free service brake due to the closed hydraulic travel circuits
• multi-disc brakes in the planetary drives working as parking and emergency brakes
• high stability due to the low centre of gravity and the use of an articulated joint
• operational safety due to the use of monitoring boards for all important system data
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -A4-
Service Training
• automatic engine shut down at too high coolant temperature, too low hydraulic oil level (when rea-
ching the lowest level the engine will be shut down after 20 seconds) and too low engine oil pressure.
The single drum rollers BW 216 D-3, BW 216 DH-3/PDH-3, BW 219 DH-3/PDH3 and BW 225 D-3/PD-
3 are very well designed down to the smallest detail, suitable for the tough requirements on large scale
construction sites all over the world.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -A5-
Service Training
List of components
Fig. 1 Position of important service points
1 Drum drive motor 13 Vibration pump

2 Reduction gear 14 Travel pump
3 Vibration motor 15 Hand pump for hood
4 Articulated joint 16 Hydraulic oil filter
5 Hydraulic oil cooler 17 Starter
6 Radiator 18 Wheels (with axle and axle drive motor)
7 Fuel filter 19 Generator
8 Pressure accumulator to compensate 20 Radiator blower
vibrations in the steering system 21 Operator's seat
9 Engine oil filter 22 Steering wheel with steering valve
10 Steering/charge pump 23 Drum
11 Fuel pre-filter
12 Deutz engine BF6M 1013 E
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -B1-
BOMAG Central Service Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values
Status: 2001-07-09
Product type: BW 216 D-3

Type No.: 580 40
Serial numbers from: 101 580 40 0101
Serial numbers up to: 101 580 40 0181
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Combustion principle: 4-stroke-Diesel
Cooling: Water
Number of cylinders: 6
Power acc. to ISO 9249: 137 kW
Power data at nominal speed of: 2200 U/min
Low idle speed: 850+/-150 U/min
High idle speed: 2350+/-100 U/min
Spec. fuel consumption: 228 g/kWh
Valve clearance, inlet: 0,3 mm
Valve clearance, outlet: 0,5 mm
Opening pressure, injection valves: 250 bar
Starter voltage: 12 V
Starter power: 3,1 kW
Travel pump:
Manufacturer: Sauer-Danfoss
Type: 90R 075
System: Axial piston-swash plate
Max. displacement: 75 cm3/U
Max. flow ratio: 172,9 l/min
High pressure limiation: 435 +/-15 bar
Charge pressure, high idle: 25+/-1 bar
Reduction gear, drum:

Type: CR 31
Transmission ratio: 45,6
Travel motor, rear:

Type: 51D110
System: Axial piston-bent axle
Max. displacement (stage 1): 110 cm3/U
Min. displacement (stage 2): 50 cm3/U
Perm. leak oil quantity: 2 l/min
Drum drive:
Type: 51C 110
http://bo_web/ext_resource/tk_tech/english/search_components_result.asp 09.07.01
Displacement stage 1: 110 cm3/U

Displacement stage 2: 40,3 cm3/U
Vibration pump:
Type: 42R 041
Starting pressure: 350+/-50 bar
Operating pressure, soil dependent: ca.100 bar
Vibration motor:
Type: MMF 044
Displacement: 44 cm3/U
Frequency: 30/36 Hz
Amplitude: 1,8/0,9 mm
Steering and charge pump:

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Max. steering pressure: 225+/-15 bar
Steering valve:
Type: OSPC 500 ON
System: Rotary valve
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Differential: No-Spin
Degree of locking: 100 %
Reduction ratio: 65,08
Filling capacities:
Engine coolant: 20 l (50% Water, 50% Anti-freeze agent on
Ethane-diol-basis)
Engine oil: 20 l (SAE 15W-40, API SJ/CF)
Hydraulic oil: 60 l (HVLP 46 VI 150)
Vibration bearing housing: 2x 1,8 l (SAE 15W-40, API SJ/CF)
Rear axle: 11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs: 2,9 l (SAE 90 EP, API GL 5)
Rear axle, transmission: 1,9 l (SAE 90 EP, API GL 5)
Reduction gear, drum: 2,8 l (SAE 90 EP, API GL 5)
AC refrigerant: 1100 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG Öl)
Status: 2001-07-09

Type No.: 580 40
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 075

Type: CR 31
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 42R 041
Vibration motor:
Type: MMF 044
Frequency: 30/36 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 40
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 075

Type: CR 31
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 42R 041
Vibration motor:
Manufacturer: Hydromatik
Type: A2FM 45
System: Axial piston-bent axe
Frequency: 30/36 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09
Product type: BW 216 DH-3

Type No.: 580 42
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 075

Type: CR 31
Travel motor, rear:

Type: 51D110
Min. displacement (stage 2): 31,4 cm3/U
Drum drive:
Type: 51C 110

Vibration pump:
Type: 42R 041
Vibration motor:
Type: MMF 044
Frequency: 30/36 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09
Product type: BW 216 PDH-3

Type No.: 580 43
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 075

Type: CR 31
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 42R 041
Vibration motor:
Type: MMF 044
Frequency: 30/36 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 42
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 075

Type: CR 31
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 42R 041
Vibration motor:
Type: A2FM 45
System: Axial piston-bent axe
Frequency: 30/36 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 43
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 075

Type: CR 31
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 42R 041
Vibration motor:
Type: MMF 044
Frequency: 30/36 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 43
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 075

Type: CR 31
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 42R 041
Vibration motor:
Type: MMF 044
Frequency: 30/36 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 43
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 075

Type: CR 31
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 42R 041
Vibration motor:
Type: A2FM 45
Frequency: 30/36 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/51
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 50
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 100
Max. flow ratio: 235 l/min

Type: CR 51
Travel motor, rear:

Type: 51D160
Drum drive:
Type: 51C 110

Vibration pump:
Type: 90R 055
Vibration motor:
Type: 90M 055
Frequency: 28/35 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/50
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 50
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 100

Type: CR 51
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 90R 055
Vibration motor:
Type: 90M 055
Frequency: 28/35 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/55
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 50
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 100

Type: CR 51
Travel motor, rear:

Type: 51D160
Drum drive:
Type: 51C 110

Vibration pump:
Type: 90R 055
Vibration motor:
Type: 90M 055
Frequency: 28/35 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/50
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 50
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 100

Type: CR 51
Travel motor, rear:

Type: 51D160
Drum drive:
Type: 51C 110

Vibration pump:
Type: 90R 055
Vibration motor:
Type: 90M 055
Frequency: 28/35 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/55
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 51
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 100

Type: CR 51
Travel motor, rear:

Type: 51D160
Drum drive:
Type: 51C 110

Vibration pump:
Type: 90R 055
Vibration motor:
Type: 90M 055
Frequency: 28/35 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/50
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 51
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 100

Type: CR 51
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 90R 055
Vibration motor:
Type: 90M 055
Frequency: 28/35 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/55
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 60
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 100

Type: CR 51
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 90R 055
Vibration motor:
Type: 90M 075
Frequency: 26/26 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/50
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09

Type No.: 580 60
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 100

Type: CR 51
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 90R 055
Vibration motor:
Type: 90M 075
Frequency: 26/26 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/55
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09
Product type: BW 225 PD-3

Type No.: 580 61
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 100

Type: CR 51
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 90R 055
Vibration motor:
Type: 90M 075
Frequency: 26/26 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/50
Filling capacities:
Ethane-diol-basis)
Status: 2001-07-09
Product type: BW 225 PD-3

Type No.: 580 61
Engine:
Manufacturer: Deutz
Type: BF6M1013E
Cooling: Water
Travel pump:
Type: 90R 100

Type: CR 51
Travel motor, rear:

Type: 51D110
Drum drive:
Type: 51C 110

Vibration pump:
Type: 90R 055
Vibration motor:
Type: 90M 075
Frequency: 26/26 Hz

Manufacturer: Bosch
Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
Rear axle:
Manufacturer: Dana
Type: CHC 193/55
Filling capacities:
Ethane-diol-basis)
Service Training
Maintenance
Single drum rollers are heavy-duty machines for extremely difficult applications in earthwork. To be able
to meet these demands the machine must always be ready to be loaded up to its limits. Apart from this
all safety installations must always be fully functional.
Thorough maintenance of the machine is therefore mandatory. It not only guarantees a remarkably
higher functional safety, but also prolongs the lifetime of the machine and of important components.
The time required for thorough maintenance is only minor when being compared with the malfunctions
and faults that may occur if these instructions are not observed.
The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance
interval all the work for shorter preceding intervals must also be performed. During the 2000 hour
interval you must also perform the maintenance work for the 250, 500 and 1000 hour intervals.
It should also be clear, that with the 2500 hours interval only the work for the 10, 250 and 500 hour
intervals must be performed.
For maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and
lubricants (oils, fuels, grease etc.).
Please refer to the operating and maintenance instructions for the individual maintenance intervals and
the description of the individual maintenance tasks.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -C1-
Service Training
Maintenance table
Running-in inspect.
1000 op. hours
2000 op. hours

10 oper. hours
50 oper. hours
(50 op. hours)
250 op. hours
500 op. hours
as required
Maintenance work Comment
Change the engine oil filter X
Change the engine oil X
Check, adjust the valve clearance X
Tighten all screw connections on intake X

and exhaust manifold, oil sump and engine
mounts
Tighten the screw connections on the X

machine
Tighten the fastening screws for the wheels X
Change the oil in the drive axle X
Change the oil in the planetary drives X
Change the oil in the axle reduction gear X
Change the oil in the drum drive reduction X

gear
Change the oil in the vibration housings see note X X X
Check the engine oil level Dipstick mark X X X X X X
Check the water separator X X X X X X
Check the fuel level approx. 340 l X X X X X X
Check the hydraulic oil level Inspection glass X X X X X X
Check the coolant level X X X X X X
Grease the articulated joint High press. grease X X X X X
Check the tire pressure 1.1 bar X X X X X
Adjust the scrapers X X X X X
Retighten the screws on the articulated X X X X

joint
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -C2-
Service Training
Running-in inspect.
10 operat. hours
50 operat. hours
1000 op. hours
2000 op. hours

(50 op. hours)
250 op. hours
500 op. hours
as required
Check condition, tension of V-belts, change X X X X

the V-belts
Check, clean cooling fins on radiator and X X X X

hydraulic oil cooler
Check the oil level in the drive axle X X X X
Check the oil level in the axle reduction X X X X

gear
Check the oil level in the planetary drive X X X X
Check the oil level in the vibration bearings X X X X
Check the oil level in the drum drive reduc- X X X X

tion gear
Change the engine oil min. 1 x year X X X
Change the engine oil filter cartridge X X X
Drain the fuel tank sludge X X X
Service the battery Pole grease X X X
Check and adjust the valve clearance Intake = 0.3 mm X X

(when engine is cold) Exhaust = 0.5 mm
Change the fuel prefilter cartridge X X
Change the fuel filter element X X
Change the oil in the drive axle min. 1 x year X X
Change the oil in the planetary drives min. 1 x year X X
Change the oil in the axle reduction gear min. 1 x year X X
Change the oil in the vibration bearings min. 1 x year X X
Check the fastening elements on the X X

engine
Check the fastening on axle and frame X X
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -C3-
Service Training
Running-in inspect.
10 operat. hours
50 operat. hours
1000 op. hours
2000 op. hours

(50 op. hours)
250 op. hours
500 op. hours
as required
Tighten the wheel nuts X X
Check the ROPS X X X
Change hydraulic oil and breather filter min. every 2 years X X
Change the hydraulic oil filter min. every 2 years X X

and after repairs in
the hydraulic
system
Change the coolant min. every 2 years X X
Clean, change the dry air filter element min, 1 x year, X

safety cartridge
min. every 2 years
Adjust the parking brake X
Change the tires X
Change the fresh air filter for the cabin X
Retighten the screw connections Observe the tighte- X

ning torques
Engine conservation Before shutting the X

engine down for a
longer period of
time
Note:
When changing filters use only the original filters specified in the spare parts catalogue for this machine.
The use of incorrect filters (e.g. insufficient pressure resistance) can lead to severe damage on engine
or hydraulic components.
The coolant for the water cooled engine must always be mixed with 40 to 50% of anti-freeze additive
(even under hot environmental conditions) as a preventive measure against corrosion and cavitation.
However, the additive proportion must not exceed 60%, since this would have an adverse effect on the
cooling ability of the coolant.
Oil change intervals in the vibration housings: after 50 h, after 500 h, after 1000 h and then every 1000 h.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -C4-
Service Training
Deutz Diesel engine
All single drum rollers BW 216 D-3, BW 216 DH-3/PDH-3, BW 219 DH-3/PDH3 and BW 225 D-3/PD-3
are powered by water cooled Deutz diesel engines of the latest product range BF6M1013E.
This engine is characterized by the following positive features:
• short and compact design,
• low noise level,
• almost vibration-free running,
• low fuel consumption,
• high power reserves and
• good access to all service points.
Crankcase and cylinders of this engine are made of alloyed cast iron. This provides rigidness and
ensures high wear resistance.
The engines are fitted with wet cylinder liners, which allows simple replacement in case of repairs.
The forged steel conrod is fitted with a compensation weight near the conrod bearing seat. This weight
compensates manufacturing tolerances with respect to weight and centre of gravity.
The pistons are made of an aluminium alloy. The combustion trough has side walls which slant 10°
inwards and is slightly offset with respect to the centre of the piston. All pistons are fitted with three piston
rings and a cast iron ring carrier for the first ring. The pistons are cooled by an oil spray.
The forged crankshaft is fitted with integrated counter-weights.
The block-type cylinder head is made of cast iron. Each of the cylinders has one intake and one exhaust
valve. The valve guides are shrunk into the cylinder. The valve seat rings are made of high quality steel
and shrunk fitted.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 -D1-
Service Training
Service side
3 4
2
5
6
14
9 8
13 12 11 10
Fig. 1: Service side BF6M1013E
1 Oil filler plug 8 Fuel pump

2 Valve, boost fuel 9 Engine mounts
3 Engine solenoid 10 Fuel filter
4 Oil pressure switch 11 Lubrication oil filter
5 Radiator blower 12 Oil sump
6 Coolant pump 13 Dipstick
7 V-belt pulley 14 Steering/charge pump
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 -D2-
Service Training
Starter side
3
1
Fig. 2: Starter side
1 Flywheel
2 Earth cable
3 Starter
4 Turbo charger
5 Generator
6 Coolant temperature switch
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 -D3-
Service Training
Lubrication oil circuit
3 4 5 6 7 8 9 10 11 12 13 14 15
2 1 22 21 20 19 18 17 16
Fig. 3: Lubrication oil circuit
1 Oil pan 12 Spray nozzle for piston cooling

2 Turbocharger return to crankcase 13 Camshaft bearing
3 Turbo charger 14 Main oil gallery
4 Oil line to turbo charger 15 Lubrication oil cooler
5 Line to mass balancing gear (2 x) 16 Lubrication oil pump
6 Oil pressure sensor 17 Pressure relief valve
7 Tappet with pulse lubrication 18 Back leak fuel valve
8 Push rod, oil supply to rocker arms 19 Lubrication oil filter
9 Line to spray nozzle 20 Suction line
10 Rocker arm 21 Crankshaft bearing
11 Return line to oil sump 22 Conrod bearing
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 -D4-
Service Training
Coolant circuit
3 1
5 4
Fig. 4: Coolant circuit
1 Radiator
2 To radiator
3 From radiator
4 Coolant oil pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder head cooling
8 Vent connection from cylinder head to heat exchanger
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 -D5-
Service Training
Checking and adjusting the valve clearance
Too big or too small valve clearance can cause failure of the engine as a result of mechanical and ther-
mal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the inter-
vals specified in the operating and maintenance instructions.
Note:
The valve clearance must be checked and adjusted when the engine is cold.
Inlet valve = 0.3 mm
Exhaust valve = 0.5 mm
• Turn the crankshaft until both valves on cylinder 1 are overlapping (exhaust valve not yet closed, inlet
valve starts to open).
• Check and adjust the valve clearance by following the adjustment schematic, black marking. For con-
trol purposes mark the respective rocker arm with chalk.
Flywheel
side
Fig. 5: Crankshaft position 1
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 -D6-
Service Training
• Turn the crankshaft one full rotation (360°) further.
Flywheel
side
Fig. 6: Crankshaft position 2
• Check and adjust the valve clearance by following the adjustment schematic, black marking.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 -D7-
Service Training
Plug-in injection pump
Deutz diesel engines of series 1013 are equipped with Bosch single injection pumps of series PF 33.
With the single injection pump concept it is possible to realize high injection pressures in conjunction
with extremely short injection lines, a prerequisite for a high hydraulic stiffness of the injection system.
This in turn establishes the basis for achieving low exhaust emission levels (soot) together with a low
fuel consumption.
The single injection pumps come with the following dimensions:
• Stroke 12 mm
• Diameter 9 mm
A snubber valve (Ø 0.7 mm) after the pressure valve prevents cavitation in the injection lines under high
pressure and during the secondary injection of the injectors.
The constant-volume relief volume is 50 mm³.
Assembly of single injection pumps
The setting of the commencement of injection pump delivery (COD) has an effect on the
• fuel consumption,
• the power output and
• the exhaust emission
of the engine.
On engines of series 1012 the commencement of delivery is set without any tolerance. The commence-
ment of delivery is indicated in degree of crank angle before top dead centre (TDC) of the piston and
depends on the application, power and speed of the engine.
The injection pump starts to deliver when the plunger is just about to close off the inlet port in the plunger
barrel.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 -D8-
Service Training
On engines with in-line injection pumps the flywheel is turned to commencement of delivery (COD) po-
sition and the closing of the fuel inlet port in the injection pump plunger is determined with a high-pres-
sure pump. Any tolerances are compensated at the coupling of the injection pump drive, with the
injection pump camshaft being turned to commencement of delivery position, relatively to the stationary
flywheel.
Since the injection pump cams on engines of series 1012 are located on the engine camshaft, the pre-
vious method for setting the commencement of delivery is no longer applicable.
The commencement of injection pump delivery must therefore be set using a different method.
The conventional setting method consists of length measurememnts for individual components and
arithmetic steps.
The permissible manufacturing tolerances of the components
• crankcase with integrated cylinder liners,
• camshaft,
• roller tappet and
• single injection pump
are determined and eliminated by setting the commencement of delivery.
In all cases, which are of interest for BOMAG mechanics, the engines are not completely overhauled,
but individual injection pumps are replaced.
Crankcase, camshaft and roller tappets remain unchanged.
This results in a certain installation measurement for the for the engine drive, which is mentioned on the
engine type plate.
This measurement can be found in the column „EP“ as CODE for each cylinder.
Note:
When replacing an injection nozzle you must also replace the corresponding high pressure line to the
injection nozzle.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 -D9-
Service Training
Determining the shim thickness for replacement of single injection pump
For the replacement of single injection pumps without any alterations to the crankshaft assembly of the
engine, a simplified method can be applied to determine the thickness of the required shim. The column
„EP“ on the engine type plate contains a code for the injection pump of each cylinder.
397
Each line represents 1 cylinder

e.g. 1st cell = cylinder 1
2nd cell = cylinder 2 etc.
Fig. 7: Injection pump code BFM 1013
With the help of the „EP“-code the correct installation dimension „Ek“ can be taken from table 1.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 11 -
Service Training
EK EP EK EP EK EP EK EP EK EP
(mm) code (mm) code (mm) code (mm) code (mm) code
144.5 145.1 145.7 349 146.3 373 146.9 397
144.525 145.125 145.725 350 146.325 374 146.925 398
144.55 145.15 145.75 351 146.35 375 146.95 399
144.575 145.175 145.775 352 146.375 376 146.975 400
144.6 145.2 145.8 353 146.4 377 147.0 401

144.625 145.225 145.825 354 146.425 378 147.025
144.65 145.25 145.85 355 146.45 379 147.05
144.675 145.275 145.875 356 146.475 380 147.075
144.7 145.3 145.9 357 146.5 381 147.1

144.725 145.325 145.925 358 146.525 382 147.125
144.75 145.35 335 145.95 359 146.55 383 147.15
144.775 145.375 336 145.975 360 146.575 384 147.175
144.8 145.4 337 146.0 361 146.6 385 147.2

