BW211D-40 SVC TRG PDF

Service Training
Single Drum Rollers

BW 211 / 212 / 213 D- 40
with Deutz engine 2012 C
Part-No. 008 097 26 11/2005

Service Training
Table of contents
Foreword A1
Documentation A2
General A3
Novelties
Technical data and adjustment values B1
Maintenance C1
Maintenance chart C2
DEUTZ diesel engine D1

Operating side D2
Exhaust side D3
Lubrication oil circuit D4
Fuel circuit D5
Checking and adjusting the valve clearance D6
Assembly of plug-type injection pump D8
Test and adjustment points D16
Travel system E1
Travel pump E3
Control E6
Charge pressure relief valve E 11
High pressure relief valve E 12
Pressure override E 14
Axle drive motor E 16
Drum drive motor E 20
Test and adjustment points, travel system E 25
Trouble shooting in travel system E 29
BW 211 / 212 / 213 D-40

Service Training
Vibration F1
Vibration pump F3
High pressure relief valves F6
Control F7
Charge pump F8
Vibration motor F9
Drum F 12
Test and adjustment points, vibration system F 14
Trouble shooting in vibration system F 16
Steering G1
Steering pump(s) G2
Steering valve G4
Articulated joint G6
Measuring and adjustment points G8
Trouble shooting steering system G9
Electrics H1
Wiring diagram
Hydraulic diagram
BW 211 / 212 / 213 D-40

Service Training
Foreword
Reliable construction equipment is of greatest advantage for all parties involved:
for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAGs philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
the location of components in the machine eases maintenance work,
the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAGs own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAGs excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.
BW 211 / 212 / 213 D-40 -A1-

Service Training
Documentation
For the BOMAG machines described in this training manual the following documentation is additionally
available:
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.
1. Operating and maintenance instructions

2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.
BW 211 / 212 / 213 D-40 -A2-

Service Training
General
The new BOMAG single drum rollers D-40 are mainly further developments of their predecessors.
These machines have been successfully and reliably used for years on construction sites all over the
world, especially in earth construction and on sanitary landfill sites.
High compaction power and excellent traction are characteristics, which are of utmost importance for
this type of machine.
All components installed in these machines are manufactured in series production and are subjected to
stringent quality tests. This guarantees a high level of reliability and safety.
As with many other BOMAG products, and here especially with the large single drum rollers of the new
generation, we have decided to use the same successful drive concept with diesel engine (water cooled)
and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the
engine directly to drum, drive wheels and steering.
The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by
slow running radial piston motors.
On construction machines the work place of the operator is of utmost importance. Under such working
conditions the health and safety of the operator must be the greatest concern.
The cabin is very spacious and clearly arranged. The drivers seat is very comfortable and can be
individually adjusted for every operator, even for his weight.
All control elements and gauges are within the reach and in the sight of the operator.
A monitoring display with light emitting diodes and clear pictograms informs the operator about any
operating faults. The operator is therefore always informed about the present condition of the machine.
The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens,
as well as a heated rear windscreen, offers clear vision to all sides.
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Service Training
Important characteristics of the new generation of single drum rollers are
strong ROPS/FOPS according to SAE-standard
the multi-disc brake in the axle serves as parking and emergency brake
high stability due to low centre of gravity and the use of an articulated joint
operating safety due to the use of monitoring boards for all important system data
automatic engine shut down under a too high engine temperature and too low engine oil pressure.
The machines of series D-40 are well designed down to the smallest detail, so that they can meet the
toughest demands on large scale construction sites all over the world.
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Service Training
Novelties
The new instrument cluster shows important warnings and control data of
the machine.
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Service Training
Technical data and adjustment values
The following pages contain technical data valid at the date of printing (see front page of this manual).
Attention!
The currently valid technical data and adjustment values can be taken from the BOMAG Intranet
or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.
BW 211 / 212 / 213 D-40 -B1-

BOMAG Central Service Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values
Status: 2005-11-23
Product type: BW 211 / 212 / 213 D-40

Type No.: 58242 / 58243 / 58244
Serial numbers from: 101 582 42/43/44 1001
Engine:
Type: BF4M2012C
Combustion principle: 4-stroke-Diesel
Cooling: Water
Number of cylinders: 4
Power acc. to ISO 9249: 98 kW
Power data at nominal speed of: 2300 1/min
Low idle speed: 900+/-200 1/min
High idle speed: 2430+/-50 1/min
Spec. fuel consumption: 225 g/kWh
Valve clearance, inlet: 0,3 mm
Valve clearance, outlet: 0,5 mm
Opening pressure, injection valves: 220 bar
Starter voltage: 12 V
Starter power: 3,1 kW
Travel pump:
Type: 90R 075
System: Axial piston-swash plate
Max. displacement: 75 cm3/U
Max. flow ratio: 172,9 l/min
High pressure limitation: 400 +26 bar
Charge pressure, high idle: 26 bar
Travel motor, rear:

Type: 51D110
System: Axial piston-bent axle
Max. displacement (stage 1): 110 cm3/U
Min. displacement (stage 2): 69 cm3/U
Perm. leak oil quantity: 2 l/min
Rinsing oil quantity: 16 l/min
Rinsing oil pressure limitation: 16 bar
Drum drive:
Type: MSE 18 1C
System: Radial piston
Displacement stage 1: 2800 cm3/U
Perm. leak oil quantity: 2 l/min
Vibration pump:
23.11.2005
BOMAG Central Service Seite 2 von 2
Type: 42R 041

Max. displacement: 41 cm3/U
Starting pressure: 345+26 bar
Operating pressure, soil dependent: ca.100 bar
Vibration motor:
Type: A10FM 45
Displacement: 45 cm3/U
Frequency: 30/35 Hz
Amplitude: 2 / 1 mm
Rinsing oil quantity: 6 l/min
Rinsing oil pressure limitation: 13 bar
Steering and charge pump:

Type: HY/ZFS11/16
System: Gear pump
Displacement: 16 cm3/U
Max. steering pressure: 175+26 bar
Steering valve:
Type: OSPC 500 ON
System: Rotary valve
Rear axle:
Type: CHC 192/51HD
Differential: No-Spin
Degree of locking: 100 %
Reduction ratio: 43,72
Filling capacities:
Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on
Ethane-diol-basis)
Engine oil: 10 l (SAE 15W-40, API CG-4 (for details see
maintenance manual))
Hydraulic oil: 60 l (HVLP 46 VI 150)
Vibration bearing housing: 2x 0,8 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)
AC refrigerant: 1300 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG l)
23.11.2005
Service Training
Maintenance
Single drum rollers are heavy-duty construction machines for extremely difficult tasks in earth
construction. To be able to meet these demands the machines must always be ready to be loaded up
to their limits. Furthermore, all safety installations, protections and guards must always be in place and
fully functional.
Thorough maintenance of the machine is therefore mandatory. This 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 hours
interval you must also perform the work described for the service intervals after 50, 250 and 500 hours.
During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and
lubricants (oils, fuels, grease etc.).
The designation specified under No: in the first column of the maintenance chart refers to the
corresponding number of the service work to be performed, as specified in the operating and
maintenance instructions. This also helps to find detailed information on the individual maintenance
tasks.
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5.3 Table of fuels and lubri-
cants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention

Observe the level marks
Engine Engine oil ACEA: E3-96/E5-02 or approx. 8,5 litres without

oil filter
API: CG-4/CH-4
SAE 10W/40
(-20 C to +40 C)
SAE 15W/40
(-15 C to +40 C)
Fuel
Diesel Winter diesel fuel approx. 150 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm2/s at 40 C
Vibration bearings Engine oil SAE 15W/40 approx. 0,8 litres
Drive axle Gear oil SAE 90, API GL5 approx. 9,5 litres
Wheel hubs Gear oil SAE 90, API GL5 approx. 1,9 per side
Air conditioning system Refrigerant R134A approx. 1400 g
Tires (only BW 213) Water approx. 295 litres
Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg

(MgCl2)
Engine cooling system Cooling system protection agent approx. 16 litres
BW 211/212/213 D-40
5.4 Running-in instructions
The following maintenance work must be per-

formed when running in new machines or
overhauled engines:
Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes

l Retighten the V-belt
After 250 operating hours

l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.
l Retighten all wheel fastening screws with the
specified tightening torque.
l Changing engine oil and oil filter
l 1. Oil change vibration bearings
l Oil change in drive axle
l Oil change in wheel hubs
After 500 operating hours

l 2. Oil change vibration bearings
BW 211/212/213 D-40
5.5 Maintenance chart
every 10 operating hours, daily
every 1000 operating hours


after 250 operating hours
Running-in instructions
No. Maintenance work Remark
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Check the dust separator X
5.12 Check the tire pressure X
5.13 Clean the cooling fins on engine and hy- X
draulic oil cooler
5.14 Check the oil level in the drive axle X
5.15 Check the oil level in the wheel hubs X
5.16 Check the oil level in the vibration bear- X
ings
5.17 Change engine oil and oil filter car- min. 1x per year X X
tridge*
5.18 Drain the sludge from the fuel tank X
5.19 Service the battery Pole grease X
5.20 Check, replace the refrigerant compres- X
sor V-belt
5.21 Service the air conditioning X
5.22 Check, adjust the valve clearance Intake = 0,3 mm X
Exhaust = 0,5 mm
5.23 Check, replace the ribbed V-belt X
5.24 Change the fuel filter cartridge X
BW 211/212/213 D-40
every 10 operating hours, daily


after 250 operating hours
Running-in instructions
No. Maintenance work Remark
as required
5.25 Change the fuel pre-filter cartridge X
5.26 Check the engine mounts X X
5.27 Oil change in drive axle min. 1x per year X X
5.28 Oil change in wheel hubs min. 1x per year X X
5.29 Oil change vibration bearings** see foot note, min. X X
1 x per year
5.30 Retighten the fastening of the axle on X
the frame
5.31 Tighten the wheel nuts X X
5.32 Check the ROPS X
5.33 Clean the oil bath air filter min. 1x per year X
5.34 Change hydraulic oil and breather fil- at least every 2 X
ter*** years
5.35 Change the hydraulic oil filter*** at least every 2 X
years
5.36 Change the coolant at least every 2 X
years
5.37 Check the injection valves X
5.38 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2 years
5.39 Adjusting the scrapers X
5.40 Adjust the parking brake X
5.41 Change the tires X
5.42 Change the fresh air filter in the cabin X
5.43 Tightening torques X
5.44 Engine conservation X
BW 211/212/213 D-40
* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h.
*** Also in case of repair in the hydraulic system.
BW 211/212/213 D-40
Service Training
Deutz diesel engine
Single drum rollers of series BW 211 / 212 / 213 D-40 are powered by a Deutz diesel engine of product
range BF4M 2012 C.
These engines are characterized by the following positive features:
short and compact design,
low noise level,
almost vibration-free running,
low fuel consumption,
low exhaust emissions (EPA II),
high power reserves and
good access to all service points.
Crankcase and cylinders of this engine are made of alloyed cast iron. This provides strength and
ensures high wear resistance.
The forged steel conrods are fitted with compensation weights near the conrod bearing seats. These
weights compensate manufacturing tolerances with respect to weight and centre of gravity.
The pistons are made of an aluminium alloy. The combustion chamber recess is slightly offset from the
middle at its side walls are inclined for 10 towards the inside. All pistons are fitted with three piston rings
and a cast iron ring carrier for the first ring. The pistons are lubricated by an oil mist.
The forged crankshaft is equipped with integrated counterweights.
The block-type cylinder head is made of cast steel. Each cylinder is fitted with one intake and one
exhaust valve. The valve guides are shrunk into the cylinder head. The valve seat rings are made of
high-grade steel and are also shrink fitted.
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Service Training
Service side
3 4
2
5
6
14
9 8
13 12 11 10
Fig. 1: Service side BFM 1013/2012
1 Oil filler neck 8 Fuel pump

2 Valve, boost fuel supply 9 Engine mounting
3 Engine solenoid 10 Fuel filter
4 Oil pressure switch 11 Lubrication oil filter
5 Cooling air blower 12 Oil sump
6 Coolant pump 13 Dipstick
7 V-belt pulley 14 Steering/charge pump
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Service Training
Starter side
3
1
Fig. 2: Starter side
1 Flywheel
2 Ground cable
3 Starter
4 Turbo charger
5 Generator
6 Coolant temperature switch
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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 sump 12 Piston cooling nozzle

2 Return flow turbo charger to crankcase 13 Camshaft bearing
3 Turbo charger 14 Main oil channel
4 Oil line to turbo charger 15 Lubrication oil cooler
5 Line to mass balance wheel (2 x) 16 Lubrication oil pump
6 Oil pressure sensor 17 Pressure relief valve
7 Valve with pulse lubrication 18 Leak oil return line
8 Push rod, oil supply to rocker arms 19 Lubrication oil filter
9 Line to spray nozzles 20 Suction line
10 Rocker arm 21 Crankshaft bearing
11 Return flow to oil sump 22 Conrod bearing
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Service Training
Lubrication oil circuit
3 1
5 4
Fig. 4: Lubrication oil circuit
1 Cooler
2 To cooler
3 From cooler
4 Coolant pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder head cooling
8 Ventilation connection between cylinder head and heat exchanger
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Service Training
FuelFuel system
7
1a
1b
1c
Fuel tank
1d
Fuel system
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Service Training
Legend:
1a Fuel lift pump

1b Fuel pre-filter
1c Water separator
1d) Water proportion sensor
2 Feed to fuel lift pump
3 Fuel lift pump
4 Connecting line lift pump main filter (fuel pre-pressure up to 10 bar)
5 Main fuel filter (pressure resistant)
6 Connecting line main filter supply for injection pump
7 Single injection pump
8 High pressure line
9 Injection nozzle
10 Leakage line
11 Pressure retaining valve - 5 bar
12 Return flow to tank
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Service Training
Fuel pre-filter with water separator
1
2
Fig. 5: Fuel pre-filter with water separator
1) Lift pump
2) Vent valve
3 Filter element
4) Water and dirt collecting bowl
5 Drain valve
6 Electric connection for water level sensor
The fuel pre-filter / water separator consists mainly of:
the dirt / water sediment bowl with water level warning sensor
and the filter element
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Service Training
Function:
The fuel lift pump draws the fuel through both filters.
The water resistant filter element retains remaining smaller dirt and water particles.
Once the water level reaches the height of the warning connections, the warning light in the dashboard
lights up.
Draining off water or fuel :
If the filter element is clogged before a service is due (indicated by e.g. a power drop), the filter may be
regenerated as follows to keep up operation of the engine:
Open the bleeding screw (this applies atmospheric pressure to the filter element and releases bigger
dirt particles from the bottom side of the filter, which will then sink down.
Open the drain valve and let approx. 0.5 l of fuel run out. The fuel above the filter element presses
through the filter element and cleans the underside of the filter element from dirt.
Close the drain valve.
Draining off larger dirt particles or sludge:
Unscrew the water separator housing
Bleed the system by operating the fuel lift pump and then tighten the bleeding screw.
Main fuel filter
Attention!
The main fuel filter is subjected to approx. 10 bar fuel pre-pressure from the fuel lift pump. This
pressure is considerably higher than on other engines. For this reason only original filter
elements must be used. Filter elements of similar design or with adequate dimensions are not
necessarily pressure resistant!
A filter element of insufficient pressure resistance will be damaged by the high pressure and will
disintegrate. This causes severe damage to the injection system!
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Service Training
Checking and adjusting the valve clearance
Excessive or insufficient valve clearance can cause failure of the engine as a result of mechanical and
thermal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the
intervals specified in the operating and maintenance instructions.
Note: The valve clearance must be checked and adjusted when the engine is cold.
Intake valve = 0.3 mm Exhaust valve= 0.5 mm
Turn the crankshaft until both valves on cylinder 1 are overlapping (the exhaust valve is not yet
closed, the intake valve starts to open).
Flywheel
side
1 2 3 4
Fig. 6: Crankshaft position 1
Check and adjust the valve clearance by following the black marking in the adjustment schematics.
For control purposes mark the respective rocker arm with chalk.
Flywheel
side
1 2 3 4
Fig. 7: Crankshaft position 2
Turn the crankshaft one full turn (360) further.
Check and adjust the valve clearance by following the black marking in the adjustment schematics.
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Service Training
Explanation of pictograms
During the following work the following pictograms are used for the reason of simplicity:
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Service Training
plug-in injection pump
Deutz diesel engines of product range 2012/1013 are equipped with plug-in injection pumps of series
PF 33 from Bosch.
The concept of the plug-in fuel injection pumps enables the realization of high injection pressures in
connection with extremely short injection lines, which contributes to a high hydraulic stiffness of the
injection system. This in turn provides the prerequisite for low exhaust emission values (soot) in
combination with a low fuel consumption.
Plug-in fuel injection pumps have the following plunger dimensions:
Stroke 12 mm
Diameter 9 mm
Cavitation in the injection lines and injection overrun, which is normally associated with high pressures,
is prevented by a return flow nozzle arranged after the pressure valve
The constant volume relief is 50 mm.
Assembling the plug-type injection pumps
The adjustment of the injection pump timing (FB) affects:
the fuel consumption,
the power
the exhaust emission
of the engine.
On engines of series 2012/1013 the start of delivery is adjusted without tolerance. The start of delivery
is entered in degree of crank angle measured from the top dead centre of the piston and depends on
application, power and speed setting of the engine.
The plug-in injection pump is in position of start of delivery when the plunger just closes the fuel supply
bore in the plunger sleeve.
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Service Training
On engines with inline injection pumps the engine drive is turned to start of delivery position and closing
of the fuel supply bore is determined by means of a high pressure pump. Occurring tolerances are
compensated in the coupling of the injection pump drive, whereby the injection pump camshaft is turned
to start of delivery position against the fixed engine drive.
The injection pump cams on engines of series 2012/1013 are arranged on the camshaft of the engine.
For this reason the conventional adjustment method for the start of delivery cannot be used.
The start of delivery of the injection pump must be adjusted using the new method.
For this the conventional adjustment method is subdivided into length measurements of individual
engine parts and calculations.
The permissible manufacturing tolerances for the components
cylinder crankcase,
camshaft,
plunger
plug-in injection pump
are measured and eliminated by the adjustment of the start of delivery.
However, in cases of interest for BOMAG engineers the engine will not be overhauled completely, but
individual injection pumps will be replaced.
Crankcase, camshaft and plunger remain unchanged.
This results in a certain installation measurement for the engine drive, which is stamped on the engine
type plate.
In column EP it is stamped as CODE for each cylinder.
Note:
If an injection pump and/or nozzle is replaced, the respective high pressure line between pump and
nozzle must also be replaced..
1. Remove crankcase ventilation and cylinder

head cover.
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Service Training
Fig. 8:
2. Remove the engine solenoid
Fig. 9:
3. Insert the pressing device, WILBR No. 100