144.825 145.425 338 146.025 362 146.625 386 147.225
144.85 145.45 339 146.05 363 146.65 387 147.25
144.875 145.475 340 146.075 364 146.675 388 147.275
144.9 145.5 341 146.1 365 146.7 389 147.3

144.925 145.525 342 146.125 366 146.725 390 147.325
144.95 145.55 343 146.15 367 146.75 391 147.35
144.975 145.575 344 146.175 368 146.775 392 147.375
145.0 145.6 345 146.2 369 146.8 393 147.4

145.025 145.625 346 146.225 370 146.825 394 147.425
145.05 145.65 347 146.25 371 146.85 395 147.45
145.075 145.675 348 146.275 372 146.875 396 147.475
Table 1: Injection pumpe code BFM 1013
E k (mm) = correct injection pump dimension determined with the „EP“-code from the engine type plate
acocrding to table 1
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 12 -
Service Training
During the manufacturing process of the single injection pump, closing of the fuel inlet port is determined
with the high pressure method. In this position - commencement of delivery position of the injection
pump plunger - the distance is measured between pump contact surface and tappet foot contact sur-
face.
The measurement „A“ is written with an electric pen on the pump in 1/100 of a mm.
Fig. 8: Marking of plunger code
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 13 -
Service Training
Fig. 9: Plugin injection pump
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 14 -
Service Training
The dimension „A“ indicates by how many 1/100 of a mm the distance between contact surface of crank-
case and tappet foot exceeds the hydraulic standard dimension Lo ..
A = XXX
Fig. 10: Representation of measurement „A“
• Lo = 119 mm - BFM 1012
• Lo = 143 mm - BFM 1013
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 15 -
Service Training
Fig. 11: Crankshaft assembly in commencement of delivery position after determination of „Ts “
The single injection pump is now frictionally and rigidly connected with the crankshaft assembly in com-
mencement of delivery position by inserting a calibrated shim „Z“.
The illustration shows that there is a distance „Ts“ between injection pump tappet foot and roller tappet,
which can be calculated as follows:
E k - (Lo + A/100)
This distance must be compensated by shim „Z“ of calculated thickness.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 16 -
Service Training
Theor. thickness Shim Theor. Shim

„T s“ thickness thickness thickness
„Ss“ „Ts “ „Ss“
(mm) (mm) (mm)
(mm)
0.95 - 1.049 1.0 2.45 - 2.549 2.5
1.05 - 1.149 1.1 2.55 - 2.649 2.6
1.15 - 1.249 1.2 2.65 - 2.749 2.7
1.25 - 1.349 1.3 2.75 - 2.849 2.8
1.35 - 1.449 1.4 2.85 - 2.949 2.9
1.45 - 1.549 1.5 2.95 - 3.049 3.0
1.55 - 1.649 1.6 3.05 - 3.149 3.1
1.65 - 1.749 1.7 3.15 - 3.249 3.2
1.75 - 1.849 1.8 3.25 - 3.349 3.3
1.85 - 1.949 1.9 3.35 - 3.449 3.4
1.95 - 2.049 2.0 3.45 - 3.549 3.5
2.05 - 2.149 2.1 3.55 - 3.649 3.6
2.15 - 2.249 2.2 3.65 - 3.749 3.7
2.25 - 2.349 2.3 3.75 - 3.850 3.8
2.35 - 2.449 2.4
Table 2:
For the determination of the theoretical shim thickness „Ts “ it is therefore necessary to determine the
measurement L o + A/100 of the new injection pump.
This measurement must be subtracted from the corrected injection pump measurement E k.
T s = Ek - (Lo + A/100) [mm]
The actual thickness of the compensation shim „Ss “ is determined according to table 2.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 17 -
Service Training
Calculation example for BFL 1013:
EP-Code on engine type plate: 397
• see table 1
corrected injection pump measurement „E k “: 146.9 mm
Lo = 143 mm (fixed measurement)
Value for A/100 on new injection pump A/100 = 133
• T s = E k - (Lo + A/100)
T s = 146.9 mm - (143 mm + 133/100 mm)
T s = 2.57 mm
• see table 2
Ss = 2.6 mm
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 18 -
Service Training
Installation of the plug-in injection pumps into the crankcase
Note:
Because of the high pressures any injection line that has been disassembled must be replaced.
To obtain uniform delivery of the single injection pumps, all pumps must be installed in a specific position
relative to each other.
• with governor installed - in case of replacement
To set the injection pump control rod to stop position use a special tool (Deutz-no. 100 830). This tool
must be inserted into the receiving bore of the shut-down solenoid.
The roller tappet of every single injection pump must be turned on the cam base circle. Turn the injection
pump linkage lever to the middle of its travel and insert the single injection pump so that the linkage lever
can be introduced into the notch of the control rod. Preload the flange screws of the single injection
pump - chamfer pointing towards injection pump body - with 5 Nm. Thereafter the screws are slackened
by 60°. Use a torque wrench with drag indicator and special tool adapter to determine the friction torque
„Mr“ is determined by turning every injection pump anti-clockwise until stop. The injection pumps are tur-
ned with the relevant Mr + 1 Nm anti-clockwise so that all of them rest against the control rod notch in
the same position, i.e. the linkage levers of all injection pumps now rest equally against the control rod
notches with 1 Nm. Then tighten all flange screws in steps with
• 7 Nm
• 10 Nm
• 30 Nm
Note:
After installation of each single injection pump the control rod must be checked for free movement
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 19 -
Service Training
Fig. 12: Setting uniform fuel delivery of single injection pumps
1 Special tool (with governor removed)

2 Timing chest cover
3 Control rod guide
4 Special tool adapter + torque wrench
5 Linkage lever for injection pump
6 Notch of control rod
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 20 -
Service Training
Control rod travel
With the governor removed, the control rod is always pressed out by the compression spring to boost
fuel position.
With the single injection pumps removed the free travel of the control rod must be min. 17 + 0.5 mm.
With the single injection pumps installed, the travel of the control rod „Y“ must be at least 16.8 mm.
The recess dimension „X“ between control rod in stop position and contact face of the governor on the
timing chest cover must be between 0.3 - 1.3 mm.
Note:
It is absolutely necessary to indicate this recess dimension, thus determined when replacing or repairing
the governor.
Fig. 13: Control rod travel
1 Full load + boost fuel X = 0.3 - 1.3 mm = recess dimension

2 Stop position Y = 16.8 mm (fitted injection pump)
3 Compression spring
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3/BW 225 D-3/PD-3 - D 21 -
Service Training
Travel system
The travel system of the single drum roller range BW 216 D-3, BW 216 DH-3/PDH-3, BW 219 DH-3/
PDH-3 and BW 225 D-3/PD-3 is a closed hydrostatic circuit. The circuit consists mainly of
• the travel pump with control and safety elements,
• the drum drive motor,
• the reduction gear for the drum drive with integrated multi-disc brake,
• the axle drive motor
• the charge pump (also for the vibration circuit),
• the hydraulic oil filter in the charge circuit
• the hydraulic oil cooler in the return flow to the hydraulic oil tank
• the pressure resistant hydraulic hoses.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -E1-
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3
BW 216 D-3, BW 216 DH-3/PDH-3
Fig. 1 Hydraulic diagram travel system

from brake valve
Lecköl zum
2.2 Thermostatventil
2.1
2
4
1 3 5
Charge pressure to vibration pump

Charge pressre from hydraulic oil filter
Service Training
1 Travel pump 3 Charge pressure relief valve
2 Servo control BW 216 = 25 bar
2.1 Orifice BW 219/225 = 29 bar
BW 216 = 0.81 mm 4 Multi-function valve
BW 219/225 = 1.02 mm 5 Axle drive motor
2.2 Orifice 6 Drum drive motor
BW 216 = 0.8 mm
-E2-
BW 219/225 = 1.0 mm
Service Training
Together with the vibration pump and the charge pump the travel pump is connected to a tandem pump
unit. The charge pump, is integrated in the vibration pump.
The travel pump is the first pump section and is directly flanged to the flywheel side of the diesel engine.
The pump delivers the hydraulic oil to the paralle connected motors on drum and on axle. The pressure
in the closed circuit generated by the resistance of the drum and the drive wheels is limited to maximum
425 bar by the high pressure relief valves in the pump.
When the machine is driving the flushing valves in the hydraulic motors for drum drive and axle drive
will flush a certain amount of hydraulic oil out of the closed circuit. This avoids overheating of the closed
travel circuit.
Leakages in the individual travel system components are compensated by the charge circuit via the
boost check valves in the travel pump.
The charge pump inside the vibration pump draws the hydraulic oil from the hydraulic oil tank and deli-
vers it through the hydraulic oil filter to the charge system in the travel pump, to the vibration pump as
well as to the control valves for the brakes (reduction gear for drum drive and planetary wheel drives)
and to the travel speed range selector valves (for drum drive motor and axle drive motor).
The charge circuit has the function to compensate leakages and flushing quantities in the closed travel
and vibration circuits and to provide the required pressure oil for the control of the travel and vibration
pumps, the speed range selection and the actuation (releasing) of the multi-disc brakes in both travel
motors.
On both travel motors it is possible to choose between two different fixed displacements.
This allows to drive the machine at different speed ranges. This reaches from the high speed range
(transport speed without vibration) with both motors running at low displacement, up to the working
speed with both motors working with high displacement.
The motors can, however, also be operated independently from each other (front high displacement –
rear low displacement, or vice versa), whereby the machine can be optimally adapted to local soil and
site conditions.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -E3-
Service Training
Travel pump
The travel pump is a Sauer-Sundstrand swash plate operated axial piston pump with variable displace-
ment for hydrostatic drives in closed hydraulic circuits.
to - from
travel motor
to - from
travel motor
Charge pressure to vibration pump
Charge pressure from hydraulic oil cooler
Fahr_pmp.eps
Fig. 2 Hydraulic diagram, travel pump
1 Travel pump
2 Control
2.1 Orifice
BW 216 = 0.81 mm
BW 219 / 225 = 1.02 mm
2.2 Orifice
BW 216 = 0.8 mm
BW 219 / 225 = 1.0 mm
3 Charge pressure relief valve
4 Non-return valve
5 Multi-function valves
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -E4-
Service Training
The pump oil flow is proportional to the drive speed (output speed of diesel engine) and the infinitely
variable displacement of the pump.
By actuating the swash plate the pump flow rate can be adjusted from "0" to maximum displacement of
the pump. When altering the swash plate position through the neutral position to the opposite side, the
direction of oil flow will be reversed and the travel direction of the machine will change.
All valves, safety and control elements needed for safe operation of the pump are integrated in the
pump. This, however, does not apply for the charge pump. The charge pump, is integrated in the vibra-
tion pump.
Fig. 3 Travel pump
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -E5-
Service Training
Cut through travel pump
2
4
5
1 3
9
10
8
11
Fig. 4 Cross-sectional view of travel pump
1 Retainer for swash plate 7 Swash plate bearing

2 Sliding piston 8 Swash plate guide
3 Control piston 9 Swash plate
4 Servo arm 10 Swashing lever
5 Servo valve 11 Charge pump (only in vibration pump)
6 Feedback unit
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -E6-
Service Training
View of roating assembly group
1
2
5 4 3
Fig. 5 Travel pump, view of rotating assembly group
1 Working pistons
2 Slipper pad
3 Preloading spring
4 Cylinder block
5 Drive shaft
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -E7-
Service Training
Description of function
Fig. 6 Function of travel pump
1 Drive shaft 5 Cylinder block

2 Drive shaft bearing 6 Multi-function valves
3 Swash plate 7 Charge pump (only in vibration pump)
4 Piston with slipper pads 8 Valve plate
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling and in turn drives the
cylinder block (5) via the splines on the drive shaft.
The cylinder block rotates with the drive shaft (1) and carries the working pistons (4). The pistons abut
with their slipper pads against the sliding face of the swash plate (3). If the swash plate is moved out of
neutral to one of the two possible oil flow directions, the working pistons will perform a full stroke during
each rotation of the cylinder block..
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -E8-
Service Training
The slipper pads are hydrostatically balanced and a retaining device holds them on the sliding surface
of the swash plate.
During a full rotation of the cylinder block each piston will move through the upper and lower dead cen-
ters back to its initial position. During this movement the pistons perform a full stroke.
During this piston stroke an oil quantity in accordance with the piston area and the length of the stroke
is sucked in through the control slots in the valve plate (8) and forced out again into the pressure hose.
Mechanical - hydraulical displacement control MA
The mechanical - hydraulical displacement control (servo control) converts the mechanical input signal
at the pump control lever (1) into a position controlling output signal. This position controlling signal de-
termines the swashing angle of the swash plate (8) and thereby also the displacement of the travel pump
as well as the swashing direction and therefore obviously also the flow direction of the pressure fluid.
The flow rate produced by the variable displacement pump is proportional to the value of the mechanical
input signal. A mechanical feedback ensures the fixed correlation between the mechanical input signal
and the swashing angle of the swash plate.
A mechanical safety device (spring) makes sure that a too fast movement of the control lever does not
damage the servo control.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -E9-
Service Training
Thermostat
housing
Fig. 7 Tandem pumpe with connections, BW 216
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - E 10 -
Service Training
1 Control solenoid, high frequency (vibration pump)
2 Control solenoid, low frequency (vibration pump)
3 Multi-function valve 425 bar (charging and pressure limitation), travel system
4 Charge pressure port to solenoid valve for brake and speed range,charging of vibration pump
5 Multi-function valve 425 bar (charging and pressure limitation, travel system
6 Adjustment screw, mechanical neutral position
7 Port L, leak oil connection to vibration pump
8 Travel control lever
9 Pressure test ports, pilot pressure
10 High pressure port B, high pressure in reverse
11 Charge pressure relief valve, 25 bar
12 Adjustment screw, low frequency
13 Port L2, leak oil to tank
14 Pressure test port MB, high frequency
15 Pressure test port MA, low frequency
16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 Charge pump (only in vibration pump)
19 Port L2, to drum drive motor 51 C 110 (flushing)
20 Adjustment screw, high frequency
21 Port D, charge pressure to filter
22 Multi-function valve 370 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between haydraulic oil tank and charge pump
24 Multi-function valve 370 bar (charging and pressure limitation), vibration low frequency
25 Charge pressure relief valve, vibration pump (blocked)
26 Port E, charge oil from travel pump
27 Port L1, leak oil connection to travel pump
28 Pressure test port MB, high pressure reverse
29 Charge oil from filter
30 Pressure test port MA, high pressure forward
31 High pressure port A, high pressure forward
32 Port C, connection from solenoid valve for brake/speed range selector
33 Leak oil port D, leak oil from axle drive motor
34 Leak oil port A, leak oil from travel pump
35 Leak oil port G, leak oil from drum drive motor
36 Leak oil port F, leak oil from vibration motor
37 Leak oil port B, leak oil to oil cooler
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Fig. 8 Tandem pumpe with connections, BW 219 / BW 225
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1 Travel pump
2 Multi-function valve 425 bar (boost check valve and pressure relief valve), travel system
3 Adjustment screw, mechanical neutral position, travel pump
4 Charge port to vibration pump and connection P to solenoid valve, speed range selector
5 Multi-function valve 425 bar (boost check valve and pressure relief valve), travel system
6 Multi-function valve 425 bar (boost check valve and pressure relief valve), vibration system
7 Multi-function valve 425 bar (boost check valve and pressure relief valve), vibration system
8 Port L, leak oil from travel pump
9 Port D, charge pressure to hydraulic oil filter
10 Port E, charge pressure from travel pump (charging system)
11 Adjustment screw, frequency
12 Adjustment screw, mechanical neutral position, vibration pump
13 Pressure test port MB, high pressure travel system
14 Charge port, from hydraulic oil filter
15 High pressure port B, to axle drive motor, left
16 High pressure port B, to drum drive motor, rear
17 Port L, leak oil to drum drive motor
18 Vibration pump
19 Charge pressure relief valvbe, blocked, vibration pump
20 Pressure test port MB, high pressure, vibration system
21 Port L, leak oil to tank port A
22 Port L, connection to vibration pump
23 High pressure port A, to drum drive motor, front
24 High pressure port A, to axle drive motor, right
25 Pressure test port MA, high pressure travel system
26 Charge pressure relief valve, 25 bar
27 Adjustment screw, frequency
28 Port S, suction line from hydraulic oil tank, internal charge pump
29 High pressure port A, vibration
30 Pressure test port MA, high pressure vibration system
31 High pressure port B, vibration
32 Internal charge pump
33 Port C, connection to solenoid valve for brake/speed range selector
34 Leak oil port D, leak oil from axle drive motor
35 Leak oil port A, leak oil from travel pump
36 Leak oil port G, leak oil from drum drive motor
37 Leak oil port F, leak oil from vibration motor
38 Leak oil port C, leak oil to oil cooler
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Benefits and particularities of the control unit
Servo1.eps
Fig. 9 Displacement control
1 4/3-way valve
2 Control lever
3 Neutral position spring
4 Orifice (0.8 mm)
5 Non-return valve
The displacement of the pump can be altered with the travel lever via the travel control cable and the
pump control lever. This requires only little force and only a little movement of the lever.
Förderv.eps
Fig. 10 Cross-section of servo control
The mechanical safety feature of the control allows rapid changes of the input signal.
The extremely accurate fits are the prerequisite for the precise transmission of the input signal.
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Servo control
The servo control (mechanical - hydraulical displacement control) converts the mechanical input signal
from the pump control lever into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (the displacement of the pump), as well as the supply
direction (flow direction of pressure fluid).
The oil quantity delivered by the pump is proportional to the value of the mechanical input signal. A me-
chanical feedback device ensures the correct correlation between mechanical input signal and swa-
shing angle of the swash plate (displacement of pump).
2 3
Fig. 11 Control piston
1 Adjustment screw for mechanical neutral position

2 Pressure spring
3 Control piston
4 Control pin receptacle
A mechanical lock (spring) makes sure that a too fast lever movement will not cause any damage to the
servo control.
The pump displacement can be altered by operating the pump control lever via the travel control lever
and the travel control cable. This requires only very little forces and only a slight movement of the lever.
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Due to the spring centring of the control the swash plate will automatically return to neutral position, in-
terrupt the oil flow and brake the machine under the following conditions:
• when shutting the engine down,
• if the external control cable comes loose,
• if the charge pressure fails.
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Multi-function valves
High pressure limitation
The pumps of the series 90 are equipped with a sequential valve, which will activate a pressure override
and a pressure relief valve, one after the other.
Once the preadjusted pressure value is reached, the pressure override valve will move the swash plate
very quickly back towards neutral position, thereby limiting the system pressure. The average response
time is less than 90 ms.
In case of a very sudden pressure increase (pressure peaks) the system uses the function of the pres-
sure relief valve to protect the system. In such an instance the pressure override valve works as a pilot
control for the piston of the pressure relief valve. The pressure relief valve, the pressure setting of which
is higher than the pressure setting of the pressure override valve, is only used if the pressure override
is not able to destroke the pump quickly enough in case of sudden pressure peaks.
Pressure override valve and high pressure relief valves are all located inside the multi-function valve in
the pump case. This so-called multi-function valve is a further development and a better kind of pressure
limitation.
1
2
6 5
Fig. 12 Multi-function valves
1 to the control 6 Output shaft

2 Multi-function valve 7 to the servo piston
3 Charge pump 8 to the servo piston
4 Charge pressure relief valve A Port A
5 Pilot pressure relief valves B Port B
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The pressure override function limits the pressure without overheating the system, whereas the high
pressure relief valve cuts off sudden pressure peaks.
Since the pressure relief valve will only respond to very sudden pressure peaks, the development of
heat is limited to only a fraction of time.
2
1
3
4
11
6
8
7
9
10
Fig. 13 Multi-function valve, details
1 Hydraulic by-pass piston 7 Pressure limitation