830 carefully into the groove in the governor
rod and tighten.
Fig. 10:
4. Turn the knurled fastening screw to press the

governor rod to stop position.
Note:
Tighten the knurled fastening screw by hand.
Fig. 11:
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Service Training
5. Set the cylinder of the injection pump to be
replaced to ignition top dead centre (valves
overlapping). Then turn the crankshaft
approx. 120 against the sense of rotation.
Note:
View on flywheel
Fig. 12:
6. Remove injection line and injection pump.
Fig. 13:
7. Take the compensation shim carefully out with

the rod magnet.
Fig. 14:
Determine the thickness of the new compensation shim:
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Service Training
Determination of the compensation shim thickness when replacing plug-in fuel injection
pumps
On the engine type plate column - EP contains a code for the plug-in fuel injection pump for each
cylinder.
295
Each line represents 1 cylinder

e.g. 1st line = cylinder 1
2. line = cylinder 2 etc.
Fig. 15: Injection pump code BFM 2012/1013
The EP-code is used to determine the installation measurement to be corrected Ek from table 1.
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Service Training
EK EP EK EP EK EP EK EP
(mm) code (mm) code (mm) code (mm) code
119,250 230 119,850 254 120,450 278 121,050 302
119,275 231 119,875 255 120,475 279 121,075 303
119,300 232 119,900 256 120,500 280 121,100 304
119,325 233 119,925 257 120,525 281 121,125 305
119,350 234 119,950 258 120,550 282 121,150 306

119,375 235 119,975 259 120,575 283 121,175 307
119,400 236 120,000 260 120,600 284 121,200 308
119,425 237 120,025 261 120,625 285 121,225 309
119,450 238 120,050 262 120,650 286 121,250 310

119,475 239 121,075 263 120,675 287 121,275 311
119,500 240 120,100 264 120,700 288 121,300 312
119,525 241 120,125 265 120,725 289 121,325 313
119,550 242 120,150 266 120,750 290 121,350 314

119,575 243 120,175 267 120,775 291 121,375 315
119,600 244 120,200 268 120,800 292
119,625 245 120,225 269 120,825 293
119,650 246 120,250 270 120,850 294

119,675 247 120,275 271 120,875 295
119,700 248 120,300 272 120,900 296
119,725 249 120,325 273 120,925 297
119,750 250 120,350 274 120,950 298

119,775 251 120,375 275 120,975 299
119,800 252 120,400 276 121,000 300
119,825 253 120,425 277 121,025 301
Fig. 16: Injection pump code table BFM 2012
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Service Training
EK EP EK EP EK EP EK EP
(mm) code (mm) code (mm) code (mm) code
145.7 349 146.3 373 146.9 397
145.725 350 146.325 374 146.925 398
145.75 351 146.35 375 146.95 399
145.775 352 146.375 376 146.975 400
145.8 353 146.4 377 147.0 401

145.825 354 146.425 378 147.025 402
145.85 355 146.45 379 147.05 403
145.875 356 146.475 380 147.075 404
145.9 357 146.5 381 147.1 405

145.925 358 146.525 382 147.125 406
145.35 335 145.95 359 146.55 383 147.15 407
145.375 336 145.975 360 146.575 384 147.175 408
145.4 337 146.0 361 146.6 385 147.2 409

145.425 338 146.025 362 146.625 386 147.225 410
145.45 339 146.05 363 146.65 387 147.25 411
145.475 340 146.075 364 146.675 388 147.275 412
145.5 341 146.1 365 146.7 389 147.3 413

145.525 342 146.125 366 146.725 390 147.325 414
145.55 343 146.15 367 146.75 391 147.35 415
145.575 344 146.175 368 146.775 392 147.375 416
145.6 345 146.2 369 146.8 393 147.4 417

145.625 346 146.225 370 146.825 394 147.425 418
145.65 347 146.25 371 146.85 395 147.45 419
145.675 348 146.275 372 146.875 396
Fig. 17: Injection pump code table BFM 1013
Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from
table 1.
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Service Training
During the manufacture of the plug-in fuel injection pump the high pressure method is used to determine
the wear in the fuel supply bore. In this position injection pump plunger in start of fuel delivery position
- the distance between pump contact face and plunger foot contact face is measured.
Measurement "A" in 1/100 mm has been written on the pump with an electric marker.
64
Fig. 18: Plunger code inscription
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Service Training
A=XXX
Fig. 19: Individual injection pump
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Service Training
Measurement "A" specifies by how many 1/100 mm the gap between contact area on cylinder
crankcase and plunger foot is longer than the hydraulic base measurement Lo.
Lo
A = XX
A/100
Fig. 20: Presentation of measurement A
Lo = 117,5 mm - BFM 2012
Lo = 143 mm - BFM 1013
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Service Training
Ek Lo+A/100
Z
Ts
Fig. 21: Drive in start of delivery position after determination of Ts
The plug-in fuel injection pump is now positively connected with the drive, which has been set to start
of delivery by inserting a compensation shim "Z" of calibrated thickness..
The illustration explains that according to calculation:
(Ek) - (Lo + A/100)
there is a gap Ts between injection pump plunger foot and roller plunger. This gap has to be
compensated with a compensation shim "Z" of appropriate (calculated) thickness.
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Service Training
Theoretical Compensation Theoretical Compensation

thickness shim thickness shim
Ts thickness Ss Ts thickness 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 1: Compensation shims 2012/1013
For the determination of the theoretical shim thickness Ts it is also necessary to determine
measurement Lo + A/100 of the new fuel injection pump, which must then be subtracted from the
corrected injection pump measurement Ek.
Ts = Ek - (Lo + A/100) [mm]
The real compensation shim thickness Ss is determined with the help of table 2.
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Service Training
Exemplary calculation for BFM 2012
EP-code read off engine type plate: 295
see table 1
corrected injection pump measurement Ek: 120,875 mm
Lo = 117,5 mm (fixed measurement)
Value for A/100 read off new injection pump A/100 = 42
Ts = Ek - (Lo + A/100)
Ts = 120,875 mm - (117,5 + 42/100 mm)
Ts = 2.955 mm
see also table 1
Ts = 3,0 mm
Exemplary calculation for BFM 1013
EP-code read off engine type plate: 397
see table 1
corrected injection pump measurement Ek: 146.9 mm
Lo = 143 mm (fixed measurement)
Value for A/100 read off new injection pump A/100 = 133
Ts = Ek - (Lo + A/100)
Ts = 146,9 mm - (143 + 133/100 mm)
Ts = 2.57 mm
see also table 1
Ts = 2,6 mm
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Service Training
8. P?lace the new calculated compensation shim
on the roller plunger.
Fig. 22:
9. Turn the injection pump control lever to

approx. middle position.
Fig. 23:
10. Apply some oil to the locating bore in the

crankcase and the O-rings on the injection
pump. Carefully insert the injection pump
control lever into the governor rod.
Fig. 24:
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Service Training
11. Attach the flange.
Note:
The chamfer must face towards the injection

pump body
Fig. 25:
12. Slightly oil the screws and tighten them

evenly with 5Nm.
Fig. 26:
13. Loosen the screws again for 60.
Fig. 27:
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Service Training
14. Carefully turn the injection pump with and
open end spanner in anti-clockwise direction
against the noticeable stop
Fig. 28:
15. Tighten the screws again for 60 and

continue in stages with tightening torques of
7 Nm, 10 Nm and 30 Nm.
Note:
Start with the outer screw, viewed from the

flywheel. (see arrow).
Fig. 29:
16. Back out the knurled screw of the pressing

device, remove the pressing device.
17. Reinstall the engine solenoid with a new O-

ring.
18. Reinstall the cylinder head cover. Tightening

torque: 9 +/-1 Nm.
Note:
If necessary replace the gasket.
Fig. 30:
19. Slightly oil the O-ring of the crankcase ventilation. Reassemble the crankcase ventilation. Tightening
torque 9 +/- 1Nm
Note: If necessary replace the gasket.
BW 211 / 212 / 213 D-40 - D 27 -

Service Training
Tools
The following tools can be ordered from the respective supplier (in brackets) under the stated part-
number.
For tools from Hazet and Bosch you should consult your nearest representative, orders to Wilbr should
be addressed to:
Co. Wilbr
P.O. box 140580
D - 42826 Remscheid
Fig. 31
Pressing device for governor rod 100 830 (Wilbr)
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Service Training
Diesel engine, components and test points
Air filter
2
2
11
1
2
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

diagram
1 Visual coolant level indicator
2 Visual air filter pressure differential
indicator
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Service Training
Fuel tank

diagram
1 Visual fuel level indicator
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Service Training
Flywheel end
1
2
3 4

diagram
1 Boost fuel valve Y 01 0/12 V
2 Coolant temperature switch with B 30 cold open,
warning light
3 Coolant temperature sensor B 113 approx. 2 at
(Option) 20C
4 Throttle lever
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Service Training
Auxiliary power take-off side
4 2 3
1 5
7
diagram
1 Engine oil pressure switch B 06 pressureless
closed,
2 Engine solenoid, speed control Y 120
3 Engine shut-down solenoid Y 58
4 Fuel pre-filter with hand pump
5 Fuel filter
6 Engine oil filter
Water separator sensor, fuel B 124
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Service Training
Diesel engine monitoring:
Warning and control lights are integrated in the instrument cluster
Display and shut-down functions
Control light Warning buzzer Shut down time Shut down time
10 s 2min
Water separator X X X
Fuel filter
Engine oil X X X
pressure
Coolant X X X
temperature
BW 211 / 212 / 213 D-40 - D 33 -

Travel circuit
from brake valve
M4 M5
from speed
0.8
BW 211 / 212 / 213 D-40

range valve
M4 M3 L
2 A
0.81
0.6
6
0.6
4 8
T3
25 bar 9
3
1
M2
B
Charge pressure to vibration pump
Charge pressure from hydraulic oil filter
Fig. 1: Hydraulic diagram travel system BW 211 / 212 / 213 D-40
1 Travel pump Sauer 90 R 075 4 Multi function valve 7 Speed range valve
2 Servo control 5 Rear axle 8 Flushing valve
3 Charge pressure relief valve 6 Axle drive motor Sauer 51 D 110 9 Drum drive motor Poclain MSE 18 1C
Service Training
-E1-
Service Training
The travel system of the single drum rollers is a closed hydraulic circuit and consists mainly of:
travel pump with control and safety elements,
Drum drive motor without brake,
axle drive motor,
rear axle with brake,
charge pump (also for vibration circuit),
hydraulic oil filter (in charge circuit),
hydraulic oil cooler with thermostat
hydraulic lines.
Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump.
The travel pump is the first pump section, flanged directly to the flywheel side of the diesel engine.
The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to (p = 400 bar between low and high
pressure sides).
A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain
oil quantity out of the closed circuit when the machine is driving (p between the two sides of the closed
circuit).
Leakage in the individual components of the circuit are replaced by the charge circuit through the boost
check valves in the travel pump.
The charge pumps draw hydraulic oil out of the tank and deliver it through the hydraulic oil filter and the
charge pressure relief valve to the boost check valves in travel and vibration pumps. The machine is
fitted with two charge pumps. One pump is integrated in the vibration pump and the other pump is driven
by the auxiliary output of the engine and serves primarily as steering pump.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits
for travel and vibration drive, as well as to release the parking brakes and to change the travel speed
ranges.
The travel motor in the axle is desired with variable displacement. The operator can choose from two
different travel speed ranges.
BW 211 / 212 / 213 D-40 -E2-

Service Training
Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.
M4 M5
2
A from/to
Travel motor
25 bar 4
3
1
from/to
Travel motor
B
Charge pressure to vibration pump
Charge pressure from hydraulic oil filter
Fig. 2: Hydraulic diagram of travel pump
1 Pump drive 3 Charge pressure relief valve

2 Servo control 4 Multi-function valves
BW 211 / 212 / 213 D-40 -E3-

Service Training
The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is
proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing
angle of swash plate) of the pump.
7 1
6 5
Fig. 3: Travel pump
1 Control lever 5 Cylinder block

2 Drive shaft 6 Valve plate
3 Swash plate bearing 7 Control piston
4 Pistons with slipper pads
With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.
When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.
All valves as well as the safety and control elements needed for operation in a closed circuit, are
integrated in the pump.
Note:
These machines are equipped with two charge pumps.
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Service Training
Cross-sectional view of 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 block 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 device
BW 211 / 212 / 213 D-40 -E5-

Service Training
View of the rotating group
4 3
5
Fig. 5: Travel pump, view of the rotating group
1 Working pistons
2 Slipper pad
3 Pre-tensioning spring
4 Cylinder block
5 Drive shaft
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Service Training
Description of function
2 3 4 5 6
1
8 6 7
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 Pistons with slipper pads 8 Valve plate
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).
With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).
BW 211 / 212 / 213 D-40 -E7-

Service Training
When moving the swash plate out of neutral position, the working pistons will perform a stroke
movement with every rotation of the cylinder block.
The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.
During a full rotation of the cylinder block each working piston will move through the bottom and top dead
centre back to the initial position. During this movement each piston performs a complete stroke.
During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.
BW 211 / 212 / 213 D-40 -E8-

Service Training
Tandem pump
BW 211 / 212 / 213 D-40 -E9-

Service Training
Tandem pump, connections and adjustment points
32
Thermostat
housing
Fig. 7: Connections and adjustment points
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Service Training
1 Control solenoid, high frequency (vibration pump)
2 Control solenoid, low frequency (vibration pump)
3 Multi-function valve 400 bar (charging and pressure limitation), travel system
4 Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
5 Multi-function valve 400 bar (charging and pressure limitation), travel system
6
7 Port L, leak oil to vibration pump
8 Travel lever
9 Pressure test port, pilot pressure
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 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 End plate with integrated charge pump (only in vibration pump)
19 Port L2
20 Adjustment screw, high frequency
21 Port D, charge pressure to filter
22 Multi-function valve 345 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between hydraulic oil tank and charge pump
24 Multi-function valve 345 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 port 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 Adjustment screw for mechanical neutral position, vibration
Thermostat housing: 33, 34, 35, 36 Leak oil port

37 cooler inlet
BW 211 / 212 / 213 D-40 - E 11 -

Service Training
servo control
The servo control (mechanical hydraulic displacement control) converts the mechanical input signal
of 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
swashing direction (flow direction of the pressure fluid).
The flow quantity delivered by the variable displacement pump is proportional to the value of the
mechanical input signal. A mechanical feedback device ensures the fixed correlation between the
mechanical input signal and the swashing angle of the swash plate (displacement of pump).
Servo cylinder
Control piston
Sliding block
Servo arm
Fig. 8: Control piston
A mechanical safety device (spring) makes sure that a too fast lever movement will not cause any
damage to the servo control.
The pump displacement can be adjusted by actuating the pump control lever via travel lever and travel
control cable. This requires only very little manual forces and only a slight movement of the lever.
Since the control is spring centred, the swash plate will automatically return to neutral position under the
following conditions, thereby interrupting the oil flow and braking the machine:
BW 211 / 212 / 213 D-40 - E 12 -

Service Training
when shutting the engine down,
if the external control cable comes loose,
if the pressure in the charge circuit drops below a certain value.
BW 211 / 212 / 213 D-40 - E 13 -

Service Training
Multi-function valves
High pressure limitation
Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override
and a pressure relief valve, one after the other.
1 2
3
A
6 5
B
4
Fig. 9: Multi-function valves
1 to the control 6 Drive shaft

2 Multi-function valve 7 to the control piston
3 Charge pump 8 to the control piston
4 Charge pressure relief valve A Port A
5 Pilot pressure relief valve B Port B
If the adjusted pressure is reached, the pressure override will move the swash plate quickly back
towards neutral position, thereby limiting the system pressure. The average response time is less than
90 ms.
BW 211 / 212 / 213 D-40 - E 14 -

Service Training
In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the
pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override
works as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the
high pressure relief valve is higher than the pressure level of the pressure override. The high pressure
relief valves will only respond if the pressure override is not able to swash the pump back quick enough
in case of sudden pressure peaks.
2 3
4
5
1
6
9 7
8
10
11
Fig. 10: Multi-function valve, details
1 Reducing fitting 7 Check valve

2 Hydraulic by-pass piston 8 Pressure limitation
3 Spring plate 9 Spring
4 Spring 10 By-pass housing
5 High pressure relief valve 10 By-pass sleeve
6 Valve seat
Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.
With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.
Note:
The multi function valves must be tightened with a torque of 89 Nm!
BW 211 / 212 / 213 D-40 - E 15 -

Service Training
Charge pressure relief valve
The machines are equipped with two charge pumps, one driven by the auxiliary output of the engine
(steering and charge pump) and the other pump is integrated in the vibration pump.
The pressures of both pumps are limited by a charge pressure relief valve.
The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety
elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted
value (26 bar).
The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits
and provides the necessary pressure to control the travel and vibration pumps and to operate the multi-
disc brakes in the travel drives.
Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.
When parking the machine on level ground with the engine running, the pressures in both sides of the
closed circuit are identical (charge pressure).
BW 211 / 212 / 213 D-40 - E 16 -

Service Training
Flushing valve
Fig. 11Cross-section of flushing valve
1 Flushing spool
2 Flushing pressure relief valve
The flushing valve is integrated in the axle drive motor. In case of a pressure increase in one of the two
sides of the closed circuit the flushing valves have the function to flush a certain quantity of oil out of the
low pressure side.
The valve is operated by the pressure difference between the two sides of the closed circuit (A and B).
If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral
position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows
through a thermostat valve back to the tank. The oil quantity flushed out of the closed circuit is
immediately replaced by oil entering from the charge circuit through the corresponding boost check
valve (part of the multi-function valve).
In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature
household of the hydraulic system is maintained at a permissible level.
BW 211 / 212 / 213 D-40 - E 17 -

Service Training
Axle drive motor,
The axle drive motor is a swash plate controlled axial piston motor of series 51 D 110 with variable
displacement.
5 7 8
6
9
11
10
4
2
Fig. 12: Axle drive motor,
1 Control piston 7 Cylinder block

2 Flushing valve 8 Universal joint
3 Control 9 Output shaft
4 Spindle with ball 10 Output shaft bearing
5 Qmin-screw 11 Working piston
6 Valve plate
BW 211 / 212 / 213 D-40 - E 18 -

Service Training
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle
between cylinder block and output shaft.
With a large angle position the motor works with maximum displacement, slow speed and high torque.
When changing the swash plate position to minimal angle the motor works with minimum displacement,
high speed and low torque.
The displacement is changed by a control piston, which is tightly connected with the valve segment.
Changing of the displacement is accomplished by pressurizing the corresponding control piston side
with pressure oil from the charge circuit via a 4/2-way solenoid valve.
Function
The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.
BW 211 / 212 / 213 D-40 - E 19 -