2 Spring cup 8 Spring
3 Spring 9 By-pass housing
4 High pressure relief valve 10 By-pass sleeve
5 Valve seat 11 Reduction
6 Non-return valve
Function of the pressure override
If the pressure in the system exceeds the setting of the pressure override valve the pressure fluid will
flow through the pressure valve (A) and through a restriction in the control piston into the passage (B)
and allows the pressure on the servo side to increase. Here the pressure is normally lower.
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The low pressure relief valve in (C) limits this pressure to a suitable level.
The pressure override valve overrides the the signal of the displacement control and causes an equili-
brium of the pressures on both sides of the control piston. The resetting torques of the swash plate chan-
ge the displacement until the system pressure has dropped again down to the adjusted pressure level.
Note:
When installing a multi-function valve it must be tightened with a torque of 15 Nm!
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Charge pressure relief valve
The charge pressure relief valve is a fixed, direct acting valve and is part of the group of safety elements
in a closed hydraulic cuircuit. This valve limits the pressure in the charge circuit to the value determined
by the setting of this valve (approx. 29 bar).
The charge circuit has the function to compensate leakages and flushing quantities in the closed travel
and vibration circuits and to provide the required pressure oil for the control of the travel and vibration
pumps, the speed range selection and the actuation of the multi-disc brakes in the travel drives.
Since the entry of cooled and filtered oil is only possible in the low pressure side of a closed hydraulic
circuit, the pressure in the low pressure side is almost identical with the charge pressure.
When the machine is parked on level ground with the engine running, both sides of the closed travel
circuit will be under charge pressure.
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Axle drive motor
The axle drive motor is a swash plate operated Sauer-Sundstrand axial piston motor (series 51 D 110)
with variable displacement.
2 3
1
10
9
6 5
8
7
Fig. 14 Axial piston motor
1 Min. swashing angle adjustment screw

2 Cylinder block
3 Synchronisation joint
4 Drive shaft
5 Tapered roller bearings
6 Working piustons
7 Control
8 Pressure relief valve
9 Control piston
10 Valve plate
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The motor can be controlled between two fixed displacements. This changes the angle between the cy-
linder block and the output shaft.
With a big swashing angle the motor works with maximum displacement, slow speed and high torque.
When changing the swash plate position to minimum angle the motor will work with minimum displace-
ment, high speed and low torque.
The displacement is changed by a control piston, which is connected with the valve segment. The dis-
placement is changed by guiding oil from the charge circuit via a 4/2-way solenoid valve to the respec-
tive control piston side.
Function
The motor is connected to the travel pump via the high pressure ports A and B. The high pressure hy-
draulic oil flows through the respective high pressure port to the back of the working pistons. Since these
pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a stroke
and cause the rotation of the connected output shaft.
Once the respective piston has exceeded its dead center (max. outstroke position), it will change over
to the low pressure side. As the rotation continues, the piston will move back into the cylinder. This pres-
ses the oil out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with spherical rollers ensures even rotation of the output shaft and the cylinder
block. The ball joints of each piston run in journal bearings, which are press-fitted in the output shaft.
For the connection of the output shaft to the pistons no other parts are required. The output shaft is run-
ning in two tapered roller bearings.
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Drum drive motor with reduction gear
2 4
3
1
5
10
9 8
Fig. 15 Planetary gear CR 31 BW 216 D-3
1 Travel motor 6 Sun gear

2 Tapered roller bearing 7 Planet carrier
3 Spur wheel 8 Brake discs
4 Hollow wheel 9 Mechanical seal
5 Planet wheel 10 Brake piston
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6
3 4 5
7 8 9 10
2
11
1 7
12
13
16
15 14
Fig. 16 Planetary gear CR 51 BW216 DH-3/PDH-3, BW 219 und BW 225
1 Travel motor 9 Planet wheel 2. step

2 Brake releasing device 10 Planet wheel 3. step
3 Mounting flange, frame 11 End cover
4 Mechanical seal 12 Planet shaft
5 Oil filler plug 13 Sun gear
6 Housing and mounting flange to drum 14 Brake discs
7 Tapered roller bearing 15 Brake piston
8 Planet wheel 1. step 16 Brake spring
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The drum of the machine is driven by a swash plate operated Sauer axial piston motor of series 51 C
110. The motor is almost identical with the axle drive motor. A detailed description is therefore not ne-
cessary.
The motor is a fast rotating hydraulic motor. Since the output speed of the motor is too high to drive the
drum, the speed is reduced to the required value by a reduction gear.
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Brake control
During operation the closed hydrostatic travel circuit has the function of a service brake. When shifting
the travel lever from full forward or reverse to neutral , the travel pump will also be returned to neutral
position. This reduces the oil flow and brakes the machine hydraulically. When setting the travel lever
to neutral position, the pump will swash back to neutral, the oil supply is stopped and the machine is
hydraulically braked to standstill.
Since slight leakages in the hydraulic circuit cannot be avoided and such leakages can cause creeping
of the machine when it is parked on a slight inclination with the engine running, the machine is additio-
nally fitted with multi-disc brakes in the drum drive and in the rear wheel drives. When engaging the tra-
vel lever in neutral position the multi-disc brakes will close and the machine can be stopped on a slope
with the engine running without the risk of rolling back.
These parking brakes can, however, also be operated via a 3/2-way solenoid valve. If the solenoid is
deenergized the multi-disc brakes in the travel drives are unloaded. The charge oil supply is interrupted
and the oil from the brake housings flows as leakage oil back to the tank.
If the brake solenoid valve is supplied with current while the engine is running and the brake is released,
the brake line to the tank is interrupted and the oil will flow from the charge circuit to the brake pistons.
The oil pressure acts against the spring pressure of the brake spring and relieves the brake discs.
Brake releasing device

in operation position
Brake releasing device

in position „brake manually
released“
Fig. 17 Manual brake releasing device
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Flushing valve
2 3 2
Fig. 18 Flushing valve
1 Flushing pressure relief valve

2 Adjustment spring for flushing spool
3 Flushing spool
Both axle drive and wheel drive motors are fitted with integrated flushing valves. The flushing valve has
the function to release a certain amount of oil from the low pressure side of the closed circuit as soon
as the pressure increases in one of the sides of the travel circuit.
The pressure difference between the two sides of the closed circuit (A and B) operates the valve. If the
pressure increases in one side this higher pressure will move the valve spool out of neutral position,
against the neutral setting spring. Oil can now flow out of the low pressure side. This opil flows through
a thermostat valve back to the tank. The flushed out oil quantity is immediately replaced via the respec-
tive boost check valve (part of the multi-function valve) with oil from the charge circuit.
In this way the closed travel circuit is always provided with cooled and filterd oil and the temperature of
the hydraulic system is maintained at a permissible level.
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Travel pump Vibration pump
Hydraulic
oil filter
Hydraulic
oil tank
Rear axle
Axle
motor
Drum drive
motor with
reduction gear
High pressure
Low pressure
Charge pressure
Leak oil
Fig. 19 Routing of hoses, travel circuit BW 219 DH-3/PDG-3 / BW 225 D/PD-3
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Vibration pump
Travel pump
Hydraulic
oil filter
Hydraulic
oil tank
Rear axle
Drum drive Axle drive

motor with motor
reduction gear
High pressure
Low pressure
Chartge pressure
Leak oil
Fig. 20 Routing of hoses, travel circuit BW 216D-3/DH-3/PDH-3
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Vibration pump
Travel pump
Brake valve
Drum drive
motor with
reduction gear
Rear axle
Charge pressure
Brake pressure
Leak oil
Fig. 21 Routing of hoses, brake syystem BW 219 DH-3/PDH-3 / BW 225 D/PD-3
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Vibration pump
Travel pump
Brake valve
Drum drive
motor with
reduction gear
Rear axle
Charge pressure
Brake pressure
Leak oil
Fig. 22 Routing of hoses, brake system BW 216 D-3/DH-3/PDH-3
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Trouble shooting travel system
The following description of trouble shooting procedures consists of a small selection of possible faults
which may occur during operation of the roller. The list is by no means complete, but the description
should help to become acquainted with systematic trouble shooting.
The problems and trouble shooting steps described in this training manual are identical with the faults
and steps described in the operation and maintenance manual for the machine.
However, in this training manual we have tried to explain the individual steps in more detail, in order to
explain why certain trouble shooting steps are necessary and why certain preparations must be made
before being able to conduct a specific measurement or test.
After this training course the participants should be able to apply the correct trouble shooting steps, even
if the actual fault is not described in this manual.
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The machine moves with the travel lever in „NEUTRAL“
Check neutral
position Fig. F1
no Adjust travel control

OK ? cable Fig. F2
yes
Check mechanical 0-
position Fig. F3
no Adjust mechanical
OK ?
0-position Fig. F4
yes
Check the servo

contro Fig. F5
no Replace the servo

OK ? control
ja
Replace the travel

pump
Fehlersuche Walzenzüge Generation 3 ETr 2

Service Training
Check he control Machine does not move (both travel directions)
cable (torn /
detached)
no Replace / attach the

OK ? control cable
yes
Check charge
pressure Fig. F6
no Check function of steering

OK ? or moveability prüfen
yes
Replace
High pressure test no steering/
Fig. F9 OK ?
charge pump
yes
no
OK ?
yes
Check magnetic coil of Check charge pressure

brake valve Fig. F10 relief valve Fig. F7
no no Replace the
OK ? OK ? charge pressure
Perform trouble relief valve
shooting in the
electric system yes yes
Check brake releasing Check leakage of brake

pressure Fig. F11 Fig. F8
Replace the
component after
no no the disconnection
OK ? OK ? of which the
Replace the brake charge pressure
valve value was OK
yes yes
Mechanical fault on
axle or drum

Service Training
Testing of individual parts
Check the drum drive

motor Fig. F12
yes Check drum drive motor

Pressures flushing valve (axial piston
OK ? motor), Fig. F14
no
Check axle drive motor /

travel pump Fig. F13 no
OK ?
Replace the
Check the axle yes flushing valve
motor flushing yes
Pressures
valve, Fig F14
OK ?
no Replace / repair the drum

drive motor
Check he servo control
no Fig. F5
OK ?
Replace the
yes flushing valve
no Replace the servo
OK ? control
Replace / repair the axle yes

drive motor
Replace / repair the travel
pump

Service Training
Insufficient travel power, max. speed not reached
Check the engine

speed Fig. F15
no Perform trouble shooting

OK ? on the engine
yes
Check travel cable for

play / wear
no Adjust / replace the

OK ? travel cable
yes
To continue see „Machine

does not drive“, starting with
„Checking the charge
pressure“
Hydraulic oil overheating (> 90°C)
Check the thermostat

valve Fig. F16
Thermostat no Replace the

opens ? thermostat valve
yes
Check the multi-function

valves Fig. F17
Check hoses for

Heating kinks / check
no
of valves ? components for
excessive heat
yes
Clean / replace the

respective multi-
function valve

Service Training
Fig. F1:
Checking the neutral position
With the travel lever in neutral position the machine must not move at all. In this operating condition the
travel pump is centred in neutral and both sides of the closed hydraulic circuit have identical pressure
(charge pressure).
If the machine moves in this condition on level ground, you should perform trouble shooting according
to the following steps.
• Set the travel lever to „neutral“-position.
• Detach the travel control cable from the travel pump.
• Start the engine (if there is no fault in the travel system the machine must stop).
• Check whether bores in ball socket and pump control lever are in line.
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Service Training
Fig. F2:
Adjusting the travel cable
• To adjust the travel control cable slacken the counter nut on the travel cable bracket.
• Turn the adjustment nut until the corerct neutral position is reached (bores are in line).
• Retighten the counter nut.
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Fig. F3:
Checking the mechanical neutral position
The mechanical neutral position of the travel pump determines the mechanical position of the pump
control piston. This piston is connected with the swash plate and its position determines the position of
the swash plate. If the piston is outside the neutral position, the swash plate will actuate the working
pistons, thereby pumping oil to the travel motors.
• Connect both control chambers on the pump control with a hose.
• Start the engine.
• If the mechanical neutral position is correct, the machine must stop.
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Service Training
Fig. F4:
Adjusting the mechanical neutral position
If te machine does still move after connecting the control chambers, the mechanical neutral position of
the pump nees to be adjusted.
• Connect 600 bar pressure gauegs to the high pressure test ports.
• Pull the plug off the brake solenoid valve and block the drum.
• Run the engine with maximum speed.
• Read the pressure gauges and adjust the mechanical neutral position by turning the adjustment
screw mechanische on the control cyloinder (see illustration), until the pressure readings are identical
on both sides (charge pressure).
For a more accurate reading repeat this test and adjustment procedure with two 60 bar pressure gau-
ges.
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Fig. F5:
Checking the servo control
• Remove the servo control.
• Check piston and linkage for mobility and wear.
• Check the nozzles, clean if necesary.
Replace a defective servo control immediately.
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Service Training
Fig. F6:
Checking the charge pressure
• Connect a 60 bar pressure gauge to the charge pressure test port.
• Start the engine and run it with max. speed
Nominal value: BW 216: 25 +/-1 bar;BW 219-225: 29 +/- 1bar .
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Fig. F7:
Checking the charge pressure relief valve
• Unscrew the valve and check for dirt and damage.
Replace a defective charge pressure relief valve immediately.
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Service Training
Fig. F8:
Checking the leakage of the brake
A leakage of the brake can cause a considerable charge pressure drop and thereby avoid opening of
the brake.
• Release the brake by shifting the travel lever out of the brake position gate.
• Loosen the brake lines to drum drive motor and axle drive one after the other, close them with suita-
ble plugs and repeat the charge pressure test.
Repair the respective component, after the disconnection of which the charge pressure is correct.
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Service Training
Fig. F9:
Checking the high pressure
• Connect 600 bar pressure gauges to the high pressure test ports.
• Pull the plug off the brake valve and block the drum.
• Start the engine and run it with full speed.
• Drive the machine against the closed brake by actuating the travel lever for a short time and read the
pressure gauges.
Nominal values: High pressure 435 +/-15 bar,

Charge pressure: BW 216: 25 +/- 1 bar; BW 219-225: 29 +/-1 bar
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Service Training
Fig. F10:
Checking the magnetic coil of the brake valve
• Start the engine and release the brake (shift the travel lever out of the brake position gate).
• Measure the applied voltage and the current consumption on the magnetic coil of he solenoid valve.
Nominal value: 12 V / ca. 5 A
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Service Training
Fig. F11:
Checking the brake releasing pressure
If the brake valve does not open, no oil will flow from the charge circuit to the brakes and the brake discs
cannot be opened.
• Install a pressure test port and a 60 bar pressure gauge into the brake line.
• Start the engine and release the brake (shift the travel lever out of the brake position gate)
• Read tzhe pressure gauge.
Nominal values: BW 216: 25 +/- 1 bar (charge pressure)

BW 219 – 225: 29 +/- 1 bar (charge pressure)
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Service Training
Fig. F12:
Checking the drum drive motor
• Disconnect the high pressure hoses from the drum drive motor and close them with plugs.
• Perform a high pressure test (Fig. 9)
If the nominal pressure values, which were not reached while the motor was still connected, are now
reached, there must be a defect in the drum drive motor. If the pressure values are not reached, the fault
must be in the axle drive motor or inside the travel pump.
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Service Training
Fig. F13:
Checking the axle drive motor / travel pump
• Disconect the high pressure hoses from the travel pump.
• Close the ports on the pump with high pressure plugs.
• Perform a high pressure test (Fig. F9)
If the pressures are now reached and the drum drive motor is OK, the fault must be inside the axle drive
motor. If the high pressure values are not reached, the fault must be in the pump.
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Service Training
Fig. F14:
Checking the flushing valves on axle and drum drive motors
In case of a faulty flusing valve a too high oil quantity may be flushed out, so that the chharge circuit will
no longer be able to replace this quantity. The charge pressure will drop and important machine
functions are no longer possible.
• Pull the valve spool out of the flushing valve.
• Check for mobility and wear.
Replace a defective flushing valve immediately.
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Service Training
Fig. F15: back to vibration:
Checking the engine speed
• Start the engine and run it with max. speed.
• Check the engine speed with a suitable measuring instrument (e.g. a digital optical rpm-meter).
Nominal value: 2300 rpm (high idle)
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Service Training
Fig. F16:
Checking the thermostat valve
If the hydraulic oil heats up to a too high temperature it will loose its lubrication properties, which may
cause damage to important compojnents in the hydraulic system.
In case of a too high hydraulic oil temperature shut down the engine immediately, let the system cool
down and perform trouble shooting. Do not restart the machine before the fault has been eliminated.
Check the function of the thermostat valve as a first measure. Up to a temperature of 60°C all leak oil,
flushing oil and return flow quantities are guided back directly to the tank. At a temperature of 60°C the
thermostat valve should start to guide hydraulic oil via the hydraulic oil cooler back to the tank.
• Feel with your hand whether the hose to the hydraulic oil cooler starts to become warm at a hydraulic
oil temperature of 60°C.
• If the thermostat valve does not open, it must be replaced immediately.
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Service Training
Fig. F17:
Checking the multi-function valves
The cross-sections of the high pressure relief valves inside the multi-function valves are very small. Hy-
draulic oil escaping from the high pressure side through the high pressure relief valve (e.g. in case of a
defective pressure override, which is also part of the multi-function valve) will cause immediate overhea-
ting of the hydraulic oil.
• Pull the plug off the brake solenoid valve.
• Block drum and wheels with suitable chocks.
• Start the engine and run it with max. speed.
• Shift the travel lever to both directions and check the multi function valves for overheating.
If one of the valves overheats replace or clean it immediately.
Attention ! Tightening torque for multi-function valves 89 Nm
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Vibration
The vibration system on the single drum rollers BW 216 D-3, BW 216 DH-3/PDH-3, BW 219 DH-3/
PDH-3 and BW 225 D-3/PD-3 works with two different frequencies and amplitudes. This allows a perfect
adaptation of the machine to various types of soils and applications.
The vibration drive is a closed hydraulic circuit. The circuit consists of
• the vibration pump,
• the vibration motor and
• the connecting pressure resistance hydraulic hoses.
Charge pressure to
hydraulic oil filter
to brake valve
Leak oil to Leak oil to
thermostat valve thermostat valve
Suction line
from hydr. 2
1
oil tank
Fig. 1 Vibration circuit BW 219/BW225
1 Vibration pump
2 Vibration motor
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -F1-
Service Training
Charge pressure
to hydraulic oil filter
to brake valve
Leak oil to
thermostat valve
Leak oil to
thermostat valve
Suction line
from hydr.
oil tank 1
2
Fig. 2 Vibration circuit BW 216
1 Vibration pump
2 Vibration motor
Together with the travel pump and the charge pump the vibration pump is connected to a tandem pump
unit. This tandem unit is directly driven by the dieselk engine.
When actuating the 4/3-way solenoid valve on the pump control from neutral position to one of the two
possible switching positions, pilot oil from the charge circuit will be guided to the respective control pi-
ston side. This moves the swash plate inside the pump to the respective side against the end stop and
the pump will start to deliver oil to the vibration motor. The vibration motor starts to run and drives the
vibrator shaft inside the drum.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -F2-
Service Training
When altering the position of the swash plate through the neutral position to the opposite side the oil
flow direction will change and the vibration motor will rotate to the opposite direction.
Since the end stops for the swash plate to both directions are adjusted for different swashing angles,
the angle of the swash plate to the stroke direction of the pistons is also different to both sides. This
angle effects the length of the piston stroke and therefore the actual displacement of the pump.
• Large angle = high displacement = high vibrator shaft speedl (frequency)
• Small angle = low displacement = low vibrator shaft speed (frequency)
The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending
on the sense of the exciter shaft rotation these weights will add to or subtract from the basic weight.
This results in the following constellations:
• Basic weight + change-over weight = high amplitude
• Basic weight - change-over weight = low amplitude
To allow most effective compaction results the vibration system is designed in such a way, that the high
amplitude works with the low frequency and the low amplitude works with the high frequency.
Fig. 3
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -F3-
Service Training
Vibration pump
Similar to the travel pump, the vibration pump is also a swash plate operated Sauer-Sundstrand axial
piston pump with variable displacement for operation in closed hydraulic circuits..
Charge pressure to
to brake valve
Leak oil to
thermostat valve
1
2
3
Suction line
from hydr.
oil tank
1 Vibration pump
2 Charge pump
3 Multi-function valves
4 4/3 way solenoid
valve
4
5 Charge pressure
relief valve (blocked)
Fig. 4 Vibration pump BW 219 / BW 225
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -F4-
Service Training
Charge pressure to
to brake valve
Leak oil to
thermostat valve
Suction line
from hydr.
oil tank
1 Vibration pump
2 Charge pump
3 Multi function valves
4 4/3 way solenoid
valve
5 Charge pressure
relief valve (blocked)
Fig. 5 Vibration pump BW 216
The pump flow rate is proportional to the engine speed and the chosen pump displacement.
When moving the swash plate out of neutral position, the oil flow to the chosen direction will increase
from “0" to maximum oil flow. When altering the swash plate position through the neutral position to the
opposite side, the oil flow will be reversed and the senso of rotation of the vibration motor will change.
All valves and safety elements for the operation of a closed circuit are integrated in the pump.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -F5-
Service Training
Vibration pump, cross-sectional view
Verstel&.eps
Fig. 6 Cross section of vibration pump BW 219 / BW 225
1 Drive shaft
2 Drive shaft bearing
3 Swash plate
4 Piston with slipper pads
5 Cylinder block
6 High pressure relief valve
7 Charge pump
8 Valve plate
The engine drives the drive shaft (1) with the cylinder block (5). The cylinder block carries the working
pistons (4).
The slipper pads abut against the sliding surface of the swash plate while a retaining device holds them
on the sliding surface.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -F6-
Service Training
During each revolution the pistons move through their upper and lower dead centers back to their initial
positions. Between the two dead centers each piston performs a full working stroke. During this stroking
movement oil is sucked in from the low pressure side and pressed out again through the slots in the
valve plate (8) into the high pressure side. The oil quantity depends on the piston area and the length
of the working stroke.
During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure in the low
pressure side presses it in. On the opposite side the piston presses it out into the high pressure side of
the closed circuit.
Control
Control piston
Control valve
Friction-free
Flange
swashing
plate
cradle bearings
Cylinder- Piston Output shaft

block
Fig. 7 Cross-sectional view of vibration pump BW 216
Control
The electric-hydraulic displacement control (remote control) converts the electric input signal into a load
dependent output signal. Since the pump is not fitted with a proportional control, but with a 12 Volt so-
lenoid valve, the pump will always be fully actuated to either side.
High pressure protection
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -F7-
Service Training
In order to secure the closed vibration circuit against too high pressures, the vibration pump is fitted with
multi-function valves. The function of these valves is described in the chapter "travel system". A detailed
description is therefore not necessary.
In order to protect the closed vibration circuit against too high pressures the vibration pump is fitted with
high pressure relief valves. The multi-function valves limit this pressure peaks to a value of max. 454
bar (pressure difference between high and low pressure side = 425 bar + charge pressure = 29 bar).
Note:
On the machines BW 216 D-3 and BW 216 DH-3/PDH-3 high pressure relief valves are used instead of
the multi-function valves (see BW 213 DH-3/PDH-3). These valves are adjusted to a pressure of 370
bar.
The screw-type high pressure relief valve cartridges contain also the boost check valves for the closed
vibration circuit. Leakages in the individual travel system components are compensated by the charge
circuit via the boost check valves in the travel pump.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -F8-
Service Training
Charge pump
The charge pump for the travel system and the vibration circuit is arranged inside the housing of the
vibration pump. The pump is an internal gear pump with fixed displacement.
The oil flow generated by the charge pump is joined together with the return flow from the steering valve
just before the hydraulic oil filter and flows through the filter to the boost check valves in the travel pump
and in the vibration pump.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -F9-
Service Training
Vibration motor
The vibration motor is a Sauer-Sundstrand axial piston motor series MMF 044 with fixed displacement
and swash plate design. Since the motor is suitable for pressures from either side, it is perfectly suitable
for closed circuit applications.
The output speed of the motor depends on the oil flow provided by the vibration pump.
Vibmot2.eps
Fig. 8 Vibration motor
1 Flushing block
2 Flushing valve
3 Cylinder block
4 Piston with slipper pads
5 Roller bearing for output shaft
6 Radial seal
7 Output shaft
8 Swash plate
9 Retaining plate
10 Tensioning spring
11 Flushing pressure limitation valve
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - F 10 -
Service Training
The drive torque increases with increasing pressure difference between the high and low pressure sides
of the closed circuit.
Reversing the flow direction of the oil reverses also the sense of rotation of the vibration motor.
When the vibration motor is switched on, the motor mustb first accelerate the vibrator shaft from stand-
still to full speed. This resistance causes a hydraulic starting pressure, which is limited to 345 bar by the
respective high pressure relief valve. Once the vibrator shaft has reached its final speed the pressure
will drop to 100 - 150 bar (operating pressure). This pressure is mainly depending on the condition of
the ground (degree of compaction, material etc.).
• Hard ground = high operating pressure
• Loose ground = low operating pressure
Vibmot.eps
Fig. 9 Hydraulic diagram vibration motor
1 Vibration motor
2 Flushing valve
3 Flushing pressure limitation valve
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - F 11 -
Service Training
The vibration motor is fitted with an integrated flushing valve. When switching the vibration on, different
pressures will build up in the two sides of the closed circuit. The higher pressure will move the valve
spool of the flushing valve against the neutral setting spring and oil will be flushed out of the low pressure
side.
A 13 bar pressure relief valve is installed in the line after the flushing valve. This valve makes sure that
only a certain quantity of oil is flushed out of the low pressure side.
This opil flows through a thermostat valve back to the tank. The flushed out oil quantity is immediately
replaced via the respective boost check valve (part of the multi-function valve) with oil from the charge
circuit.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - F 12 -
Service Training
Drum
4
14
5 9
7 13
6
10
3 8 11
12
Fig. 10 Cross-sectional view of drum
1 Drum shell 8 Change-over weight

2 Vibration bearing 9 Coupling vibr.-motor – vibrator shaft
3 Basic weight 10 Travel bearing
4 Vibration bearing housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Vibrator shaft 13 Vibration motor
7 Elast. coupling between shafts 14 Flanged housing
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - F 13 -
Service Training
Hydr.-
oil
Hydraulic filter
oil cooler
Vibration
pump
High pressure
Low pressure
Vibration Charge pressure

motor Leak oil
from oil cooler to tank
from thermostat to oil cooler
Fig. 11 Routing of hoses, vibration circuit BW 219 DH-3/PDH-3 / BW 225 D-3/PD-3
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - F 14 -
Service Training
Hydraulic Vibration Hydr.-

oil cooler pumpe oil
filter
High pressure
Vibration
Low pressure
motor
Charge pressure
Leak oil
from oil cooler to tank
from thermostat to oil cooler
Fig. 12 Routing of hoses, vibration circuit BW 216 D-3/DH-3/PDH-3
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - F 15 -
Service Training
Trouble shooting vibration
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - FTr 1 -
Service Training
No vibration (travel system OK)
Check vibration
pressures Fig V1
Charge pr. OK
Charge pr. OK Starting pr. too
Stating pr. zero low
Check magnetic Check coupling on
coil on vibration OK ? vibration motor
valve Fig. V4 Fig. V2
Charge press. /
Starting pr. to low
Voltage / no Check vibration
current OK ?
pump Fig. V3
yes Perform trouble Repace / repair the

shooting in electric no
OK ? vibration pump
system
yes
Check the solenoid Check vibration motor

valve, replace if flushing valve, Fig. V7
necessary
no Replace the flushing

OK ? valve
yes
Replace / repair the

vibration motor
Fehlersuche Walzenzüge Generation 3 FTr 2

Service Training
Vibration works only with either high or low amplitude
Check the magnetic

coil of the vibration
valve Fig. V4
Voltage / no Perform trouble

current OK ? shooting in electric
system
yes
Check the solenoid valve
no Replace the solenoid

OK ? valve
yes
Check the high pressure

relief valve for the faulty
amplitude, clean or replace
if necessary

Service Training
Vibration frequency too low (travel system OK)
Check the engine
speed Fig. F15
no Perform trouble shooting

OK ? on the engine
yes
Speed no Adjust speed for low or high

drop > 10%? frequency Fig. V5
yes
a
Check vibration
pressures Fig. V1
Charge pr. OK
Operating pr. too
high
Check vibration
OK ? bearings, replace if
necessary Fig. V6
all pressures to low
Check the vibration

pump Fig. V3
no Replace / repair the

OK ? vibration pump
yes
Check the vibration motor

flushing valve Fig. V7
no Replace the flushing

OK ? valve
yes

vibration motor

Service Training
Fig V1:
Checking the vibration pressures
A too low charge pressure is an early indicator for a fault (leakage) in the closed circuit or in the charge
circuit. The pump cannot be correctly actuated.
A too low starting pressure indicates extreme leaks in the closed vibration circuit or a defective vibartion
coupling.
A too high operating pressure is an indicator for damaged vibration bearings or a too high filling level in
the vibrator housings.
• Connect 600 bar pressure gauges to the high pressure test ports.
• Stand the drum on rubber tires.
• Run the engine with full engine speed.
• Switch the vibration on and read the pressure gauges.
Nominal values: Charge pressure: BW 216: 25 +/- 1 bar; BW 219 - 225: 29 +/- 1bar
Starting pressure: BW 216: 350 +/- 50 bar; BW 219 – 225: 410 +/- 20 bar
Operating pressure on rubber tires: low amplitude approx. 80 +/- 20 bar
high amplitude approx. 140 +/- 25 bar
BW 216 BW 219 / BW 225
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Fig. V2:
Checking the coupling on the vibration motor
• Remove the vibration motor.
• Check the coupling parts between motor and shaft.
• Replace defective parts.
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Fig. V3:
Checking the vibration pump
• Close the high pressure ports on the vibration pump with suitable plugs.
• Check the vibration pressures, see Fig. V2
If the pressure values are now reached but not with the connected vibration motor, the vibration motor
is faulty and must be replaced. If the pressures are not reached replace the vibration pump.
BW 216 BW 219 / BW 225
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Fig. V4:
Checking the magnetic coil of the vibration control valve
• Switch the ignition on.
• Switch on vibration at high or low frequency.
• Check voltage and current draw on the magnetic coil with a multi-meter.
Nominal values: 12V / 2,5 A
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Fig. V5:
Adjusting the speeds for high and low frequency
If the engine speed is correct and the drop in vibrator shaft speed is less than 10%, the respective fre-
quency must be adjusted on the vibration pump.
• Slacken the counter nut on the corresponding adjustment screw.
• Turn the adjustment screw until the required vibrator shaft speed is reached (the adjustment screw
for high amplitude sticks out further than the adjustment screw for low amplitude).
• Retighten the counter nut.
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Fig. V6:
Checking the vibrator shaft bearings
• Remove the vibration motor.
• Check the moveability of the vibrator shaft bearings.
• Replace defective parts.
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Fig. V7:
Checking the flushing valve on the vibration motor
• Unscrew the flushing valve from the vibration motor.
• Check the flushing spool for damage and moveability.
• Replace a defective flushing valve.
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Steering
The single drum rollers BW 216 D-3, BW 216 DH-3/PDH-3/BW 219 DH-3/PDH-3 and BW 225 D-3/
PD-3 are equipped with a hydrostatically operated articulated steering system.
The steering system consists mainly of:
• the steering/charge pump,
• the steering valve,
• the steering cylinders and
• the pressure resistant connecting hoses.
The steering pump delivers the hydraulic oil from the hydraulic oil tank to the steering valve and the con-
nected steering unit. If the steering is not operated the complete oil flow will be directly guided through
the fine filter to the charge ports for the closed hydraulic circuits for travel and vibration systems.
to the hydraulic
oil filter
from the steering/

charge pump
Lenkung.eps
Fig. 1 Hydraulic diagram steering
1 Rating pump
2 Distributor valve
3 Anti-cavitation valve
4 High pressure relief valve
5 Non-return valve
6 Shock valves
7 Anti-cavitation valves
8 Steering cylinders
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -G1-
Service Training
When turning the steering wheel the oil flow is guided through the distributor valve to the steering cylin-
ders.
A measuring pump inside the steering unit measures the oil quantity with respect to the steering angle
performed by the steering wheel and delivers it to the steering cylinders.
The steering cylinders extend or retract and articulate the machine.
The steering valve contains also a pressure relief valve. This valve limits the steering pressure to 175
bar. Since the oil is available for the charge system after it leaves the steering unit, the charge pressure
of 29 bar must be added to this pressure. The maximum steering pressure is therefore approx. 204 bar.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -G2-
Service Training
Steering/charge pump
The steering/charge pump is a gear pump with fixed displacement.
The pump is driven by the auxiliary drive of the diesel engine and draws the hydraulic oil directly out of
the hydraulic oil tank. The oil flows then via the steering valve and the fine filter to the boost check valves
in the travel and vibration circuits or, when operating the steering wheel, first to the steering cylinders.
Vib-pump.tif
Fig. 2 Steering pump
Function of the gear pump
The drive pinion of the steering pump is connected to the auxiliary drive of the engine via a coupling.
Driving pinion and driven gear are located by a bearing plate, so that the teeth of both gears mesh with
only minimum clearance.
The pumping chambers are formed by the tooth flanks, the inside wall of the housing and the front faces
of the bearing plates.
These chambers carry the hydraulic oil from the suction side to the pressure side. This causes a vacuum
in the suction side, which draws the hydraulic oil out of the hydraulic oil tank. The hydraulic fluid is trans-
ported in the tooth chambers from the suction side to the pressure side, from where it is then pressed
to the consumers. To ensure a safe function of the pump, the tooth chambers must be as tightly sealed
as possible, so that the hydraulic fluid can be transported from the suction side to the pressure side al-
most without any losses.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -G3-
Service Training
Outer gear pumps have gap seals. Depending on the operating pressure this will cause losses from the
pressure side to the suction side. To make sure that not to much oil is lost through these gaps during
operation, the bearing plate on the cover side is provided with an axial pressure field, whereby the bea-
ring plates are pressed against the faces of the gears.
These pressure fields are always loaded with system pressure.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -G4-
Service Training
Steering valve
The steering vale consists mainly of:
• the distributor valve,
• the rating pump,
• the steering pressure relief valve and
• the shock valves.
1
2
9 3
8
6
7 Orbit.eps
Fig. 3 Orbitrol valve
1 Neutral position springs

2 Housing
3 Inner spool
4 Outer spool
5 Universal shaft
6 Ring gear
7 Gear
8 Non-return valve
9 Pressure relief valve
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -G5-
Service Training
When turning the steering wheel the oil flow from the steering pump is guided through the distributor
valve to the rating pump and from there to the respective steering cylinder sides.
The rating pump determines the correct oil quantity in dependence on the turning angle of the steering
wheel.
The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar
+ charge pressure.
The steering unit carries so-called shock valves for each pressure side to the steering cylinders. These
valves are adjusted to 200 bar. They compensate extreme pressure peaks which could be introduced
into the system by e.g. driving over obstacles, thereby protecting the system against overloads.
Each of these shock valves is provided with an additional anti-cavitation valve. These anti-cavitation val-
ves protect the system against cavitation in case of a reaction of the shock valves.
A non-return valve at the inlet of the steering unit makes sure that no hydraulic oil can flow back to the
pump, if the machine would suddenly be actuated by external forces. In such a case the steering cylin-
ders would work as pumps and press the oil back to the steering pump.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -G6-
Service Training
Articulated joint
The articulated joint is the connection between the front frame with the drum and the rear frame with the
operator's platform, the diesel engine and the drive wheels.
Gelenk_2.eps
Fig. 4 Articulated joint
The rear console is tightly bolted to the rear frame.
The front console is fastened to the rear cross-member of the front frame with screws. Due to the rocker
bearings between front and rear console both frame sections of the machine can oscillate relative to
each other by +/- 12°. THis allows the machine to keep optimnal ground contact, even under extremely
difficult soil conditions.
The front console is connected to the rear console by means of two vertical pins. These vertical pins are
fitted in rocker bearings.
The front console carries the welded on bearing eyes for the steering cylinders.
When turning the steering wheel the steering cylinders will extend or retract. The piston rods will swivel
the front console around the vertical pins. The machine articulates and steers.
All bearing points on the articulated joint are maintenance free and do not require any lubrication.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -G7-
Service Training
Steering
Steering pump
valve
Hydr.-
oil
filter
Hydraulic
oil tank
Steering
cylinder
High pressure
Low pressure
Charge pressure
Suction line
Fig. 5 Routing of hoses, steering system BW 219 DH-3/PDH-3
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -G8-
Service Training
Steering
Steering pump
valve
Hydr.-
oil
filter
Hydraulic
oil tank
Steering
cylinder
High pressure
Low pressure
Charge pressure
Suction line
Fig. 6 Routing of hoses, steering system BW 216 DH-3/PDH-3
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -G9-
Service Training
Trouble shooting steering system
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - GTr 1 -
Service Training
No steering function / steering sticky / end stops are not reached
(travel system OK)
Check the steering

pressure Fig. L1
Check mobility of
yes steering cylinders and
OK ?
articulated joint
no
Check steering/
charge pump Fig. L2

no steering/charge
OK ? pump
yes
Check the steering

cylinder Fig. L3
Replace the
no respective steering
OK ?
cylinder
yes
steering valve
Fehlersuche Walzenzüge Generation 3 GTr 2

Service Training
Fig. L1:
Checking the steering pressure
• Connect a 600 bar pressure gauge to the steering pressure test port.
• Start the engine and run it with full speed.
• Turn the steering wheel against the end stop, hold it and read the pressure gauge
Nominal value: 225 +/- 15 bar
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Fig. L2:
Checking the steering/charge pumpo
• Install a 200 bar pressure relief valve between steering pump outlet and high pressure hose to the
steering valve.
• Connect a 600 bar pressure gauge.
• Start the engine (low idle speed) and read the pressure gauge.
Nominal value: 200 bar (adjustment value of the pressure relief valve)
If the steering pressure is not correct, replace the steering/charge pump.
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Fig. L3:
Checking the steering cylinders
• To find out whether a steering cylinder is defective, i.e. has an internal leakage you may disconnect
the hydraulic hoses „L“ and „R“ from the steering cylinders and close them with suitable plugs.
• Check the steering pressure (see Fig. L1): If the steering pressure is now reached, but not with the
steering cylinders connected, one of the steering cylinders is defective. After this test reconnect both
cylinders.
To find out which of the two cylinders is defective proceed as follows:
• Start the engine and, if possible, actuate the steering fully to left or right and hold the machine in this
fully actuated position.
• If the machine has been articulated to the left, the hoses for rod side of the left hand cylinder and the
piston side of the right hand cylinder must now be disconnected.
• Try< to steer to the same direction again as before. If hydraulic oil runs out of one of the cylinder the
respective cylinder is defective and must be replaced.
• Repeat this procedure to the opposite direction (the cylinders may only be leaking to one direction,
e.g. from piston to rod side and vice versa).
BW 216 D-3, BW 216 DH-3/PDH-3

Service Training
Electric system, single rollers generation -3
The new single drum rollers of generation -3 are equipped with two easy to change control logic modu-
les.
1 2 3 4 5 6 8
13 11 10
9
12
Fig. 1: Electric installation box
1 Relay K06 6 Relay K05 11 Generator module A23