Service Training
Rear axle
Releasing the axle drive brake manually (on both axle drive designs)
For manual releasing of the brakes on the rear axle you should proceed as follows:
Fig. 13: Manual releasing of rear axle brakes
Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.
Turn the brake releasing screw (2) in against the stop.
To release the brake tighten the screw for max. 1 complete turn.
Attention!
Turn the screws on both sides in uniformly (alternately by 1/4 of a turn)
Repeat this procedure on the opposite side of the axle.
BW 211 / 212 / 213 D-40 - E 20 -

Service Training
Front drum drive motor: Radial piston motor MSE 18 2 CX
On single drum rollers of series D-40 the drum is driven by a hydraulic radial piston motor.
These drum drive motors consist of three housing parts, the flat distributor, the cylinder block with the
working pistons and the output shaft.
2 3
4
1
43090070
6 5 4 5
Fig. 14: Drum drive motor
1 Drive shaft with output flange

2 Piston with roller
3 Oil distributor
4 Cylinder block
5 Cam ring
6 Bearing plate
The housing consists of:
BW 211 / 212 / 213 D-40 - E 21 -

Service Training
bearing section (drive shaft bearings),
torque section (cam race) and
oil distributor.
Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure
oil presses the working pistons with the rollers against the cam race of the torque section and forces the
rollers to roll along the cam race.
This transforms the axial movement of the pistons to a radial movement of the cylinder block. The
cylinder block transfers this rotation via a splined connection to the output shaft.
The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc
and the rubber elements to the drum.
The function of the radial piston motor is described hereunder. The piston positions described in this
explanation can be seen in the related illustration.
The movement of a piston along the cam race must be examined in several phases during a full rotation:
2
3
Fig. 15: Function of the radial piston motor
BW 211 / 212 / 213 D-40 - E 22 -

Service Training
Piston position 1:
The oil enters into the oil distributor under pressure, flows through the distributor and presses against
the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the
roller along the cam and causes a rotation of the cylinder block.
Piston position 2:
At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The
piston continues his travel along the cam race towards the valley between two cams. As the movement
continues the opening cross-section for the oil supply decreases.
Piston position 3:
Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston
is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first
piston out of the dead centre.
Piston position 4:
Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now
connected with the low pressure side and the reverse movement of the piston presses the oil back to
the pump.
Piston position 5:
The pumping movement of the motor back to the pump comes to an end, the connecting bore between
cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre
position. This point is the start of a new working cycle.
Reversing the oil flow reverses also the rotation of the motor.
The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc
and the rubber elements to the drum.
BW 211 / 212 / 213 D-40 - E 23 -

Service Training
Travel circuit: Drum drive with radial piston motor
1
4
6 1
n
ctio 1 Travel pump
i r e
e ld 2 Vibration pump
r av 3 Travel lever
T 4 Hydraulic oil filter
High pressure 5 Rear axle
Low pressure 6 Axle drive motor
7 Drum drive motor
Charge pressure
8 Hydraulic oil tank
Leak oil (case pressure)
Fig. 16: Single drum rollers D-40, travel circuit, hose installation
BW 211 / 212 / 213 D-40 - E 24 -

Service Training
Brake control: Travel motor in axle
Brake valve
Charge pressure
Brake releasing pressure
Leak oil
Fig. 17: Brake circuit
BW 211 / 212 / 213 D-40 - E 25 -

Service Training
Travel drive, components and test points
Travel pump:
2
2 1
1
diagram
1 Test port, forward 10, MD max. 426 bar
2 High pressure port, forward 10, A
3 Charge pressure port 7, MA 26 bar
BW 211 / 212 / 213 D-40 - E 26 -

Service Training
Travel pump: right hand side
2 3
1
diagram
1 Test port, reverse 10, MC max. 426 bar
2 High pressure port, reverse 10, B
3 Travel control (travel control cable)
BW 211 / 212 / 213 D-40 - E 27 -

Service Training
Front travel motor, without brake (radial piston motor)
2 1
2 1
45 3
4
6
3

diagram
1 High pressure port, forward 12, L
2 High pressure port, reverse 12, R
3 Cross-flushing of travel pump T1 12
4 Leak oil port 12, 1
BW 211 / 212 / 213 D-40 - E 28 -

Service Training
Rear travel motor: Axle motor
1
4
3 2
6
5
7

diagram
1 Solenoid for speed range selector Y31 14 Motor Qmax---
valve depressurized,
Motor Qmin---
26 bar
2 Flushing valve 14
3 High pressure port, drum drive 14, A
motor forward
4 High pressure port, drum drive 14, B
motor reverse
5 High pressure from travel pump 14, A
forward
6 High pressure from travel pump 14, B
reverse
7 Qmin- setscrew 14
BW 211 / 212 / 213 D-40 - E 29 -

Service Training
Brake valve
11

diagram
1 Brake valve Y 04 08, open, 12V closed,
de-energized
BW 211 / 212 / 213 D-40 - E 30 -

Service Training
Travel lever console
BW 211 / 212 / 213 D-40 - E 31 -

Service Training
Travel lever

diagram
1 Initiator for backup alarm B14 0 / 12V, normally
closed
2 Initiator for brake B13 Normally closed,
opened in braking
position
0/12V
BW 211 / 212 / 213 D-40 - E 32 -

Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
Machine travels with travel lever in 'Neutral'

Machine does not drive (forw. and reverse)
Machine drives to one direction only
Max. travel speed not reached

TROUBLE SHOOTING TRAVEL
Hydraulic oil overheating

SYSTEM
BW 211 / 212 / 213 D-40
SYMPTOMS
POSSIBLE CAUSES
Brake valve (electric/mechanical/hydraulic) 1
Brake in axle-drive motor (mechanical/hydraulic) 2 2 3
Travel speed range switch position /defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/ travel pump high pressure limitation
3 2 3 3
dirty/out of adjustment/defective
Adjustment of travel cable 1 2
Travel pump mechanical neutral 3 3
Travel pump(s) defective 3 3 2
Axle drive motor control valve (electric / mechanical / hydraulic) 1 2
Flushing valve axle drive motor seized 3
Travel motor(s) defective 3 3
Hydraulic oil cooler soiled (internally/externally) 1
Thermostat (hydraulics) soiled/jammed/defective 2
Clutch- Dieselmotor-Pumpe 2
Dieselmotor 1
BW 211 / 212 / 213 D-40

Service Training
Vibration system
The vibration system of the single drum rollers of generation D-40 works with two frequencies and two
amplitudes. This enables perfect adaptation of the machine to various types of soil and different
applications.
The vibration drive is a closed hydraulic circuit. The circuit consists of:
the vibration pump,
the vibration motor and
the pressure resistant connecting hoses
from charge pump via to release the brake

Travel pump
Charge oil
Vibration pump
D M3 E
L2 N
Block
M1
M2
S
B
2
1
M4
M5
Fig. 1: Vibration circuit
1 Vibration pump
2 Vibration motor
BW 211 / 212 / 213 D-40 -F1-

Service Training
Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly
driven by the diesel engine.
When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral
position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to
one of the two control piston sides. The swash plate inside the pump will swash to the corresponding
side and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the
vibrator shaft inside the drum.
When altering the position of the swash plate through the neutral position to the opposite side, the oil
flow will change its direction and the vibration motor will change its sense of rotation.
Since the end stops for the swash plate are set to different swashing angles to both directions, the angle
for the piston stroke is also different to both sides. This angle influences the length of the piston stroke
and thereby the actual displacement of the pump.
Large angle = high displacement = high vibrator shaft speed (frequency)
Small angle = low displacement = slow vibrator shaft speed (frequency)
The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending
on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic
weights.
This results in the following constellations:
Basic weight + change-over weight = high amplitude
Basic weight - change-over weight = low amplitude
In order to achieve effective compaction results the vibration system is designed in such a way, that high
amplitude is coupled with low frequency and low amplitude with high frequency.
Fig. 2:
BW 211 / 212 / 213 D-40 -F2-

Service Training
Vibration pump
Similar to the travel pump the vibration pump is also a swash plate operated axial piston pump with
variable displacement for operation in a closed circuit.
The displacement of the pump is proportional to the engine speed and the chosen displacement.
When actuating the swash plate out of neutral position the flow quantity to the chosen direction will
increase from 0 to the maximum value. When altering the position of the swash plate through the
neutral position to the opposite side, the oil flow will change its direction and the vibration motor will
change its sense of rotation. All valves and safety elements for operation in a closed circuit are
integrated in the pump.
from charge pump via Releasing the brake

Travel pump
Charge oil
Vibration pump
D M3 E
1 Vibration pump
L2 N 2 Charge pump
3 High pressure limitation
Block
4 4/3-way solenoid valve
A
M1
M2
S
B
M4
M5
Fig. 3: Hydraulic diagram vibration pump
BW 211 / 212 / 213 D-40 -F3-

Service Training
Function
1 2
5 4 3
Fig. 4Cross-section of vibration pump
1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate
BW 211 / 212 / 213 D-40 -F4-

Service Training
1
2
5
4 3
Fig. 5 Cross-section of vibration pump
1 Control
2 Servo piston
3 Friction free swash plate bearing
4 Attachment plate
5 Spool valve
The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.
The slipper pads rest against the sliding surface of the swash plate and are at the same time held on
the sliding surface by a retaining device.
During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.
BW 211 / 212 / 213 D-40 -F5-

Service Training
During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into
the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he
closed circuit.
Control
The electro-hydraulic displacement control (remote control) converts the electric input signal to a load
controlling output signal. Since the pump is not equipped with a proportional control, but a 12 Volt
solenoid valve, the pump is always actuated to one of the two end stop positions.
Charge pumps
These machines are equipped with two charge pumps.
One of the pumps is an external gear pump, which is directly driven by the auxiliary output of the engine
and serves also as steering pump.
The second pump is an internal gear pump and is located in the end cover of the vibration pump.
The oil flow generated by the charge pumps is joined together with the return flow from the steering
valve before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and
vibration pump.
BW 211 / 212 / 213 D-40 -F6-

Service Training
High pressure relief valves
As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.
Fig. 6Pressure relief valve
1 From the charge pump

2 Closed circuit
3 High pressure relief valve with
integrated boost check valve
Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 371 bar
(pressure difference between high and low pressure side = 345 bar + charge pressure = 26 bar).
The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit. The function of these valves has already been described in the chapter "travel
system".
BW 211 / 212 / 213 D-40 -F7-

Service Training
Vibration motor
The vibration motor is a Bosch-Rexroth (Hydromatik) axial piston motor of series A10FM 45 with fixed
displacement in bent axle design. Since the motor can be subjected to pressure from both sides, it is
most suitable for the use in closed hydraulic circuits.
The output speed of the motor depends on the oil quantity supplied by the vibration pump.
2 3
4 5
1
8 7
9
10
Fig. 7Cross-section of vibration motor
1 Flushing valve block

2 Flushing valve
3 Working pistons with slipper pads
4 Roller bearing for output shaft
5 Radial seal
6 Output shaft
7 swash plate
8 Retaining plate
9 Pre-tensioning spring
BW 211 / 212 / 213 D-40 -F8-

Service Training
The output torque raises with increasing pressure difference between low and high pressure side in the
closed circuit.
Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.
When switching the vibration on the motor must first start to move the resting vibration shaft. This
resistance causes a hydraulic starting pressure, which is limited to 345 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).
Hard ground = High operating pressure
Loose ground = Low operating pressure
A MA
3 1
B MB
Fig. 8Circuit diagram of vibration motor
1 Vibration motor
2 Flushing valve
BW 211 / 212 / 213 D-40 -F9-

Service Training
The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a
pressure difference will appear between the two sides of the closed circuit. The higher pressure moves
the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low
pressure side.
1
A
Fig. 9 Flushing valve
1 Flushing spool
2 Flushing pressure limitation valve
The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.
This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.
BW 211 / 212 / 213 D-40 - F 10 -

Service Training
Drum
4
14
5 9
7 13
6
10
3 8 11
12
Fig. 10Cross-section 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 Vibrator housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Vibrator shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing
BW 211 / 212 / 213 D-40 - F 11 -

Service Training
Vibration system: Components and test ports
Vibration pump
11
2
3
2
5 6 3
6
5 4
4
diagram
1 Pressure test port, charge pressure MA 26 bar
2 Hydraulic oil filter (charge circuit) 07
with visual pressure differential
indicator
3 High pressure port, low MF
amplitude
4 High pressure port, high ME
amplitude
5 Solenoid valve, low amplitude Y08 12V / 3,33A
6 Solenoid valve, high amplitude Y07 12V / 3,33A
BW 211 / 212 / 213 D-40 - F 12 -

Service Training
Vibration pump

diagram
1 Pressure test port, vibration MF max. 371 bar
pressure low amplitude
2 Pressure test port, vibration ME max. 371 bar
pressure high amplitude
low amplitude high amplitude
BW 211 / 212 / 213 D-40 - F 13 -

Service Training
Vibration motor

diagram
1 High pressure port, high amplitude 16
2 High pressure port, low amplitude 16
3 Leak oil and flushing oil port 16 approx. 7 l/min,
incl. flushing
quantity
4 Flushing spool 16
5 Flushing valve 16 13 bar
BW 211 / 212 / 213 D-40 - F 14 -

Service Training
Trouble shooting
Procedure:
No vibration (charge pressure OK)

Vibration only with one amplitude
Exciter shaft speed too low
TROUBLE SHOOTING
VIBRATION
BW 211 / 212 / 213 D-40
SYMPTOMS
POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1
Vibration push button (on/off) 1
Electrics defective / wiring 2 2
Pump control (electrical / hydraulic) 1 1
Pressure override / high pressure relief valves in vibration pump
2
soiled/out of adjustment/ defective
Charge pump / charge pressure relief valve
2
soiled/ defective
Vibration pump frequency adjustment 2
Vibration pump defective 2 2
Coupling between diesel engine and travel pump defective
Exciter shaft bearings defective 3
Vibration motor coupling defective 2
Vibration motor defective 2 1
Diesel engine 1
BW 211 / 212 / 213 D-40

Service Training
Steering
Single drum rollers of series BW 211 / 212 / 213 D-40 are equipped with a hydrostatically operated
articulated steering system.
The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.
to charge
system
1
7
6
5
3
2
4
from steering pump
Fig. 1Steering hydraulics
1 Rating pump
2 Distributor valve
3 Steering pressure relief valve (p =175 bar)
4 Check valve (pre-loaded to 0.5 bar)
5 Anti-cavitation valve
6 Shock valves (240 bar)
7 Steering cylinders
The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.
When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.
The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.
BW 211 / 212 / 213 D-40 -G1-

Service Training
Steering pump
The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.
9 9 6 1 7
8
2
4 5
Fig. 2Steering pump
1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals
BW 211 / 212 / 213 D-40 -G2-

Service Training
Working principle of the gear pumps
The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of
both gears mesh with minimum clearance when rotating.
The displacement chambers are created between the tooth flanks, the inside wall of the housing and
the faces of the bearing plates.
When the pump is running the chambers transport hydraulic oil from the suction side to the pressure
side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The
tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.
To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic
fluid can be transported from the suction side to the pressure side without any losses.
For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.
This pressure field is always under the actual system pressure.
BW 211 / 212 / 213 D-40 -G3-

Service Training
Steering valve
The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and
shock valves.
9 2
5
8
Fig. 3Cross-sectional view of steering valve
1 Neutral setting springs

2 Housing
3 Inner spool
4 Outer spool
5 Universal shaft
6 Ring gear
7 Gear
8 Check valve
9 Pressure relief valve
When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating
pump. The rating pump guides the oil flow through the distributor valve to the corresponding
sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the
rotation angle of the steering wheel.
This oil flow to the steering cylinders articulates the machine and causes a steering movement.
BW 211 / 212 / 213 D-40 -G4-

Service Training
240 bar
p = 175 bar
240 bar
0,5 bar
Fig. 4Steering valve, hydraulic diagram
The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.
The charge pressure value must be added to this pressure, because the oil leaving the steering system
is fed into the charge circuit for the closed travel circuits.
The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks
which may occur, e.g. when driving over obstructions, and protect the system against overloads.
Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.
A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case
of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would
act as pumps and press the oil back to the pump.
BW 211 / 212 / 213 D-40 -G5-

Service Training
Articulated joint
Front and rear frames of the single drum rollers are connected by an oscillating articulated joint. This
ensures that drum and wheels are at all times in contact with the ground, even when driving extreme
curves.
Fig. 5Articulated joint
BW 211 / 212 / 213 D-40 -G6-

Service Training
The rear console is tightly bolted to the rear frame.
The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.
The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.
The steering cylinder anchor point is welded to the front console.
When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.
All bearings on the articulated joint are maintenance free and do not require any lubrication.
Notes on assembly:
When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.
Please follow the instructions in the repair manual for the articulated joint.
BW 211 / 212 / 213 D-40 -G7-

Service Training
Steering: Components and test ports
Steering pump

diagram
1 Steering pump (and charge pump) 09
2 Steering pressure test port MB max. 175+26 bar
BW 211 / 212 / 213 D-40 -G8-

Service Training
Vibration and noise damper
The damper is located in the steering/charge circuit directly after the steering and charge pump.
It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.
The damper is mounted to the front plate of the rear frame, between both steering cylinders.
BW 211 / 212 / 213 D-40 -G9-

Service Training
Steering valve
The steering valve is located under the operator's stand
BW 211 / 212 / 213 D-40 - G 10 -

Service Training
Trouble shooting
Procedure:
TROUBLE SHOOTING STEERING

SYSTEM
BW 211 / 212 / 213 D-40
End stops are not reached
Steering hard to move
No steering function
SYMPTOMS
POSSIBLE CAUSES
Steering orbitrol valve 2 2 1
Steering/charge pump 1 1 2
Steering cylinder 3 3 3
Articulated joint 3 3 2
BW 211 / 212 / 213 D-40

Service Training
Electrics: Single drum rollers D-40
This chapter describes the peculiarities in the electric system and the necessary adjustments. This
instruction solely describes the electrical testing of D-40 machines belonging to single drum roller
series.
Function test:
Turn the ignition key to "Ignition ON".
The round gauge runs a 3 second self test.
All control lights are active during this time.
Brake control light (travel lever in braking position), charge control light (engine stopped) and oil
pressure warning light (engine off) are active.
Warning and control lights are integrated in the instrument cluster!
Table 1: Inspection of display and shut-down functions
Control light Warning buzzer Shut down time Shut down time
10 s 2min
Water separator X X X
Fuel filter
Engine oil X X X
pressure
Coolant X X X
temperature
BW 211 / 212 / 213 D-40 H1

Service Training
Instrument cluster
Electric control cabinet with vibration module
Vibration module
BW 211 / 212 / 213 D-40 H2

Walzenzge D-40
Tankanzeige (Widerstand Masse gegen Pin 2):