2 Relay K26 7 Relay K11 12 Didode module
3 Relay K22 8 Fuse box 13 Terminal bar X1:
4 Relay K48 9 Relay K04
5 Relay K36 10 Relay K32
The electric installation box holds the following modules:
• Generator module (A23),
Simple trouble shooting is possible by simply bridging the input and output potentials.
The generator module is able to convert the different signals from various generator manufacturers into
a D+ signal. This allows to use different engines from various manufacturers, without having to change
the vehicle electrics for this purpose.
• Diode module
The diode module is used in the speed range logic for switching the different spee ranges.
The optionally available ASC (Anti Spin Control) provides optimal traction for wheels and drum. This en-
sures safe driving on difficult soil and maximum gradability on inclinations.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -H1-
Service Training
Power supply (Fig. 2)
Battery
When the engine is at rest the voltage supply for the vehicle electrics is accomplished via two parallel
connected rechargeable and maintenance free 12 V batteries.
The minus pole of the battery (G01:05,11) is connected to the vehicle ground (Potential 31).
The plus pole of the battery (G01:02,08) is connected to potential 30 via the main fuse (F00:02).
There is a direct connection between the battery (+),
• terminal B+ on the generator (G02:15),
• starter (M01:05) (Fig. 3) terminal 30.
• battery (-) minus to vehicle ground potential 31.
Note:
The potentials 30, 31 and B+ are always directly connected to the battery. The current can only be in-
terrupted by discharging or disconnecting the battery.
Generator
When the engine is running a 14 V generator (G02:16) supplies the vehicle electrics with current via
terminals B+ (to potential 30) and B- (to potential 31).
Terminal D+ supplies a (+) or (-) signal to the module for generator (A23:23). When the engine is at rest
terminal D+ is negative (ground potential). The charge control light in the fault monitoring board (A15)
(Fig. 3) lights up. See also section „Fault Monitoring Board“.
Sockets
The machines are fitted with two sockets (XS:36/XS:39). These are connected to potential 30 and pro-
tected via fuse (F05).
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -H2-
Service Training
Fig. 2:
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -H3-
Service Training
Ignition and starter circuit (Fig. 3)
Ignition switch (S00) in position "0" (ignition off)
The ignition switch (S00:04) is permanently energized from the battery (G01) (Fig. 2) via the main fuse
(F00) (potential 30) and fuse (F13:05).
In this position the connection to the coil of relay (K11:28) is interrupted and the relay drops off. The
solenoid valves (Y58:32) for fuel supply shut-off or (Y13:37) engine solenoid (depending on type of en-
gine equipment) are no longer supplied with electric current and the engine will stop.
Ignition switch (S00) in position "1" (ignition on) with the engine at rest
In this position the coil of relay (K11:26) is supplied with electric current.
Relay (K11) switches potential 30 to potential K11 (15/54). The fault monitoring board (A15) (Fig. 4) sup-
plies the coil of relay (K22:40) with current, the relay switches. Current flows now
• from potential K11
• via fuse (F14:37),
• the closed emergency stop switch (S01:37),
• the closed contacts of relay (K22:37)
• to the solenoid valve (Y58:32) for fuel shut-off or (Y13:37) the engine solenoid.
The engine is now ready for starting.
Ignition switch (S00) in position "3" (starting)
Note:
Position "2" is not used.
In this switch position current flows from terminal 50a on the ignition switch (S00:06) to the contact of
relay (K05:07).
If the travel lever is in "0" - and braking position, the proximity switch (B13:15) will open, the coil of relay
(K48:15) is no longer energizes and the contact switches over.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -H4-
Service Training
Current flows now
• via relay (K48:17)
• to the coil of relay (K05:09).
The contact closes and current can now flow to the starter (M01:05) terminal 50. The magnetic switch
of the starter is energized and the starter turns the diesel engine.
Note:
The starter (M01) receives electric current directly from potentials B+ and 31.
When releasing the ignition key the ignition switch will automatically return to position "1".
During the starting process a 50a signal is transmitted to the fault monitoring board (A15) (Fig. 4).
This signal makes sure that the warning buzzer will not sound and the automatic shut-down facility is
not activated during the starting process (see description of fault monitoring board).
To repeat the starting process the ignition must first be switched off (protection against repetitive star-
ting).
Ignition switch (S00) in position "1" (ignition on) with the engine running
When the engine is running the generator (G02) (Fig. 2) will produce electric current. This current flows
from terminal D+ to the generator module (A23). The output signal MD+ supplies the operating hour me-
ter (P00) with voltage.
The MD+ -signal is additionally fed to the fault monitoring board (A15) (Fig. 4) and to the brake control
relay (K36) (Fig. 6).
The internal logic of the fault monitoring board switches the charge control light off.
The automatic shut-off system in the fault monitoring board (A15) is activated and the warning buzzer
will sound whenever a fault occurs.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -H5-
Service Training
Fig. 3:
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -H6-
Service Training
Fault monitoring board (Fig. 4)
Ignition on, engine at rest
When switching the ignition on, the program is reset to a defined initial condition.
As a self-testing function all warning and control lights will light up for a moment.
Should a fault occur already at this stage, the respective indicator light will continue to light.
Warning buzzer (H07:22) and shut-down relay (K22:40) (Fig. 3) remain deactivated, because there is
no oil pressure yet. If the time between „ignition on“ and „starting“ was too long, starting would not be
possible.
Engine running
The fault monitoring board is active, warning buzzer and shut-down relay are enabled.
Within the determined times all sender signals must change to the respective potential for the condition
„OK“. If not the following lights will light:
• the signal fields,
• the warning buzzer is activated
• and the shut-down relay will be switched after the predetermined time.
Engine stalled, ignition on
The fault monitoring board remains active, warning buzzer and shut-down relay will be activated after
predetermined time periods.
To reach a clearly defined initial condition the ignition must be switched off for a moment before starting
a new starting process.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -H7-
Service Training
Fig. 4:
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -H8-
Service Training
Fig. 5:
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 -H9-
Service Training
Engine shut down by the shut-down relay
The fault, that led to the shut-down is stored and displayed.
The warning buzzer remains enabled. Other indications, caused by the standstill of the engine, will no
longer be displayed. The operator can recognize the and rectify the fault.
Then switch the ignition off to deactivate the shut-down relay and to enable a new starting process.
Function group Colour of indicator Shut-down time

Hydraulic oil filter (B21) red 2 minutes
Coolant temperature (B53) red 2 minutes
Engine oil pressure (B06) red 10 seconds
Coolant level (B55) red 10 seconds
Brake closed (H01) redt -
Charge control (MD+) yellow -
Air filter (B03) yellow -
Hazard light (H06) red -
Indicator on (H05) green -
Anti Spin Control ASC yellow -
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 10 -
Service Training
Brakes (Fig 6)
When the engine is at rest there is no hydraulic oil pressure available, the brake discs cannot be un-
loaded, the brake is automatically closed.
Travel lever in position „brake“ with the engine running
When the engine is running and the generator is fully functional, the generator (G02:15) (Fig. 2) will send
a D+ signal or the generator module (A23:24) (Fig. 2) a MD+ signal to the brake relay (K36:33).
When the travel lever is in „brake“-position, the coil of relay (K48:05) is not energized.
Current flows now
• via fuse (F25)
• and the contacts of relay (K48:07)
• to the coil of relay (K05:09) (Fig. 3).
Starting is now possible.
Current flows also
• via fuse (F25)
• to the fault monitoring board (A15:17) (Fig. 4).
The control light „brake closed“ (H01) lights up.
Travel lever actuated
When actuating the travel lever
• the proximity switch (B13:05) closes,
• relay (K48) switches over
• and the current flow to relay (K05:09) (starting) (Fig. 3) is interrupted.
Starting of the engine is not possible.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 11 -
Service Training
If the engine is running and the generator is fully functional,
• the coil of relay (K36:34) is energized,
• the contact closes.
Current can now flow
• via the contact of relay (K48:07),
• to the solenoid valve (Y04:34) when the emergency stop switch (S01:34) is closed.
The brake is released.
If there is no MD+ signal, e.g. because of a broken V-belt, a defective generator or if the engine has
been stalled when driving up a hill, the coil of relay (K36:34) is no longer energized. This opens the con-
tact (K36) and interrupts the current flow to the solenoid valve (Y04:34), the brake will close.
To be able to drive the machine for a short time, even with a broken V-beltor a defective generator, the
contacts 30-87 of relay (K36:34) must be bridged to open the brake.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 12 -
Service Training
Fig. 6:
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 13 -
Service Training
Speed range selection (Fig. 7)
Driving in reverse
When shifting the travel lever to reverse on level ground the coil of relay (K26:05) is not energized.
Current flows now
• via the fuse (F26:23),
• through the closed contact (K26:07)
• to the back-up alarm buzzer (H14:11).
The back-up alarm buzzer sounds.
Forward travel
The proximity switch (B14:05) closes in this position.
Current flows now
• the closed proximity switch (B14:05)
• to the coil of relay (K26:05).
The relay switches over, the current supply to the warning buzzer (H14:11) is interrupted.
Current flows also
• via the fuse (F26:23)
• to the speed range selector switch (S42:24).
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 14 -
Service Training
Speed ranges
Depending on the position of the speed range selector switch (S42:23) the solenoid valves (Y30:19,
Y31:29)
• for both travel motors (drum and axle),
• only for the front travel motor (drum),
• only for the rear travel motor (axle)
• or no motor at all will be energized.
This gives the operator the possibility to influence the gradability of the machine by changing the displa-
cement of the travel motors. He always switches the motor of the slipping axle to low displacement.
If the speed range selector switch (S42:23) is in position 1 „turtle“, none of the two solenoid valves
(Y30:11/Y31:18) is energized. In this switching condition both drum and axle drive motors are working
with high displacement. The machine drives in low speed range (working speed).
In switching position 2 current flows
• switch (S42:23)
• to the solenoid valve (Y30:19).
The drum drive motor changes to low displacement.
Current flow to the solenoid valve (Y31:29) is prevented by the diode (V02:22).
In switch position 3 current flows
• switch (S42:23)
• to the solenoid valve (Y31:29).
The axle drive motor changes to low displacement.
Current flow to the solenoid valve (Y30:19) is prevented by the diode (V03:27).
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 15 -
Service Training
If the travel speed range selector switch (S42:23) is in position 4 „rabbit“, both solenoid valves
(Y30:11/Y31:18) are energized. In this switching condition both drum and axle drive motors are switched
to low displacement. The machine drives in high speed range (transport speed).
In this switch position current flows
• switch (S42:23)
• to both diodes (V02:22 and V03:27)
• to both solenoid valves (Y30:19 and Y31:29).
Drum drive motor and axle drive motor change to low displacement.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 16 -
Service Training
Fig. 7:
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 17 -
Service Training
Anti Spin Control (ASC)
On extreme gradients and slippery ground the Anti Spin Control (ASC) provides optimal traction and
avoids spinning of drum or wheels.
If physical limits are reached it is quite obvious that even the ASC will not be able to improve the traction
of the machine.
The following machines have the ASC Anti-Spin-Control (Fig. 9) as standard equipment:
• BW 213 DH-3/PDH-3
• BW 214 DH-3/PDH-3
• BW 216 DH-3/PDH-3
• BW 219 DH-3/PDH-3
• BW 225 D-3/PD-3
The machines with Anti Spin Control (ASC) in the travel system are equipped with the following sensors:
• analogue inclination sensor (B57)
• analogue travel lever sensor
• sensors for rotating speed and detection of sense of rotation (B59/B60).
For safety reasons the following assembly groups (Hardware) are electronically monitored:
• area monitoring of the inclination sensor
• area monitoring of the travel lever sensor
• fault monitoring of the rotary speed sensor
• fault monitoring of the solenoid valves
• fault monitoring of the internal 5 V sensor supply voltage.
Additionally monitored (Software):
• Checking of the signals for the sense of rotation
• Checking of the signal for the neutral start lock
• Checking of the version of the operating system.
When detecting a fault, e.g. breakage of cable or short circuit, the ASC-system is deactivated and an
error status is displayed (monitoring board).
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 18 -
Service Training
Voltage at the analogue input on the plug (X1:52) of the inclination sensor
Inclination Position of drum Voltage (V)

-45° (100%) uphill 0,5
-5,7° (10%) downhill 2,15
0° level ground 2,5
+5,7° (10%) uphill 2,75
+45° (100%) uphill 4,5
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 19 -
Service Training
Vibration (Fig. 11)
Switching the vibration on
Current flows:
• via fuse (F03:05)
• to the toggle relay (K04:05).
When pressing the push button (S13:05) the toggle relay switches and the contact of the toggle relay
(K04:05) closes.
Current flows now to the selector switch for high / low amplitude (S35:29).
Depending on the switch position current will flow to the solenoid valve (Y07:29) for high amplitude or
(Y08:34) for low amplitude. The chosen vibration will start.
BW 216 D-3, BW 216 DH-3/PDH-3

BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 20 -
Service Training
Fig. 8:
BW 216 D-3, BW 216 DH-3/PDH-3
BW 219 DH-3/PDH-3, BW 225 D-3/PD-3 - H 21 -
Inhaltsverzeichnis: BW 212...225−3 mit Cummins, Perkins und Deutz Motor
table of contents: BW 212...225−3 with Cummins, Perkins and Deutz engine
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 582 700 70 Stromlaufplan circuit diagram
002 Versorgung, Heizung, Steckdosen supply, heating unit, socket
003 Starten starting unit
004 Signalhorn, Überwachung, Anzeigen warning horn, monitoring, indicators
005 Frequenzanzeige, Tachograph, Geschwindigkleitsanzeige frequency meter, tachograph, speedometer
006 Fahren, Fahrstufen und Bremse driving, speed ranges and brakes
007 Vibration, Speed Control vibration, speed control
008 Anti− Schlupfregelung, Lenkung anti spin control, steering
009 Variocontrol variocontrol
010 Omegameter, Terrameter omegameter, terrameter
011 Detailansicht Drucker− und Bedieneinheit (Option) detail view printer− and operation unit (option)
012 Berieselung sprinkler system
013 Beleuchtung , Arbeitsscheinwerfer, StvZO illumination, working head lights, StvZO
014 Kabine, Klimatisierung cabin, air conditioning
015 Anbau Vibrationsplatten assembling unit vibration plates
101 Bauteilliste component listing
201 Schaltkasten e−box
29.05.2000
Werner Stromlaufplan 001 001 582 700 70
29.05.2000 circuit diagram
Seis 001
30 3:1
B+
3:7
F24:C 1 1
4:4 F40 F05
25A 30A
Box B A Box A A
F05:A
10:4
X1 X1 X1 X1 X1
1 2 3 4 5 X1:80 X1:10
emergancy service
Zusatzausrüstung innerhalb der Kabine
option inside of cabin
Notbetrieb
Steuergerät
control unit
E30
Heizgerät A13
D+ 4 1 2 15/54
rt max.20A
heating unit
A23 15/54 Modul Generator nenn.2A

module generator
− 5 3 MD+
1 br
F00 Sicherung Batterie X1:13
125A
2 fuse, battery n n
X18−1:2
X1:28 4 n
X17−1:3
n
MD+ 4:3 gn
1
Y14
B+ D+ S28
2
X1:29 gn
Schalter Kabinenheizung
G02
0,18A
switch, cab heating

P00 D+
B− W 86
30 + + K36 86 K09
+ +
V24 Kraftstoffpumpe XS XS
12V 12V
G01 − G03 − X17−1:4 fuel pump heating unit − −
31 85 85
−
X18−1:1 Außerhalb der Kabine montiert
assembled outside of cabin
X1:12 X1:37 X1:32 X1:126 X1:37
W
4:7
31 3:1
Load Dump Modul Generator 6:7 14:3 Betriebsstundenzähler Steckdosen

load dump module generator engine hour meter socket
Batterien
battery
zweite Batterie ab BW178,

aber nicht bei BW 212 Übersee Version Nur bei Klimaanlage
second batterie up BW178, only acc. to air conditioning
but not assembled in 212 oversee version
29.05.2000
1 1 582 700 70
Werner Versorgung, Heizung, Steckdosen
29.05.2000
Seis supply, heating unit, sockets 002
2:20 30 30 7:1
K11:30
87 3x1,5
9:12
3
F13 30
K32 Box A 30A
C K11
3:2
30 3:3
F13:C 9:18 Anschluß ZA 87
K30 K11:87
14:2 Klimaanlage 4:1
connection option
air conditioning F14 1 Nur bei ASC
30A
X1:8 Box C A only acc. to ASC
X1:41 Nur bei VARIOCONTROL

only acc. to VARIOCONTROL
30
P0123
7:19
9:13
6:7
8:2
S00 17
11 21 31 42 51 62
15/54 19 Not−Aus Schalter
S01 emergancy shut off
58 50a
Startschalter
ignition switch 12 22 32 41 52 61
X1:11 X1:9
only acc. to cabin
X1:40 Nur bei Speed−Control

only acc. to speed
nur bei Kabine
control
K05 30 K22 30
6:6 4:12
87 87a 87 87a
50A 4:4
X1:7A X1:6 X1:7 X1:17 X1:16
X18−1:7
X18−2:7 X18−2:8 X18−2:1 X18−2:2 X18−2:5
X17−2:6 X17−2:5 X17−2:4 X17−2:3 X17−2:8 X17−1:6
+
B54
_t B+
EW + HW max. 69A
2:10
CUMMINS:max. 0,8A
−
PERKINS:max 1.5A
KHD:max. 4,0A
HW max. 1,1A
AW max. 55A
max. 10−13A
X1:46
max. 3A
AW HW
K32 86 K11 86 Y117 1 B+ 50 50a 2 ws rt 1 1
R02 Y01 V08 2 Y13 Y13 Y58 2 V05
M01 M
1 1
85 85 − 2 1 sw 2 2
31
X1:73 X1:31 X1:58 X1:58
2:20 31 31 4:1
3:2 3:14 Kaltstartbeschleuniger Starter Startmehrmenge Hubmagnet BT..−Motor CUMMINS

cold starting unit starter start boost fuel shut off solenoid BT..−engine, CUMMINS
Glühkerze Nur für KHD−Motor Hubmagnet Motor KHD

glow plug only acc. to KHD−engine shut off solenoid engine, KHD
Nur bei PERKINS Kraftstoffabstellung

fuel switch off
only acc.to. PERKINS Optional, je nach Motor
optional, acc. to engine
29.05.2000
1 1 582 700 70
Werner Starten (je nach Motorausstattung)
29.05.2000
Seis starting unnit (acc. to engine versions) 003
K11:87 K11:87
3:20 6:1
F24:C 3 X1:21
2:10 F24 30A
5:1
50A Box C ASC ERROR
3:10 C 8:4
X1:23
2:11 MD+ MD+ 6:5
F26:B X1:26 13:11
6:8
W
2:6
6
Warnblinker / hazard light

Bremse zu / brake closed
F23 X1:28 X1:17 X1:21 X1:22 X1:23 X1:26
30A
Box C F X1:36
hydraulic oil temperature

Sammelstöranzeige
Hydrauliköltemperatur
monitoring module
Kühlmitteltemperatur
collant temperature
engine oil pressure
br/ge
Drehzahlmesser
ws/rt
X1:99
gn
Motoröldruck
Tankanzeige
rt
level gauge
RPM meter
ws/ge
volt meter
Voltmeter
A15
Taster Signalhorn
push button horn ws/bl
or
+ + + + + +
ws
13 24
sw
ge
vi
bl
gr
S03
ws/gn
Q n P V
ws/gr
br/gn
P01 P02 P03 P13 P14 P12
14 23 G − G − G − G − G − −
Blinker rechts / indicator RH

X1:24 X1:31 X1:27 X1:19 X1:18 X1:30 X1:20 X1:25
Blinker links / indicator LH

X18−1:5
X18−1:4
X18−2:3
X1:15 X1:14
X17−1:8
X17−1:1
X17−2:2
X1:130 13:18
X18−1:6 X18−1:3
X1:131 13:18
SUMMER
X1:100 X1:101 X1:34 X1:102 X17−1:7 X17−1:2 14:2
max. 5A
max. 5A
0,18A
0,12A
Geber Geber X5:1
sender sender
86 WK G B53 1 2 B21 2 B03 3 B55 3
1 1 1 1 rt
B11 B11 K22 H07 P P P Q
R03 R04
2 2 2 2 sw B06 3 4 4
85
X5:2
X1:103 X1:32 X1:37 X1:105 X1:32 X1:31

31 31
3:20 5:1
Signalhörner 3:14 Warnsummer Hydraulikölfilter

warning horns Zweite Hupe nicht bei warning buzzer oil filter
BW 212 Übersee Version Motoröldruck Luftfilter
second warning horn not used engine oil pressure air cleaner
acc. to. BW 212 oversea version
Kühlmitteltemperatur Kühlmittelvorrat
collant temperature coolant stock level
29.05.2000
1 1 582 700 70
Werner Signalhorn, Überwachungen, Anzeigen
29.05.2000
Seis warning horn, monitoring, indicators 004
4:20 X1:21 X1:21 10:1
F07:C
13:11
nicht verwendet
X1:115 X1:113 X1:114

not used
1 X1:117 Tachographenmodul
2 module, tachograph A2+A3
P09
B16 3 5 6 A1
4 X1:118 1 B3
A16
7,8,9 2 B4
4 3 C4
Aufnehmer Vibration
transducer vibration
Anzeige
A5+A6 indicator
B60:3
10:4
X1:119
Frequenzanzeige
OUT+
OUT−
OUT+
OUT−
15/54
15/54
Geschwindigkeitsanzeige
frequency meter
P05 P04
−
−
in
in
A06 Elektronik A05 Elektronik
transducer transducer
speedometer
+
+
− 1 3 4 − 1 3 4
057 665 90 (BW 213/214/216/211−3) 1 4
29Hz / 35Hz
057 665 89 (BW 225−3)