0 Ohm --> Tank voll
65 Ohm --> Tank leer
Wenn kein Tauchrohrgeber angesclossen ist
oder ein
Kabelbruch vorliegt, erlischt die Tankanzeige
komplett
Abschaltzeiten der Ausgnge:
Motor (Pin 9) abschalten nach 2 Min. bei Strung Wasserabscheider (Pin 3/4).
Motor (Pin 9) abschalten nach 10 Sek. bei ldruckfehler (Pin16).
Warnsummer (Pin 1) einschalten bei Strung Wasserabscheider (Pin 3/4) oder bei ldruckfehler
(Pin16).
Translation
Operating hour meter: Red 7-segment display
Holding strap: Steel, galvanized and yellow chromium coated
Foil: Dead Front (black RAL 9005)
Front screen: Printed, scratch-proof plastic foil (polyester resin)
Imprint: White RAL 9010
Printed symbol: Black Dead Front
Housing: Impact-proof plastic made of PBT GF20
Cover: Polycarbonate black
Knurled nut: Polyamide
Rated voltage: 12V
Operating voltage: 8V to 32V
Lights 1 - 12: 4 x SMD-Top-LED with max. 12oo mcd/mm
Fuel level gauge: LED-bar display (9 x green, 1 x red)
Degree of protection: Front side IP 67, back side IP 54
Operating temperature -40C to +90C
Storage temperature: -25C to +85C
Plug: Connection by means of 20 pin TYCO (1-174960-1)
plug and sealable 4-pin programming and service plug

Plug assignment with operating hour meter
Pin- Function
Number
1 OUT 1
2 Bar graph
3 Water separator L9
4 Water separator L9
5 L10
6 Low Active Preheating L11
7 High Active Hazard light L12
8 High Active Day + Night switching all LEDs and 7-segment display
9 OUT 2
10 -BATT/GND
11 High Active Brake L1
12 L2
13 L3
14 High Active Charge control L4
15 L5
16 Low Active Oil pressure L6
17 Low Active Engine temperature L7
18 High Active Direction indicator 1 L8
19 High Active Direction indicator 2 L8
20 + BATT
Technical description
Vibration Module
- 057 667 34 -
December 2004
Description
This module is an electronic toggle relay for 12 and 24 Volt. A ground switching pulse on Pin (S) sets the output
(56b) (operating voltage applied to the output). The next pulse resets the output (56b) (no operating voltage
applied to the outlet). If the operating voltage (15/54) is switched off, the output will remain dead when switching
on again.
Description
Here this modul it concerns an electronic toggle relay for 12 volt and 24 volt. By an impuls (ground potential) at pin (S)
the output (56b) is set (supply voltage is on the output) and reset (no supply voltage is on the output) by the next
impulse. If the supply voltage is switch off, then there is no output signal after the resetting.
E:\Bauteile_Datenblaetter_mit_TNr\STW\05766734\05766734_Technische
Beschreibung.doc
Alexander Hehner / TE 2/2
Inhaltsverzeichnis: BW 177..219 D4/D40
table of contents: BW 177..219 D4/D40
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing no.
001 582 702 09 Stromlaufplan Circuit Diagram
002 582 702 09 Versorgung, Starten, Motordrehzahl supply, starting unit, enginespeed
003 582 702 09 MotorHeizflansch, Signalhorn, GeschwindigkeitAnz. engine heatingflange cont., warning horn, speedometer
004 582 702 09 Bremse, Rckfahrwarneinr., Anzeige brake, back up alarm, indicator
005 582 702 09 Fahrstufen, Sitzkontaktsch., Vibration speedranges, seatswitch, vibr.
006 582 702 09 ZA Messtechnik option measurement equipm.
007 582 702 09 BOMAG Compaction Management BCM BOMAG Compaction Management BCM
008 582 702 09 ZA Beleuchtung und StvZO opt. illumination and StvZO
009 582 702 09 ZA Kabine, Beleuchtung, Radio, Tachograph opt. cabin, headlights, radio, tachograph
010 582 702 09 ZA Kabinenheizung, Klimaanlage, Zusatzheizung opt. cabinheater, air conditioning, add. heater
101 582 702 09 Bauteilliste component listing
16.11.2005
Vogt Stromlaufplan 001 001 582 702 09
16.11.2005 circuit diagram
Seis 001
30 6:1
K30
9:2
15:54
2:10 K11 30
X1
X1:15E 2:10
17E
X1:10
X1:9
87 87a
F13 1 1
F105
30A
2 20A
2 K11/87 3:1
X1:15A
X1
X36:B
X36:A
X37:A
17A X1
S00 30 27E X1:30E
30
B+
2:11 K35
nur ohne Sitzkontaktschalter

1 1 F39
without switch seatcontact

2:16 F14
4qmm
15A 15A
Startschalter 87a 87 2 2
starting switch 15 54 58 19 17 50a
X1 X1 X1:30A
15:54 27A
switch engine speed

Schalter Motordrehzl
2:13 80 K32:86
X1 9:2
79 S120 11 23
Sicherung Heizflansch
30 F14:2
5:9
K114
Hauptsicherung
X37:B 2:14 S01:21

X1:3 X1:4 5:9
heatingflange
V01
main fuse
3:2 87a 87
2 1 K11:86 K05 30 12 24 X1:151
125mA
4:5
6:5
only at BW 219 D4 and D40 USA version, otherwise option
30(3)
4:3 21 11 31 ?
nur bei BW 219D4 und D40 USA Version, sonst Option
K14
K61 87 87a
3:5 86 1 K61 30 S01
87(4) 86
F48 2 F00 2 R10 2:5 22 12 32 ?
82 OHM K35
87 87a NOTAUS
125A
125A
85 2 K05/87
only acc.to air conditioning
1 1
nur bei Klimaanlage 3:2 85 Emerg.Stop
X1:53
4:13 X1:152
K61/85
6:2 B+ X1 X1 X1 X1 30
X1:60 K22
X1 D+ MESX 2:5 7 8 58 59
1 4:9
G03 + G01 + X1 2x2.5qmm 87 87a
65 X38:A 2
B+ X1
50A / 10A
3.9A
D+ V47
125mA
81 X1
G02
30 50 1 54
AUX
86 AW
167A
86 86 86 Y01 2 + HW 1
K09 Y13
B W M01 K114 Y120
311
1 1 K36 K11 M
S30 W 1 70A/1A 2
R19 85
X1:66 85 85 85
2 X1
X1 X1 55
X1:55 X1:56
Option
3.8A
option
2 62 63
X1:168
31 31 3:1
2:8 4:4 10:7 2:18 2:16 2:13
Trennschalter Batterie
break switch battery
Heizflansch Batterie Batterie Generator Starter Startmehrmenge Hubmagnet Drehzahl Kraftstoffabschaltug
heatingflange battery battery generator starter start boost fuel sol. engine speed fuel shut off
16.05.2005
1 1 582 702 09
Vogt Versorgung, Starten, Motordrehzahl
16.05.2005
Seis supply, starting unit, enginespeed 002
2:20 K11/87 K11/87 4:1
F24:2
4:10
4:19
GLH
2:10 K11:86 X1
52
2:13 K05/87 X1
78 X1
X1 28E
75
F23 1
10A
2 X1
X1 92
28A
Geschwindigkeitsanz.
OUT+
15/54
Lern
Test
speedometer
X1:155 +
only at BW 219 D4 and D40 USA version, otherwise option

Nur bei BW 219 D4 und D40 USA Version, sonst Option
modul heatingflangecontrol
assembled in enginearea
P04
Modul Heizflanschsteuerung
Anbau im Motorbereich
Modul Geschw. A05

13 23 modul speedometer
5 2 7 1 S03

OUT
in
14 24 X1
A13
93
X1 X1
Taster Signalhorn
push but. warning horn
3 4 6 97 98
X1 X1 ZA Geschwindigkeitsanzeige
101 102 option speedometer
1
assembled in enginearea
nicht bei D40/BW211D4 ohne SN1

Anbau im Motorbereich
relais heatingflange
not at D40/BW211D4 ohne SN1

Relais Heizflansch
X1:171
K14
2
2
V21
V22
+
dir. X1:173
4.2A
4.2A
B60 DIR MESX 6:2
1
1
B11 1 B11 1 speed SPEED MESX 6:2
X1:172
2 SPEED TAC
9:6
1 2 2
B113
X1 X1 X1 X1
57 64 99 100 X1:174
2:20 31 31 4:1
Khlmitteltemperatur Signalhorn Signalhorn Sensor Achse

collant temperature warning horn warning horn sender axle
nur bei ZA Messtechnik, Geschw.Anzeige und Tachograph

only at opt. measurementequ., speedometer and tachograph
16.11.2005
1 1 582 702 09
Vogt MotorHeizflansch, Signalhorn, GeschwindigkeitAnz.
16.11.2005
Seis engine heatingflange cont., warning horn, speedometer 003
3:20 K11/87 K11/87 5:1
Zentralstecker Sammelanzeige (Ansicht von hinten)
X1 X1:31E mainplug monitoring module (view from backside)
29E
9 8 7 6 5 4 3 2 1
1 1
F25 F24
10A 10A
2 2 X5:120
Sammelanzeige 201918 1716151413 121110
X1
X1:31A monitoring module
29A 6 Vorglhen
A15 GLH
F24:2 3:5
3:15 Warnbl.
7 BLW
8:16
X1 15/54
20 19 Blinker rechts
BLR
FUEL 8:17
HOURS
X1:156 86 OUT2
9 18 Blinker links
BLL
F25:2 8:17
5:2 OUT1 Sitz
1 12 A68/6
Position (Bremse ein)
5:9
Bel.
8 4
X12 X13 8:5
geffnet in 0
1 1 BEL 10 3
proximity switch forwards and "0"position

proximity switch travel lever "0"position
BR/BN 30 BR/BN
30 2 14 11 13 15 17 16 5
Initiator Vorw. und Null