A51
26Hz / 26Hz
057 664 92 (BW 219−3)

3 2 5
26Hz / 32Hz
BW 156−179−3: −−−−
BW 213,214,216−3: PIN 4: +
BW 219−3: PIN 3: +
BW 225−3: PIN 4,3: + KA
7:3
BW 212−3: PIN 1: − GA
7:3
BW 212D/PD−3 Variom.: PIN 4: + / PIN 1: −
X1:116
4:20 31 31 6:1
Platine Frequenzanzeige
ZA Frequenzanzeige ZA Geschwindigkeitsanzeige ZA Tachograph

option frequency meter option speedometer option tachograph
29.05.2000
1 1 582 700 70
Werner Frequenzanzeige, Tachograph, Geschwindigkeitsanzeige
29.05.2000
Seis frequency meter, tachograph, speedometer 005
4:20 K11:87 K11:87 7:1
F25 4 F26 2
30A 30A
Box C D Box C B
4:11 F26:B F26:B 8:4
X1:106 X1:36 X1:44 X1:44
X6:2 X7:2
BR/BN BR/BN 30 K26 30 23 1234 2
B13 B14 Schalter Fahrstufen S42 Schalter Fahrstufen
K48 6:2 6:4 S42 switch, speed range switch, speed range
BL/BU SW/BK 87a 87 87 87a 24 1 5 7 3
BL/BU SW/BK
X6:1 X6:3 X7:1 X7:3 4:20 X1:23 X1:23 8:3

NEUT"0" 10:4
option speed − control

30
proximity switch forward / zero position
ZA Speed − Control
K36 2:8 X1:51
87a 87
proximity switch, tavel lever "0"
not asssembled acc. to speed − control

X1:43
Initiator Vorwärts u. Null
Initiator Fahrhebel "0"
SC2
not asssembled acc. to speed − control
entfällt bei Speed − Control

7:15
21
S01 3:14
22 V02 V03
entfällt bei Speed − Control
2 1 1 2
X1:42 X1:33 X1:56 X1:57 X1:56
SC1 7:9 X1:91
max. 1,67A (Poclain)

max. 1,23A (Sauer)
option speed − control
X1:108 X1:107
ZA Speed − Control
max 1,23A
max 1,23A
max. 1,8A
0,18A
0,18A
0,18A
X9:1
86 86 86
1 rt 1 1 1
K48 K26 K05 Y04 V09 H14 Y31 V09 Y30 V09 Y31 V09
2 sw 2 2 2
85 85 85
X9:2
X1:31 X1:105 X1:54 X1:37 X1:92 X1:32 X1:54 X1:58 X1:54
5:20 31 31 8:1
6:7 6:9 3:8 Magnetventil Bremse Stufenumschaltung hinten Stufenumschaltung vorn

speed range selection, rear speed range selection, front
solenoid valve brake
Rückfahrwarnsummer Stufenumschaltung hinten

back up alarm speed range selection, rear
212 Übersee Version sowie
156/177 mit einstufigem Poclain Standard und BW 212 CE! Bei ASC siehe Blatt 8
212 oversea version and standard and BW 212 CE! Acc. to ASC see on sheet 8
156/177 with non switchalbe poclain
29.05.2000
11 1 582 700 70
Werner Fahren, Bremse, Fahrstufen
29.05.2000
Seis driving, brake, speed ranges 006
6:20 K11:87 K11:87 8:1
F03 5 1=Vorw. 2=Rückw. 3=Bremse F60 4

Box C E 1=forw. 2=backw. 3= brake Box D D
3
Anschluß für Variocontrol S75 1 1
X1:38 connections for variocontrol
39/41
X1:38 1 2 2
9:1 2 3
S09:24 9:6 Fahrhebel X1:151
S54 42
travel lever
30 56a Modul Vibration 20 19 21 18 38 40 34 35 Geschwindigkeissensor
module vibration speed sensor S01
S
+
−
X1:147 3:14
149
148
K04 B60 Fahrstufenbereiche
56b SC1 1 41
6:2 speed ranges
gn
gn
gn
S 56 sw 4 br
X14:1 2 3
Notbetrieb X1:150 bl 3 2 S48 23
gn
bl
ws
rt
emergency service
X1:146
only acc. to speed control
Aktivierung 24
X1:145 X1:153 enable
nur bei Speed−Control
X1:39 X1:152
Signal
11 6:17 SC2 X1:154
−5V
+5V
30 Qmin/Qmin
S08 K43
18 14 25 15 04 11 05 27 19 08
12 7:17 X1:155
Man. / Automatik 1 1
man. / automatic 87 87a R20 R21 A17 Elektronik
330 Ohm 330 Ohm electronic
2 2
06 07 12 02 03 23 21 20 26 17 16 1 10
X1:104 X1:96 Anschluß nur bei ASC
X1:159
X1:160
X1:161
X1:164
X1:165
X1:166
connections only acc.
push button, travel lever
ohne ASC und USA S42:61 8:7 ASC X1:156 X1:65

Version
S42:62 8:7 X1:68
Taster Fahrhebel
without ASC and

X1:69
USA version 1
68 Ohm
X1:120 X1:157 X1:70
R22
X1:33
2 Anschluß Diagnosegerät
X8:2
24 13 87a 87 87 87a connection diagnosis tool
S35 G 0 K 7:14 7:15
10,17 bei Gessmann Hebel
3/10
S13 Vibration klein/groß K77/1 K77/2
vibration high / low 30 30
X9:1
4/17 23 14 X1:158 X1:162
KA
5:17
X1:163
X8:1 5:17 GA rt 2 2 A Y62 Y62 D
0.166A
X1:94 X1:95 H14 V06 V07
max. 2,5A max. 2,5A sw 86 86 86 86
1 1 B C K77/1 K77/2 K77/3 K43 1
Y07 1 Y08 1 H30
X9:2
87a 87 85 85 85 85 2
V09 2 V09 2 7:16
K77/3
30
X1:103 X1:93 X1:32 X1:58
X1:167 X1:168 X1:168
3:20 30 30 12:1
Vibration vorne groß Vibration vorne klein Rückfahrwarnsummer Ansteuerung Fahrpume 7:11 7:12 7:12 7:4
vibration front, high vibration front, low back up alarm contril travel pump
langer Bremsweg / Fehler

Ansteuerung und Ventile entfällt bei Variocontrol ZA Speed − Control long stopping distance / failure
connections and valves not used acc. to variocontol option speed − control
29.05.2000
1 1 582 700 70
Werner Vibration, Speed − Control
29.05.2000
Seis vibration, speed − control 007
7:20 K11:87 K11:87 12:1
F51 1 F63 3
30A F26:B
Box D 6:20 7:5 S42:62 Box D C
A
S42:61
X1:44 7:5
X1:60 +45_G=4,5V X1:109 Lenkhebel
emergency service
−45_G=0,5V steering lever
1
31 4 1V L NR
Not−Betrieb
S42 B57
123 21 12 43 61 PVREL
S01 Fahrstufen Neigungssensor 3 2,5V
N
N
3:14 speed ranges slope sensor
32 22 11 44 62 2 4V
S71
0,5V−4,5V 5 6
+ N S N −
X1:61
ASC ERROR
4:19
X1:23
6:8
V01
max. 3,6A
BW 219 with axle−motor 110
BW 219 mit 110er Achsmotor
BW 178 wwith axle i=32

BW 178 mit Achse i=32
1 2 Anschluß Diagnosegerät
connection diagnosis tool
X1:110
X1:111
X1:72 X1:71 X1:48 X1:45 X1:52 X1:68 X1:65 X1:70 X1:69
01 10 27 20 08 09 18 16 26 17 24 Signalstrom: 0,25mA
09: 0− Signal = 1.Gang + Vibration signal current: 0,25mA
18: Analogsignal Neigungssensor
15 A36 Elektronik 27: 1− Signal bei Fahrhebel in 0− Raste
09: 1−Signal und 08: 1−Signal = 2.Gang + Vibration
Signalspannung neutral: 6V
electronic
X1:S
09: 1−Signal und 08: 0−Signal = Transportgeschw. ohne Vibration

signal voltage, neutral: 6V
02 03 04 06 07 12 13 19 05 14 28+22 25 11 Signalspannung Regelbereich: 3V−9V
signal voltage, control range: 3V−9V
X1:57 X1:56 X1:63 X1:66 X1:67 X1:86 X1:87 Leistungsaufnahme: 8W
input: 8W
X1:63
max. 1,67A (Poclian)
max. 1,23A (Sauer)
direction
direction
speed
speed
alte Maschinen PIN 15: 0V
X4:1 2 3
bl bl
old Typs PIN 15: 0V
3 3 2 1
B59 B60
1 1 R07
ws ws
Y30 Y31 2 2
3
br br
2 2 X1:65 1 4 X1:85 1 4 Y64 −
sw sw
X1:59 X1:55 X1:64 X1:84
X1:62 X1:54 X1:112
6:20 31 31 9:1
Bandagenmotor Achsmotor Poti Fahrhebel Achsgeschwindigkeit
motor, drum motor, axle potentiometer travel lever sensor axle speed
Magnetventil Lenkung
Bandagengeschwindigkeit solenoid valve steering
sensor drum speed
Serie nur bei DH/PDH− MAschinen und alle BW 225−3 ZA
series only acc. to DH/PDH− versions and all BW 225−3 types option
29.05.2000
1 1 582 700 70
Werner Anti − Schlupfregelung, Lenkung
29.05.2000
Seis anti spin control, steering 008
X1:38 X2:6 X1:38 10:17
7:7
X2:47 X2:7 Vibration Aus/Ein Aufnehmer Verstellmotor Beschleunigungssensoren K11:30 3:6 F13:C F13:C
Vibration on/off sensor, adjustable notor acceleration sensors 3:19 Automatik/Manuell/Prüfen Hand/Prüfen Automatik 14:1
8,5V 1x1,5 1x1,5 automatic/manuell/test manuell/test automatic X2:48
AGND
X12:2 X2:31
X3:2 51 S13:2
X12:4 X2:32
X2:31
X2:72 X2:71 X2:72 10:14
S01 S13:8 X2:37 X2:55
X3:6 X3:11 X3:1 +15V X3:5 10:14
3:14
X2:10
X2:56
X2:8
X12:6
X2:31
X2:31
X2:36
−15V
52 S104
X2:38
S09:24 X3:3 AMP

emergency service hor./vert.
X2:45 X2:46
monitoring modul
7:7
for BW 177 with Pleiger

X3:4 X2:1E X2:2E X12:5
Für BW 177 m. Pleiger
Anzeigemodul
G− P26 − B62 − B62 1 2 3 1 2 3
X2:32
X2:32
S09 23 F67 1 F84 1 R23
13 1kOhm
S65
+/sw
30A 10A
−15V +15V 2 2
vertikal = 12V
Amplitudenanzeige
amplitude indicator
AGND
Notbetrieb V/H
24 X2:1A X2:2A
G+ +15V −15V R24
X20:2
X20:1
BH BV
X1:94 B61 S S X21:2 X21:1
+
1kOhm
14
X2:49 −/rt X3:7 X3:8 + +
S107 S106
S/ws
1x0,75 / Elektronik
R25
X11:19
X11:10
5x0,75 / Leistung
X11:9
AGND AGND
X2:66
X2:67
X3:9 1kOhm S S
X2:20
X2:11
P16
X2:39
X2:70
X2:69
X2:42
Zündung 15/54
X2:9
X11:8 TERRA2 X20:3 1−6 X21:3 1−6
X2:68
R26
X12:3
TERRA1 10:9 X2:58 1kOhm
F1 F2
10:9 X2:57
Signal Vibration ein
CAN+
CAN−
8,5V Notbetrieb
X2:35
X2:33
X2:34
X2:12
AGND
X2:13
+15V
−15V
12V
alive
X2:21
2 12 9 30 29 1 23 28 56 57 58 59 60 54 6 7 8 27 26 15
14 19 1 17 3 2 5 13 16 15 S13:1 10:14 X2:16 X11:1
A44:2,3 ESX Steuerung (Typ 7265)
X11:11
X11:13
X11:12
X11:3
X11:5
X11:7
X11:6
A46 Modul Variocontrol 10:6 A37
X11:2
X11:4
module variocontrol A44:1 ESX control unit (typ 7265)
10:6
X2:53
X2:52
X2:54
34 35 46 61 62 63 64 49 55 24 25 38 39 40 41 4 5 3 16
Gehäuse
Fahrtrichtungserkennung
18 4 10 9 7 8 12 11 6
X2:17
X2:18
X2:15
X2:14
X2:40
X2:78
X2:22
X2:63
X2:73
X2:5
X2:74
AGND X2:81
X2:79
X2:80
X2:82
X2:23 X2:77
X2:24 X2:76
1 X2:75
RxD
TxD
X2:25
X2:59 X2:60 X2:61 X2:62
X3:16
H04 2 X3:12 X3:13 X3:14 X3:15 S131 23 S132 23 S133 23 S134 23
H56
H57
1 1 1 1
1 1 1 1 P11
X11:15
X11:16
X11:17
X11:18
X11:14
V09 Y22 V09 Y119

X2:41
24 24 24 24
2 2 2 2 2 2 2 2 12V + −
Y125 Y128 Y126 Y127 Ventil Vibration
X3:17 X3:18 solenoid valve, vibration X3:19
X2:83
X2:64
X2:4 X2:5
8:20 31 X2:3 31 10:1
Auslaßventil (4)
solenoid valve outlet (4) X2:29 A37:19 X2:19 A37:13
Einlaßventil (1) Einlaßventil (3) X2:30 A37:31 X2:26 A37:14 Ventil Arretierung Fertig Stop Löschen
solenoid valve inlet (1) solenoid valve inlet (3) X2:91 A37:32 X2:27 A37:17 solenoid valve, adjustment ready stop erase
X2:92 A37:47 X2:28 A37:18
Anzeige Störung Auslaßventil (2) X2:93 A37:48 Reserveklemmen Weiter Start Drucken Drucker
indicator failure solenoid valve outlet (2) terminals for resist continue start print printer
29.05.2000
1 1 582 700 70
Werner Variocontrol
29.05.2000
Seis variocontrol 009
5:20 X1:21 9:20 X1:38 X1:38 15:1
NEUT"0"
6:8
F05:A
2:19
5:14 B60:3 X1:81 Stecker für in Planung
befindliche Zusatzanwendungen
X1:83 connectors for additional
X1:90
X1:88
equipment, not jet available
Spannungsversorgung GPS
BCM V24 Mate−N−Lok

+
Handeingabegerät
Datenleitung GPS
Datenleitung GPS
1
BCM V24 Sub−D
11:12
11:12
11:12
11:13
11:13
11:13
11:14
11:15
11:15
11:15
11:16
max. 10A
max. 1A
E07 P07
2 −
S6:1
S5:1
S6:3
S6:5
S6:6
S6:9
S5:3
S6:2
S5:2
S6:4
S5:4
X2:9
S11:1−25
S8:1−10
S7:1−15
S19:1−6
S20:1−9
S9:1−5
connector board, omega meter

S21:6
S4:1
S4:2
S6:1
S6:2
S6:3
S6:4
S6:5
S6:6
S6:9
S5:1
S5:2
S5:3
S5:4
Koppelplatine Omegameter
X2:50 AGND
Nur bei Anbau VARIOCONTROL

S13:9
S1:3
S1:2
S4:1
S4:7
only acc. to VARIOCONTROL
Kopplung Komponenten Terrameter S13:8
gleichzeitigem ASC−Anbau
X1:85 A33 connector board, terra meter components S13:2

S13:1 S2:1 A08
Winkelsignal
S16:1
S21:1
S18:1
S12:1−5
S17:1−8
S14:1−5
S16:3
S16:7
S15:3
S15:5
S15:6
S15:7
S21:5
S16:2
S18:5
S18:6
S15:8
S18:2
S15:4
S4:3
A44:2,3
modul, terra meter
S2:2
S2:3
S2:4
S2:5
Modul Terrameter
9:8
also assembled
0−5V
+5V
15/54 6 2,3 r−out
S13:1
9:8
11:16 S16:1
11:11 S18:1
11:17 S16:3
11:17 S16:7
11:6 S15:3
11:6 S15:5
11:7 S15:6
11:7 S15:7
11:16 S16:2
11:12 S18:5
11:12 S18:6
11:7 S15:8
11:11 S18:2
11:6 S15:4
r−out
br speed 4 9:15 S13:2
1
bl X1:87 w−in S13:8
3 8 1/4 w−out
9:15 5
B60 A44
Versorgung von "B60" bei
supply of "B60" if ASC is
und BW 216/219/225
BW 213/214 H−Version
ws r−in 5
2 X1:86
sw 4 direction
1 w−out 5 5 8
7
gnd
B62
Beschleunigungsaufnehmer (90_G)
acceleration sensor (90_G)
P15 Dip−Schalter 1: Geschlossen, für Bandagenart "D"
Dip−Schalter 1: Offen, für Bandagenart "PD"
15 8 Bildschirm Dip−Schalter 2: Geschlossen, für BW 213/214/217/219
B62 diplay
Dip−Schalter 2: Offen, für BW 142/172/212
X1:84 9:8 A44:1 X10:1−19 Alle anderen Dip−Schalter : keine Verwendung
Dip−switch 1: closed, for "D" − drum

B62
7 Dip−switch 1: open, for "PD" − drum
Dip−switch 2: closed, for BW 213/214/217/219
TERRA1 ST1:1 Dip−Schalter 2: open, for BW 142/172/212
9:8 Signalübertragung bei
all other Dip−switches : no use
TERRA2 angebauter Variocontrol ST2:1−8 Schnittstelle
9:9 A35
jeweils an PIN 1
ST1:2 interface
X1:82 X1:89 X1:54

9:20 31 31 12:1
Sensor Achsgeschwindigkeit Beschleunigungsaufnehmer (BH)

sensor, axle speed acceleration sensor (BH)
Beschleunigungsaufnehmer (BV)
acceleration sensor (BV) Terrameter, Ausrüstungsumfang VM2−VM5 Omegameter, Ausrüstungsumfang VM1
terra meter, applications VM2−VM5 omega meter, application VM1
29.05.2000
1 1 582 700 70
Werner Omegameter, Terrameter
29.05.2000
Seis omega meter, terrameter 010
Druckereinheit
S12 S4 P11 printer−unit
ST21 S14 S5 20
Koppelplatine BTM05
S6
S15
link−unit BTM05
S16 S7
Druckercontroller
printer−controller
paper formfeed
Papiervorschub
3
S17 S153
S8 X15 X16
S18 1 3 4 2 6 5 4 3 2 1
4
S9
S19
X13 X14
S10 1 2 3 4 5 6 7 1 2 3 4
S13
S6:1
S6:2
S6:3
S6:4
S6:5
S6:6
S6:9
S5:1
S5:2
S5:3
S5:4
S20 S11
10:11
10:11
10:11
10:11
10:10
10:10
10:13
10:13
10:12
10:12
10:12
10:11
10:12
10:12
10:12
10:13
10:13
10:10
10:11
10:11
10:11
10:10
10:10
10:9
10:9
S16:1
S18:1
S15:3
S15:5
S15:6
S15:7
S16:3
S16:7
S15:8
S18:5
S18:6
S16:2
S18:2
S15:4
Bedieneinheit
operation−unit
+ + +
23 23 23 13 13 23 X2 X2 X2 X2 X2
S131 S132 S133 S152 S140 S134 H56 H57 E07 E05 E04 P07 P05 P04
X1 X1 X1 X1 X1 − − −
24 24 24 14 14 24
START DRUCKEN TEST−NORMAL WEITER Bel. Omegameter Omegameter Geschwindigkeitsanzeige

start print test−normal continue illum. omegameter omegameter speedometer
STOP PD−D LÖSCHEN FERTIG Bel. Frequenzanzeige Frequenzanzeige
stop PD−D clear comp. achieved illum. frequency meter frequency meter
Bel. Geschwindigkeitsanzeige
illum. speedometer
29.05.2000
1 1 582 700 70
T. Seis Detailansicht Drucker− und Bedieneinheit
29.05.2000
Werner detail view printer− and operation−unit 011
8:20 K11:87 K11:87 13:1
7:20 30 30 13:1
2 5
F37 40A
F06 30A
Box B Box D
B E
X1:135 X1:138
X1:141
4s abschaltverzögert
11 23
K23 30 S05 012 15 in V 4s − −
01
12:12 Schalter Berieselung
switch, sprinkler system 1s 2s
87 87a K37
12 24 Zeitrelais
timing relay
X1:142
87a St+
X1:139 15 out 30 87 St− −
0,18A
86 K46 30
K46 12:6
87 87a X1:144
85
X1:136 X1:140 X1:143
max. 7,2A
1,83A
max 8A
0,18A
+ 1 2 +
86
M02 A01 1 M03 1
M V09 Y06 K23 M V09 Y06
2 2
− 85 −
3/4 1,83A
X1:137 X1:134
10:20 31 31 13:1
Berieselungspumpe 12:9 12:4 Emulsionspumpe Berieselungsventil

sprinkler pump emulsion sprinkler pump solenoid valve sprinkler
Alternativer Anbau für Entfällt bei

Intervallschalter Berieselungsventil Emulsionsberieselung Emulsionsberieselung
interval switch solenoid valve sprinkler alternative assembling for not assembled acc. to
emulsions sprinkler application emulsions sprinkler application
29.05.2000
1 1 582 700 70
Werner ZA Berieselung
29.05.2000
Seis option sprinkler systhem 012
13:9
X1:128
87
4,6A
Box A
12:20 31
12:5 30
Scheinwerfer links
F11
2
head light LH
12:20 K11:87
K16 30
B
X22:2 X23:2
X22:1 X23:1
4,6A
15A
S15
87a
Scheinwerfer rechts
2
E16 1 E17 1
head light RH
13:10
012
K06
X1:58
X1:98
0,18A
switch, StvZO
Schalter StvZO
85
86
24
S53 23
32
31
Schalter Arbeitsbeleuchtung
switch, working head lights
12
11
30A
0,42A
Umrißleuchte vorne links
Seis
2
contour indicator front, LH
Werner
24
23
0,42A
29.05.2000
29.05.2000
Umrißleuchte hinten links
X1:97
2
2 F18
contour indicator rear, LH

B Box D
15A
Box B
F09
X24:3
X1:129
0,42A
Schlußleuchte links
2
4
tail light, LH
D
0,42A
Parkleuchte links
2
parking light, LH
werfer ohne StvZO
lights without StvZO
0,42A
Parkleuchte rechts
2
parking light, RH
Anschluß Arbeitsschein−
connection working head
Box B
15A
F10
X24:1 X25:2 X26:2 X27:2
X25:1 X26:1 X27:3

X1:132
0,42A
Schlußleuchte rechts
2
5
E
tail light, RH
0,42A
Umrißleuchte vorne rechts
2
contour indicator front, RH
0,42A
Umrißleuchte hinten rechts
2
contour indicator rear, RH
13:2
Schalter Rundumkennleuchte
E41 1 E42 1 E13 1 E12 1 E14 1 E15 1 E43 1 E44 1 K16

X1:133 0,18A switch, rotary beacon
85
86
E32
S38
−
+
24
23
Rundumkennleuchte
rotary beacon
13:3
87
4,6A
Arbeitsscheinwerfer hinten links
2
5
working head lights, rear lh.

K06 30
X1:77
30A
4,6A
F22
87a
Arbeitsscheinwerfer hinten rechts
2
Box A
working head lights, rear rh.
bei ROPS−Aufbau
4:19
4,6A
Arbeitsscheinwerfer vorne links
werfer / Rundumleuchte
working head lights, front lh.
Connection head lights /

Anschluß Arbeitsschein−
rotary beacon with ROPS

Box A
30A
S14
F19
X1:76
X1:26
4,6A
5:15 F07:C
Arbeitsscheinwerfer vorne rechts

2
4
working head lights, front rh.

D
01
Warnblinkschalter
switch, hazard light
0.166A
Box B
Bel. Tankanzeige
F07
2
15A
01
illumination level gauge

Box A
30A
F21
X1:35
24
23
0.166A
Bel. Öldruckanzeige
2
3 6
CF
option illumination, working head lights, StvZO illumination

6
illumin. oil pressure indicator
ZA Beleuchtung, Arbeitsscheinwerfer, StvZO Beleuchtung

11
12
0.166A
15A
Bel. Hydrauliköltemperatur
F08
illumin. hydraulic oil temperature

Box D
63
64
with cabin
0.166A
F bei Kabine
Bel. Temperaturanzeige
2
illumin. temperature indicator

STV1
34
33
0.166A
Bel. Drehzahlmesser
2
STV2 14:15
14:15
43
44
illumination RPM meter

Connection head lights
0.166A
Bel. Voltmeter
2
illumin. voltmeter
Anschluß Arbeitsscheinwerfer
S37
0.166A
Bel. Frequenzanzeige
2
illumin. frequency meter

L0R
switch indicator
Schalter Blinker
0.166A X2:51
Bel. Vektoranzeige
2
E27 1 E28 1 E23 1 E25 1 E01 1 E45 1 E22 1 E02 1 E03 1 E46 1 E05 1 E54 1
L0R
illumin. vector indicator X2:43

X2:5
14
13
X2:44
49
A02 31
23
24
1
Blinkgeber
indicator relay
49a
X1:133
4:19
4:19
1,75A
Blinkleuchte VL
2
indicator front, LH
1
1,75A
X1:130
X1:131
X1:130
Blinkleuchte HL
2
indicator rear, LH
X25:3 X24:2 X26:3
1,75A
Blinkleuchte VR
2
E08 1 E09 1 E10 1
indicator front, RH
X27:1
1,75A
X1:131
Blinkleuchte HR
2
E11 1
30
K11:87
indicator rear, RH
582 700 70
31 14:1
013
X29/1:5
3:2 K30
X1:79 X29/2:8 STV2
13:14
9:19 F13:C STV1
Reserve
13:14
reserve
X1:121 B C D E F A
F42 F43 F44 F31 F17 F02
30 30
K33 K09 2 3 4 5 6 1
14:5 2:9
87 87a 87 87a X32:1
X1:122
S45 3 7 2 7 2
X34:1 01W 01W 012 3
01 01
B
0123 Schalter Klimaanlage
S102 switch, air conditioning 4
S21 5 4 S20 5 4 S44
5 1
A12 S38 5
L MH C B51 15 B51
+ + + +
X28/2:6
X28/2:8
X28/2:5
X28/2:7
X29/2:5
X29/2:7
X28/2:2
X29/2:6
X29/2:2
X29/2:1
− − − −
ge/rt
rt/ge
31 7 1
rt
B29 1
Lüfter Thermostat
M _t
X29/1:6
X29/1:7
X29/1:3
blower M09 thermostat
X28/1:7
X28/1:5
X28/1:6
X29/1:8
X28/1:3
X28/1:8
X29/1:4
2
X34:2 X34:3
Überwachung Kühlmitteldruck
monitoring coolant pressure
X31:1
X30:1
X31:3
X33:1
X31:4
X30:3
X30:3
X33:3
X1:123
30 4
K49
14:4 B75 P 1 1 1 1 1
5A
LP HP E32
M09 +
87 87a 3 E29 M05 M M04 M M E27 E28 E23 E25
2 2 2 2 2
4,6A
4,6A
4,6A
4,6A
1
14,2A
1,3A
2,9A
4,7A
−
V15
2
X32:2 X30:2 X31:2 X33:2
X1:125 X1:27 X1:124
max. 3,5A
X1:75 X1:74
ZA
2 Y15 1 K49 86 K33 86 + + option
V11 M07 M M06 M
1 2
85 85
0,18A
0,18A
− −
max. 3,8A
max. 3,8A
SUMMER X1:126 X1:116 X1:78 X1:73

4:14
13:20 31 31 15:1
14:3 14:2 Innenleuchte Wascher hinten Wascher vorn Arbeitsscheinwerfer hinten Radio
inside light, cabin washer rear washer front working head lights, rear radio
Magnetkupplung Klimagerät Wischer hinten Wischer vorne Kabinenlüfter Arbeitsscheinwerfer vorn Rundumkennleuchte
magnetic clutch, air conditioning windscreen wiper, rear windscreen wiper, rear cab ventilator working head lights, front rotary beacon
Option Klimaanlage
option air conditioning
29.05.2000
1 1 582 700 70
Werner Kabine, Klimatisierung
29.05.2000
Seis cabin, air conditioning 014
F03 / Box C / Anschluß E
10:20 X1:38 X1:38
X1:169
X16:1
Initiator entfallen, K67 30 S130

H0S 13 23
Heben / Senken
Verkabelung bleibt bestehen 15:3 lift / let down
proximity switch excluded, 87 87a
057 551 10
wiring still the same 14 24
X1:170 X1:171
X16:3 X16:2
1 3 4 8
Schnellverschluß − Kupplung
Relaisspule entfallen
Verkabelung bleibt bestehen
A54 Ansteuermodul K30 30
quick connecting clutch
control module relais−solenoit excluded

15:5 wiring still the same
X15:2
X15:2
5 6 7 2
87 87a
1
X15:1
X15:1
X19:1
X19:3
X19:2
V14
X1:176 2 057 529 51 057 529 51
1 2 2 1
V12 V13
S
+
23
S36
S139 X1:172 X1:173 X1:174 X1:175
24 Relaiskontakt entfallen
X1:178 X1:179 Prop. Verstellung Vibration Ein / Aus X1:180 Verkabelung bleibt bestehen
prop. adjustment vibration On / Off relay−contact excuded
wiring still the same
X1:177
Verkabelung bleibt bestehen

0,18A
0,18A
Anzeigeleuchte entfallen
indicator light excluded
2.5A
2.5A
2.5A
K67 86 K30 86
wiring still the same

1 1 1 1
Y98 Y122 V09 Y124 V09 Y123 V09
85 85 2 2 2 2
Lütze Lütze Lütze
X1:116 X1:112 X1:116 X1:112

14:20 31 31
15:13 15:10
Prop.−Ventil Vibrationsfrequenz Platten Platten heben
prop.− valve vibration frequency plates lift plates
Hydraulik Umschaltung Platten senken

hydraulic switch over let down plates
29.05.2000
1 1 582 700 70
Werner Anbau Vibrationsplatten
29.05.2000
Seis assembling unit vibration plates 015
Name Bl. Pf. Benennung title TYP
A01 012 6 Intervallschalter Berieselungssystem Interval switch, sprinkler system
A02 013 17 Blinkrelais Indicator relay
A05 005 9 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer MODUL
A06 005 4 Elektronik Frequenzanzeige vorne Electronic system, frequency meter, fr. MODUL
A08 010 18 Elektronik Omegameter Electronic system, Omegameter
A12 014 17 Radio Radio
A15 004 13 Platine Ueberwachungsmodul Printed circuit board, monitoring module
A16 005 14 Elektronik Tachograph Electronic system, tachograph
A17 007 11 Elektronik Geschwindigkeitskontrolle Electronic, speed control
A23 002 8 Platine Generator Printed circuit,generator
A33 010 7 Zentralplatine Kopplung Verdichtungskomponenten Connection dircuit board, compac. components
A35 010 14 Versorgungsplatine Suppling circuit board
A36 008 2 Elektronik Antischlupfregelung Elektronic antispin control
A37 009 11 Elektronik Variomatic Elektronic variomatic
Seis
29.05.2000
Werner
29.05.2000
A44 010 5 Zusatzelektronik Additional control unit

A46 009 2 Modul Variomatik Modul, variomatik
A51 005 17 Platine Frequenzanzeige Circuit board,frequenzy meter
A54 015 6 Modul Pumpenansteuerung Modul pump control
B03 004 19 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B06 004 15 Druckschalter Motoroel Pressure switch, engine oil
B11 004 1 Signalhorn Warning horn MAX. 5A
B11 004 3 Signalhorn Warning horn MAX. 5A
B13 006 2 Naeherungsinitiator Fahrhebel links Proximity switch, travel lever, lh.
B14 006 4 Naeherungsinitiator Fahrhebel rechts Proximity switch, travel lever, rh.
B16 005 3 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 004 18 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B29 014 5 Raumthermostat Room thermostat
B51 014 17 Lautsprecher Radio Speaker radio
B51 014 18 Lautsprecher Radio Speaker radio
B53 004 16 Temperaturgeber Kuehlmittel Temperature switch, collant
B54 003 5 Temperaturgeber Starthilfe Temperature switch, starting assistance
B55 004 19 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B57 008 9 Neigungssensor Stufenumschaltung Slope sensor, speed range selection
B59 008 11 Aufnehmer Bandagengeschwindigkeit Sensor, drum speed
B60 007 15 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 009 7 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 009 9 Beschleunigungsaufnehmer Acceleration sensor
component listing

B75 014 5 Kuehlmitteldruck coolant pressure
Bauteilliste
E01 013 12 Beleuchtung Tankanzeige Illumination, level gauge

E02 013 14 Beleuchtung Temperaturanzeige Illumination, temperature gauge
E03 013 14 Beleuchtung Drehzahlmesser Illumination, rpm meter
E04 011 13 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E05 011 12 Beleuchtung Frequenzanzeige vorne Illumination, frequency gauge, front
E05 013 16 Beleuchtung Frequenzanzeige vorne Illumination, frequency gauge, front
E07 010 17 Beleuchtung Omegameter Illumination, Omegameter
E07 011 12 Beleuchtung Omegameter Illumination, Omegameter
E08 013 18 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 013 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 013 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 013 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 013 6 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 013 5 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 013 6 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 013 7 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 013 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 013 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E22 013 13 Beleuchtung Temperaturanzeige Hydr.−oel Illumination, temp. gauge, hydraulic oil
E23 013 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 014 16 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 013 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 014 17 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 013 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 014 15 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 013 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 014 16 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 014 7 Innenleuchte Kabine Inside light, cabin 1,3A
E30 002 12 Heizgeraet Heating unit MAX.20A/NENN2A
E32 013 9 Kennleuchte Warning light
E32 014 20 Kennleuchte Warning light 5A
E41 013 4 Umrissleuchte vorne links Contour illumination front, lh. MAX. 0,42A
E42 013 4 Umrissleuchte hinten links Contour illumination rear, lh. MAX. 0,42A
E43 013 7 Umrissleuchte vorne rechts Contour illumination front, rh. MAX. 0,42A
E44 013 8 Umrissleuchte hinten rechts Contour illumination rear, rh. MAX. 0,42A
E45 013 13 Beleuchtung Oeldruckanzeige Illumination oil pressure indicator
1
E46 013 15 Beleuchtung Voltmeter Illumination volt meter

E54 013 16 Beleuchtung Vektoranzeige Illumination vector indicator
F00 002 3 Hauptsicherung Batterie Fuse, main, battery 125A

F02 014 19 Ersatzsicherung Fuse, spare
9
F03 007 2 Sicherung Vibration Fuse, vibration 30A

F05 002 19 Sicherung Steckdose Fuse, socket 30A
F06 012 6 Sicherung Berieselung Fuse, sprinkler system 30A
F07 013 12 Sicherung Warnblinker Fuse, hazard light 15A
582 700 70
F08 013 13 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 013 5 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 15A
F10 013 7 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 15A
F11 013 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 003 5 Sicherung Startschalter Fuse, starter switch 30A
101
F14 003 14 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 30A
F17 014 17 Sicherung Radio Fuse, radio
F18 013 4 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 013 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F21 013 13 Sicherung Instrumentenbeleuchtung Fuse, illumination of gauges 30A
F22 013 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 004 2 Sicherung Signalhorn Fuse, warning horn 30A
F24 004 14 Sicherung Ueberwachungsmodul Fuse, monitoring module 30A
F25 006 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 30A
F26 006 14 Sicherung Magnetv. Fahrstufenumsch. Fuse, sol. valve, speed range sel. 30A
F31 014 13 Sicherung Kabinenluefter Fuse, cabin ventilator
F37 012 4 Sicherung Berieselungspumpe Fuse, sprinkler pump 40A
F40 002 12 Sicherung Kabinenheizung Fuse, heating unit cab 25A
F42 014 7 Sicherung Kabineninnenleuchte Fuse, inside light cab
F43 014 8 Sicherung Wischermotor hinten Fuse, wipermotor rear
F44 014 11 Sicherung Wischermotor vorn Fuse, wipermotor front
F51 008 2 Sicherung Antischlupfregelung Fuse, antispin control 30A
Seis
29.05.2000
Werner
29.05.2000
F60 007 19 Sicherung Speed − Control Fuse, speed − control 30A

F63 008 16 Sicherung Lenkung Fuse, steering 30A
F67 009 12 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 30A
F84 009 13 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
G01 002 3 Batterie Battery 100 AH

G02 002 5 Generator Generator
G03 002 4 Batterie Battery 100 AH
H04 009 2 Meldeleuchte Betriebsstoerung Indicator light, breakdown

H07 004 14 Warnsummer Betriebsstoerung Warning buzzer, breakdown
H14 006 9 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer
H14 007 8 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer
H30 007 19 Meldeleuchte Geschwindikgeitskontrolle Indicator light, speed control
H56 009 14 Meldeleuchte "Weiter" Indicator light, "continue"
H56 011 10 Meldeleuchte "Weiter" Indicator light, "continue"
H57 009 15 Meldeleuchte "Fertig" Indicator light, "ready"
H57 011 10 Meldeleuchte "Fertig" Indicator light, "ready"
K04 007 2 Schrittrelais Vibration Toggle relay, vibration

K05 006 6 Relais Startstrom Relay, starting current BOSCHW
K06 013 3 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 9 Relais Klimageraet Relay, air conditioning BOSCHW
K11 003 3 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K16 013 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K22 004 12 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K23 012 12 Relais Berieselungssystem Relay, sprinkler system BOSCHW
K26 006 4 Relais Rueckfahrwarneinrichtung Relay, back up alarm BOSCHW
K30 015 5 Relais Ueberlastschutz Relay, overload protection BOSCHW
component listing
K32 003 2 Relais Kabine Relay, cabin BOSCHL

K33 014 5 Relais Warnsummer Betriebsstoerung Relay, warning buzzer, failure indication BOSCHW
Bauteilliste
K36 002 8 Relais Bremskontrolle Relay, brake control BOSCHW

K37 012 16 Zeitrelais Timing relay
K43 007 17 Relais Vibration Relay, vibration BOSCHW
K46 012 6 Umschaltrelais Switching relay BOSCHW
K48 006 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K49 014 4 Relais Warnsummer Relay, warning buzzer BOSCHW
K67 015 3 Relais Vibrationsabschaltung Relay, vibration deactivation BOSCHW
K77/1 007 14 Relais Override Relay, override BOSCHW
M01 003 7 Starter Starter

M02 012 4 Berieselungspumpe Sprinkler pump 8A
M03 012 14 Emulsionsberieselungspumpe Emulsion sprinkler pump MAX. 7,2A
M04 014 10 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 014 8 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 014 11 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 014 9 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 014 3 Kabinenluefter Cabin ventilator
M09 014 14 Kabinenluefter Cabin ventilator 14,2A
P00 002 10 Betriebsstundenzaehler Operating hour meter

P01 004 5 Tankanzeige Level gauge
P02 004 6 Temperaturanzeige Hydraulikoel Temperature gauge, hydraulic oil
P03 004 7 Drehzahlmesser Rpm meter
P04 005 11 Geschwindigkeitsanzeige Speedometer
P04 011 17 Geschwindigkeitsanzeige Speedometer
P05 005 5 Frequenzanzeige vorne Frequency meter, front
P05 011 16 Frequenzanzeige vorne Frequency meter, front
P07 010 19 Omegameter Omegameter
P07 011 15 Omegameter Omegameter
P09 005 18 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 009 19 Drucker Printer
P11 011 12 Drucker Printer
P12 004 11 Voltmeter Volt meter
P13 004 8 Anzeige Motoroeldruck Pressure gauge, engine oil
P14 004 10 Anzeige Kuehlmitteltemperatur Temperature gauge, coolant
2
P15 010 13 BCM 03 Bildschirm BCM 03 terminal

P16 009 19 Fehleranzeige Variomatic Fault indication, varimatic
P26 009 5 Anzeige Amplitude amplitude indicator
R02 003 6 Gluehkerze Glow plug 0,8A

9
R03 004 4 Geber Tankanzeige Sender, level gauge

R04 004 5 Geber Hydraulikoeltemperatur Sender, hydraulic oil temp.
R07 008 8 Potentiometer Geschwindigkeitsk. Potentiometer speed control
R20 007 9 Widerstand Resistor 330 OHM / 25W
582 700 70

R23 009 14 Widerstand Resistor 1KOHM
102
S00 003 5 Startschalter Starter switch

S01 003 14 Schalter NOT AUS Switch, emergency off NOTAUSH
S03 004 2 Taster Signalhorn Push button, warning horn
S05 012 6 Berieselungsschalter Switch, sprinkler system
S08 007 4 Vibrationsschalter man./autom. Switch, vibration, man./autom.
S09 009 6 Vibrationsschalter vorne Switch, vibration, front
S13 007 2 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 013 12 Warnblinkschalter Switch, hazard light
S15 013 3 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 014 11 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 014 8 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S35 007 4 Vibrationsschalter klein/gross Switch, vibration low/high
S36 015 9 Vibrationsschalter Switch, vibration
S37 013 16 Schalter Blinker Switch, indicator
S38 013 9 Schalter Kennleuchte Switch, warning light
Seis
29.05.2000
Werner
29.05.2000
S38 014 20 Schalter Kennleuchte Switch, warning light

S42 006 11 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S44 014 13 Schalter Kabinenluefter Switch, cabin ventilator
S45 014 7 Kabineninnenleuchte Switch, cabin inside light
S48 007 19 Zusatzschalter Speed Control Additional switch, speed control
S53 013 3 Schalter Arbeitsbeleuchtung Switch, working lights
S54 007 17 Schalter Fahrstufen Switch, speed ranges
S65 009 2 Schalter Vibration horizontal/vertikal Switch, vibration horizontal/vertical
S71 008 17 Schalter Lenkung Switch, steering
S75 007 11 Schalter Fahrhebel Switch, travel control lever
S102 014 3 Schalter Klimaanlage Switch air conditioning
S104 009 15 Schalter man./autom. Switch man./autom.
S106 009 17 Schalter Verdichtungsenergie Switch, compaction energy
S107 009 16 Schalter Amplitutenverstellung Switch,amplit. adjustment
S130 015 16 Schalter Platten Heben / Senken Switch, plates lift / let down
S131 009 16 Schalter Start Switch, start
S131 011 4 Schalter Start Switch, start
S132 009 16 Schalter Stop Switch, stop
S132 011 5 Schalter Stop Switch, stop
S133 009 17 Schalter Drucken Switch, print
S133 011 6 Schalter Drucken Switch, print
S134 009 18 Schalter Loeschen Switch, erase
S134 011 8 Schalter Loeschen Switch, erase
S139 015 6 Schalter Frequenzverstellung Switch, frequency control
S140 011 8 Schalter Test / Normal Switch, test mode / standard mode
S152 011 7 Schalter PD−D Switch, PD−D
S153 011 18 Papiervorschub paper formfeed
component listing
V01 008 6 Diode Diode DIODENMODUL

Bauteilliste

V06 007 9 Diode Diode DIODENMODOL
V07 007 10 Diode Diode DIODENMODOL
V09 006 8 Diode Diode
V09 009 9 Diode Diode VENTIL
V09 009 12 Diode Diode LÜTZE
V11 014 1 Diode Diode WAGO, FE5B
V15 014 3 Diode Diode FE5B
V24 002 1 Load−Dump−Modul Load−dump−modul
X1:1 002 1 WAGO, E−KASTEN WAGO, E−BOX

X1:S 008 2 WAGO, E−KASTEN WAGO, E−BOX
3

9

582 700 70

103

Seis
29.05.2000
Werner
29.05.2000

component listing

Bauteilliste

4
X1:7A 003 6 WAGO, E−KASTEN WAGO, E−BOX

9

582 700 70

104

Seis
29.05.2000
Werner
29.05.2000

component listing

Bauteilliste

5

9

582 700 70

105

X2:3 009 7 VARIOCONTROL variocontrol
Seis
29.05.2000
Werner
29.05.2000

X2:1A 009 12 VARIOCONTROL variocontrol
X2:1E 009 12 VARIOCONTROL variocontrol
X2:2A 009 13 VARIOCONTROL variocontrol
X2:2E 009 13 VARIOCONTROL variocontrol
component listing

Bauteilliste

6

9

582 700 70

106
X3:1 009 8 WEIDMÜLLER, BANDAGE Weidmueller drum

Seis
29.05.2000
Werner
29.05.2000

X4:1 008 8 AMP, POTI FAHRHEBEL AMP, poti travel lever
X5:1 004 14 AMP, WARNSUMMER AMP, buzzer
X5:2 004 14 AMP, WARNSUMMER AMP, buzzer
X6:1 006 1 AMP FAHRHEBEL AMP, travel lever
X9:1 006 9 AMP WARNSUMMER AMP, buzzer
XS 002 19 Steckdose Socket
XS 002 19 Steckdose Socket
X10:1−19 010 13 SCHALTBAU FAHRERSTAND SCHALTBAU, operators platform
X11:1 009 19 SCHALTBAU DIAGNOSE Schaltbau diagnosis
component listing

Bauteilliste

X12:2 009 14 AMP, SCHALTER AMP, switch
X13:1 011 12 Druckerschnittstelle intreface printer
X14:1 007 17 AMP ARMATUREN AMP, dash board
X15:1 011 12 Druckercontroller Printer−controller
X15:1 015 4 PLATTEN KUPPLUNG ANBA plates clutch assembling unit
X15:1 015 5 PLATTEN KUPPLUNG MASC plates clutch, machine
X15:2 015 4 PLATTEN KUPPLUNG ANBA plates clutch assembling unit
X15:2 015 5 PLATTEN KUPPLUNG MASC plates clutch, machine
7
X16:1 015 3 AMP, SENSOR AMP, sensor

9

X17−1:1 004 16 MOTORSTECKER MOTOR engine plug, engine side
582 700 70

107

X18−1:1 002 6 MOTORSTECKER MASCH. engine plug, machine side
Seis
29.05.2000
Werner
29.05.2000

X19:1 015 6 AMP POTI PLATTEN APM poti vibration plates
X20:1 009 16 AMP POTI S107 AMP poti S107
X22:1 013 2 STECKER SCHEINW. STVZ connector head lights StvZO
X24:1 013 5 STECKER SCHLUßLEUCHTE connector tail lights
X25:1 013 6 STECKER PARKLEUCHTE connector parking lights
X30:1 014 9 WISCHER HINTEN connector wiper rear
component listing

X30:3 014 8 STECKER WISCHER HINTE connector wiper rear
Bauteilliste

X31:1 014 12 WISCHER VORN connector wiper front
X32:1 014 7 STECKER INNENLEUCHTE connector inside light, cabin
X32:2 014 7 STECKER INNENLEUCHTE connector inside light, cabin
X33:1 014 14 STECKER LÜFTER connector blower
X34:1 014 3 STECKER KLIMAANL. KAB connector air cond. cabin
X28/1:3 014 11 KABINE HAUPTSTECKER main connector cabin
Y01 003 10 Magnetventil Startmehrmenge Solenoid valve, start boost fuel

8
Y04 006 7 Magnetventil Bremse Solenoid valve, brake MAX. 1,8A

Y06 012 9 Magnetventil Berieselung Solenoid valve, sprinkler system 1,83A
Y06 012 17 Magnetventil Berieselung Solenoid valve, sprinkler system 1,83A
Y07 007 4 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high MAX. 2,5A
Y08 007 5 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low MAX. 2,5A
9
Y13 003 13 Hubmagnet Motor Shut off solenoid, engine 1,1A/55A

Y13 003 15 Hubmagnet Motor Shut off solenoid, engine 4A
Y14 002 15 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 014 2 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
582 700 70
Y22 009 10 Magnetventil Vibration Solenoid valve, vibration

Y30 006 15 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 1,23A/1,67A
Y30 008 5 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 1,23A/1,67A
Y31 006 11 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
108
Y58 003 16 Magnetventil Kraftstoffabschaltung Solenoid valve, fuel switch off 0,8A
Y62 007 11 Magnetventil Verstellung Fahrpumpe Solenoid valve, adjusting travel pump
Y62 007 12 Magnetventil Verstellung Fahrpumpe Solenoid valve, adjusting travel pump
Y64 008 18 Magnetventil Lenkung Solenoid valve, steering 0,33A
Y98 015 9 Magnetventil Vibrationsfrequenz, hinten Solenoid valve, vibrat.freq.,rear
Y117 003 5 Kaltstartbeschleuniger cold starting unit 3A
Y119 009 13 Magnetventil Arretierung Solenoid valve, adjustment
Y122 015 12 Magnetventil Platten heben Solenoid valve, lift plates 2,5A
Y123 015 18 Magnetventil Platten senken Solenoid valve, let down plates 2,5A
Y124 015 16 Magnetventil Hydraulikumschaltung Solenoid valve, hydaulic switch over 2,5A
Y125 009 3 Einlassventil 1 Intake valve 1
Y126 009 5 Einlassventil 3 Intake valve 3
Y127 009 5 Auslassventil 2 Exhaust valve 2
Y128 009 4 Auslassventil 4 Exhaust valve 4
Seis
29.05.2000
Werner
29.05.2000
component listing
Bauteilliste
99
582 700 70
109
Relais für weitere Optionen:
relays for further options:
Für Zusatzausrüstung Kabine und Beleuchtung
Klimaanlage / air conditioning K09,K33,K49 for optin cabin and working head lights
Blinkbegrenzung / StvZO illumination K16,A02
Berieselung / sprinkler systhem K23,K46
Speedcontrol / speedcontrol K43,K77/1,K77/2,K77/3
Vibrationsplatten / vibration plats K30,K67,K115 057 664 33
Module für weitere Optionen

modules for further options
ASC / ASC B57
K06 K26 K22 K48 K36 K05 K11
Terrameter, BTM,Variocontrol / terrameter, BTM, variocontrol A44
Berieselung / sprinkler systhem K37
F05 F40 F14 F51
Tachograph / tachograph A16
F11 F37 F26 F18
Vibrationsplatten / vibration plats A54
Vibrationsfrequenz / vibrationsfrequenz A06 057 268 42 F13 F07 F24 F63
057 543 05
F19 F09 F25 F60
057 664 38
F22 F10 F03 F06
057 564 17 057 664 06
K32 F21 Res F23 F08
057 564 22
057 564 23 A23 Box A Box B Box C Box D

K04 057 551 53
057 510 99
057 564 19 057 564 25 057 564 20
057 564 21 057 564 24 057 564 29
057 510 98
101
100
103
105
106
107
108
120
104
11
10
13
15
16
17
19
31
51
91
12
18
21
14
41
30
33
35
36
37
39
50
55
56
57
73
75
76
77
79
90
93
95
96
97
99
20
23
25
26
27
29
32
38
58
92
98
78
80
22
28
7a
34
40
43
49
54
74
94
24
42
44
1
5
6
7
9
2
8
4
X1:73−80 nur bei Kabine

x1:73−80 only acc.to. cabin
nur bei Arbeitsbeleuchtung

only acc. to head lights
nur bei Arbeitsbeleuchtung
Nur bei Perkins Motor belegt

only acc. to head lights
only used acc. to Perkins engine
BW 212−3
29.05.2000
1 1 582 700 70
Werner Schaltkastenübersicht BW 212−3
29.05.2000
Seis overview e−box BW 212−3 201
057 664 33
K06 K26 K22 K48 K36 K05 K11

F05 F40 F14 F51
058 172 38
F11 F37 F26 F18
057 268 42 F13 F07 F24 F63
057 543 05
F19 F09 F25 F60
Susmic 16 für ASC 057 664 38
Susmic 16 for ASC F22 F10 F03 F06
F21 Res F23 F08
K32
057 664 06
057 510 99
A23
K04
Box A Box B Box C Box D
057 510 98
nur für Kabine
only acc. to cabin 057 551 53

Klimaanlage / air conditioning K09,K33,K49
weitere Klemmenbereiche:
further terminal sections: Berieselung / sprinkler systhem K23,K46
Klimaanlage / air conditioning X1:121−126 Speedcontrol / speedcontrol K43,K77/1,K77/2,K77/3
111
101
110
113
115
116
117
119
112
118
114
100
103
105
106
107
109
102
108
120
104
91
93
95
96
97
99
92
98
94
Blinkbegrenzung / StvZO illumination X1:128−133 Vibrationsplatten / vibration plats K30,K67,K115

Berieselung / sprinkler systhem X1:134−144
Speedcontrol / speedcontrol X1:145−168 Module für weitere Optionen
Vibrationsplatten / vibration plats X1:169−180
ASC / ASC B57
057 564 17 Terrameter, BTM,Variocontrol / terrameter, BTM, variocontrol A44
057 564 22 Berieselung / sprinkler systhem K37
057 564 23 Tachograph / tachograph A16
057 564 19 057 564 25 057 564 20 Vibrationsplatten / vibration plats A54
057 564 21 057 564 24 057 564 29 Vibrationsfrequenz / vibrationsfrequenz A06
V01
V02
V03
V04
V05
V06
V07
V08
057 664 03
1 1 1 1 1 1 1 1
1 2 3 4 5 6 7 8
11
10
13
15
16
17
19
31
51
61
71
12
18
21
81
14
41
30
33
35
36
37
39
50
53
55
56
57
59
60
63
65
66
67
69
70
73
75
76
77
79
93
90
20
23
25
26
27
29
32
38
52
58
62
68
72
83
85
86
87
89
78
80
22
28
82
88
7a
34
40
43
45
46
47
49
54
64
74
24
42
48
84
44
1
5
6
7
9
2
8
4
2 2 2 2 2 2 2 2
H07
057 513 10
Schaltkasten Grundversion
e−box, basic version
29.05.2000
1 1 582 700 70
Werner Schaltkastenübersicht Grundversionen
29.05.2000
Seis overview e−box, basic versions 202
057 664 33
057 666 01
K06 K26 K22 K48 K36 K05 K11
F05 F40 F14 F51
330_O
330_O
68_O
F11 F37 F26 F18
R22
R21
R20
058 179 92
057 268 42 F13 F07 F24 F63
057 543 05
F19 F09 F25 F60
057 664 38 057 665 68
Susmic 16 für Speedcontrol F22 F10 F03 F06
Susmic 16 for speedcontrol
F21 Res F23 F08
K32
057 664 06
A23
K04 057 551 53 Box A Box B Box C Box D
057 510 99
nur für Kabine
only acc. to cabin
057 510 98

Klimaanlage / air conditioning K09,K33,K49
weitere Klemmenbereiche:
further terminal sections: Berieselung / sprinkler systhem K23,K46
Klimaanlage / air conditioning X1:121−126 Speedcontrol / speedcontrol K43,K77/1,K77/2,K77/3
111
101
110
113
115
116
117
119
112
118
114
100
103
105
106
107
109
102
108
120
104
91
93
95
96
97
99
92
98
94
Blinkbegrenzung / StvZO illumination X1:128−133 Vibrationsplatten / vibration plats K30,K67,K115

Berieselung / sprinkler systhem X1:134−144
Speedcontrol / speedcontrol X1:145−168 Module für weitere Optionen
Vibrationsplatten / vibration plats X1:169−180
ASC / ASC B57
057 564 17 Terrameter, BTM,Variocontrol / terrameter, BTM, variocontrol A44
057 564 22 Berieselung / sprinkler systhem K37
057 564 23 Tachograph / tachograph A16
057 564 19 057 564 25 057 564 20 Vibrationsplatten / vibration plats A54
057 564 21 057 564 24 057 564 29 Vibrationsfrequenz / vibrationsfrequenz A06
V01
V02
V03
V04
V05
V06
V07
V08
057 664 03
1 1 1 1 1 1 1 1
1 2 3 4 5 6 7 8
11
10
13
15
16
17
19
31
51
61
71
12
18
21
81
14
41
30
33
35
36
37
39
50
53
55
56
57
59
60
63
65
66
67
69
70
73
75
76
77
79
93
90
20
23
25
26
27
29
32
38
52
58
62
68
72
83
85
86
87
89
78
80
22
28
82
88
7a
34
40
43
45
46
47
49
54
64
74
24
42
48
84
44
1
5
6
7
9
2
8
4
2 2 2 2 2 2 2 2
H07
057 513 10
Schaltkasten mit Speedcontrol

e−box, with speed control
29.05.2000
1 1 582 700 70
Werner Schaltkastenübersicht mit Speedcontrolanbau
29.05.2000
Seis overview e−box with assembled speedcontol 203
057 563 57 057 563 56
Anschlußstecker ESX 7265 057 563 58 057 563 55
connector ESX 7265
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
057 563 54
057 564 21
057 564 22
057 564 24 057 564 20 057 564 25
057 564 35
11
10
13
15
16
17
19
91
12
18
21
14
30
93
20
23
25
26
27
29
92
22
28
94
24
5
6
7
9
8
1
4
3
2
A37 A46
F67
F84
582 701 38 057 664 70

X2:1−30
057 564 17 057 564 29
057 564 36
31 32 33 34 35 36 37 45 46 47 48 49 50 51 59 60 61 62 63 64 65 73 74 75 76 77 78
38 39 40 41 42 43 44 52 53 54 55 56 57 58 66 67 68 69 70 71 72 79 80 81 82 83 84
P18
057 664 63
Anschlußstecker ESX 7265
X2:31−84 connector ESX 7265
X11:1−19
057 565 20 057 565 19 X11:1−19
057 662 52
Innenseite Zusatzelektrik Außenseite Zusatzelektrik 057 662 51
inner side additional electric outside view additional electric
Zusatzelektrik für Variocontrol

additional electrical equipment for variocontrol
29.05.2000
1 1 582 700 70
Werner Schaltkastenübersicht für Zusazelektrik Variocontrol
29.05.2000
Seis overview e−box for additional equipment variocontrol 204

bw216dh 3 bw225d 3 Service Training PDF

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bw216dh 3 bw225d 3 Service Training PDF

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Training Manual

Single Drum Rollers

BW 216 D-3, BW 216 DH-3/PDH-3

Part-No. 008 098 29 4/2000

DEUTZ Diesel engine D1

BW 216 D-3, BW 216 DH-3/PDH-3

BW 216 D-3, BW 216 DH-3/PDH-3

BW 216 D-3, BW 216 DH-3/PDH-3

1. Operating and maintenance instructions

2. Spare parts catalogue

BW 216 D-3, BW 216 DH-3/PDH-3

* These documents are part of the training manual

BW 216 D-3, BW 216 DH-3/PDH-3

• strong ROPS/FOPS according to SAE standard

BW 216 D-3, BW 216 DH-3/PDH-3

BW 216 D-3, BW 216 DH-3/PDH-3

Fig. 1 Position of important service points

1 Drum drive motor 13 Vibration pump

BW 216 D-3, BW 216 DH-3/PDH-3

BOMAG Central Service - Technical data and adjustment values

Product type: BW 216 D-3

Reduction gear, drum:

Travel motor, rear:

Displacement stage 1: 110 cm3/U

Steering and charge pump:

BOMAG Central Service - Technical data and adjustment values

Product type: BW 216 D-3

Reduction gear, drum:

Travel motor, rear:

Displacement stage 1: 110 cm3/U

Steering and charge pump:

BOMAG Central Service - Technical data and adjustment values

Product type: BW 216 D-3

Reduction gear, drum:

Travel motor, rear:

Displacement stage 2: 40,3 cm3/U

Steering and charge pump:

BOMAG Central Service - Technical data and adjustment values

Product type: BW 216 DH-3

Reduction gear, drum:

Travel motor, rear:

Displacement stage 1: 110 cm3/U

Steering and charge pump:

BOMAG Central Service - Technical data and adjustment values

Product type: BW 216 PDH-3

Reduction gear, drum:

Travel motor, rear:

Displacement stage 1: 110 cm3/U

Steering and charge pump:

BOMAG Central Service - Technical data and adjustment values

Product type: BW 216 DH-3

Reduction gear, drum:

Travel motor, rear:

Displacement stage 2: 27,5 cm3/U

Steering and charge pump:

BOMAG Central Service - Technical data and adjustment values

Product type: BW 216 PDH-3

Reduction gear, drum:

Travel motor, rear:

Displacement stage 1: 110 cm3/U

Steering and charge pump:

BOMAG Central Service - Technical data and adjustment values

Product type: BW 216 PDH-3