Initiator Farhebel"0
GND
D+
K48 K26
Bremse
Tankanzeige
Wasserabscheider
B13 B14
Motorldruck
ltemperatur
Luftfilter
4:2 4:6
Hydrauliklfilter
5:9
5:9
Khlmittelfllstand
87a 87 87a 87
BL/BU SW/BK BL/BU SW/BK
B06:1
D+
30 X1 X1 X1
K36 69 87 76
2:7
87a 87 X1 X1 X1 X1
X12 3 X12 2 X13 3 X13 2 110 71 X1:77 X1:72 111 112
X1 X1 X1 X1 X1
K48:87A 106 67 X1:74 73 X1:68 107 108
4:13
X1:147 K26/87A 5:9
K61/85
11
X1:61
S01 X1
2:18 109 2:6
12 SITZWARN.
K48/86 5:9 5:9 X1
X1:150 X1 X1
105
X1:148 X1:153 114 90 K48:87A X8 1 X8 2
300mA
6:2 4:3
Sensor
X10
X1:113 BRAKE MESX 2 X21:1
125mA
2.5A
X1 or B21 3 B03 3 2 1 B06 1 B55 B124

X9 89 +
86 86 Y04 86 1 86 R03
K48 K05 1 K26 K22 P P _t P Q
H14+ + bl 4 4 B30 2
H07
2 P
85 85 85 X9 85 X10 X21:2
2 3 X1:117 X1:57
125mA
125mA
X1:149 X1 X1:82 X1:117

X1:117 129 X1:117
3:20 31 31 5:1
4:3 2:11 4:8 2:18 nicht bei D40

not at D40 nicht bei D40/BW177 D4
not at D40/BW177 D4
Magnetventil Bremse Rckfahrwarnsummer Warnsummer Strung Tankgeber Luftfilter Motorldruck Sensor Wasserabschei
solenoid valve brake buzzer back up alarm buzzer failure sender fuel
air cleaner engine oil pressure sens. water separator
Hydrauliklfilter ltemperatur Khlmittelstand
Resist. buzzer hydraulik oil cleaner oil temperature coolant stock level
16.11.2005
1 1 582 702 09
Vogt Bremse, Rckfahrwarneinr., Anzeige
16.11.2005
Seis brake, back up alarm, indicator 004
4:20 K11/87 K11/87 8:1
X1:32E
D+ F03 1
4:13
15A 2
B06:1
4:17 X1:32A
4:3 K48/86
2:20 F14:2 Nur mit Sitzkontaktschalter

only with switch seatcontact
nur D40/BW177D4 Standard DMaschinen/D40 USA
ldruck
Fahren
only D40/BW177D4 Standard Dmaschines/D40 USA
D+
F25:2 1 12 13 14 30 56
modul vibration
4:8
Modul Vibration
K04
31
Nur ohne Sitzkontaktschalter

A68 Modul Sitzschalter/Vibration
without switch seatcontact

module seatswitch/vibration
S 56b
switch speed ranges
Schalter Fahrstufen
13 4 6 9 11 15 5
S42 1234 2
S42
1 5 7 3 S01:21
14 2:20 X1:158 X1:157
Fahrstufensch.
switch speed ranges K26/87A
4:8 X14 X11
1
B 1 X1:159
V09 X1 14
S13
88
23 13
A68/6 3 S35
S58
4:19 13
pushbutton vibration
X1:143 X1:144 X1:162 X1:143 SITZWARN. 4
4:10 24 14
Taster Vibration
2
switch seatcontact
Sitzkontaktschalter
V05 X1:161 X1:160
V02 V03
2 1 1 2
GA MESX
6:2
KA MESX 6:2
X1:141 X1:137 X1:142 X1:141
X1:116 X1:115
1.23A
1.23A
1.23A
X6 X7
9:6 GA
9:7 KA
Y31 Y30 Y31 X14 X11 1 1
3.33A
3.33A
1 1 1 1 Y07 Y08
A 2
a b
2 2 2 2
X6 X7
X1:149
X1:154
X1:149
X1:149
2 2
X1:124 X1:138 X1:124 X1:124
X1:118
31 31 6:1
4:20
Schalter Vibration klein/gro

nur BW216+219D4 switch vibration small/big ampl.
only BW216+219D4
Stufenumsch. hinten Stufenumschaltung vorn Stufenumschaltung hinten Vibration vorne gro
switching axle switching drum switching axle vibration big ampl.
Vibration vorne klein
Stufenumschaltung vorn
switching drum vibration small ampl.
16.11.2005
1 1 582 702 09
Vogt Fahrstufen, Sitzkontaktsch., Vibration
16.11.2005
Vogt speedranges, seatswitch, vibr. 005
Beschleunigungssensoren Beschleunigungssensoren Drucker Anzeige BMFSA Display Messtechnik BOP
acc. sensor front acc. sensor rear printer Display BMFSA display measurem. BOP
GND
2:20 30 30 8:1
Pot 30
K11/87
8:20 Pot 15
X2:66 X2:70 X2:47 X2:48 X2:49

X1:145 X42:1 X42:2 X42:3
X2:71
X46:B X46:A X46:E
X1:33E X1:35E 31
+
nur bei BTM+/BTM prof

only at BTM+/BTM prof
1 1 S01
F148 F146 2:18 X2:56 X2:53 X2:60 X2:57
nur bei BEM

10A 15A
only at BEM
2 2 32
X4:C
X4:E
X4:D
X48:2 X48:1 X49:2 X49:1 P33
X1:33A X1:35A X1:146
P16
B62 B62 F1 F2
+/sw
+/sw
F148:2 X1:34E /gg /gg
7:15
CAN+ CAN
nur bei BTM prof
X74:3
X74:5
X74:4
1 X46:D X46:F
only at BTM prof

F84
10A
2 15g/bl 15g/bl X42:4 X42:5
20g/br
20g/br
X2:57 X1:34A P11
X48:3 X48:4 X49:3 X49:4

X74:1 X74:2
X2:50 X2:51
X2:54 X2:55 X2:58 X2:59 X4:A X4:B R20
AGND MESX
Aufn. hinten 15g
Aufn. hinten 20g

Aufn. vorne 15g
Aufn. vorne 20g

1 2
Elektronik
Leistung
Pot. 15
60OHM
X2:64 X2:65
CAN1+
CAN1
RxD TxD
X44:31
X44:1
X44:56
X44:57
X44:59
X44:60
X44:30
X44:7
X44:5
X44:58
X44:29
X44:27
X44:26
X44:28
X44:54
X44:4
A83
X44:38
X44:15
X44:35
X44:14
X44:32
X44:36
X44:37
X44:38
X44:41
X44:53
X44:33
X44:55
X44:65
X44:66
X44:67
X44:68
X44:3
MesstechnikRechner
measurement calc. unit
GND
GA MESX CAN3+ CAN3
EVIB
5:17
GND
5:17 KA MESX CAN3 7:15
SPEED MESX X1:85
3:16
DIR MESX X2:49 X2:52 + CAN3+
3:16 7:15
PITCH MESX P07 E
VIB
4:5 BRAKE MESX

D+ MESX
2:6 X2:63 X2:66 X1:82
8:4 BEL MESX

31 31 7:1
5:20
EVIBMeter
EVIBmeter
nur bei BEM

only at BEM
16.11.2005
1 1 582 702 09
Vogt ZA Messtechnik
16.11.2005
Seis option measurement equipm. 006
F148:2
6:2
CAN3
6:18
6:18 CAN3+
CAN3+
1 R242 CAN3
120 OHM
X2:61 X2:62
R25
1 2
120 OHM
X4:N X4:M
X75:7 X75:2
A87
USBCAN Schnittst.
USBCAN Interface BCM
X2:70
X76:1 X4:G
X76:2
P15
X4:F
X2:63
BCM 05
nur bei BCM

only at BCM
6:20 31 31 8:1
16.11.2005
1 1 582 702 09
Vogt BOMAG Compaction Management BCM
16.11.2005
Seis BOMAG Compaction Management BCM 007
5:20 K11/87 K11/87 6:2
6:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
F11 F18 F07 F08
15A 10A 15A 15A
30
X1:301
X1:18A K06 X1:19A X1:25A
X1:26A
8:4 X1:305
X1:83
Schalter StvZO 87 87a
switch, StvZO
13 23
012 31 11 23 Anschlu Arbeitsschein L0R
werfer ohne StvZO L0R Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschlu Arbeitsscheinwerfer
X1:306
X1:307
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:302
X3:4 X3:5 with cabin 30 49L 49R

STV1
9:17 A02
STV2
9:17
X1:23E X1:24E
K16 30 31 82 L R
8:9 F09 F10
Schalter Arbeitsbeleuchtung
15A 15A
switch, working head lights
87 87a X1:23A X1:24A
4:11 BLL X1:91

4:19
13 BEL BLR
4:19
X1:96
Arbeitsscheinwerfer hinten rechts
Arbeitsscheinwerfer vorne rechts

S53 14
connection working head
Arbeitsscheinwerfer hinten links

Anschlu Arbeitsschein
Arbeitsscheinwerfer vorne links
working head lights, front rh.

working head lights, front lh.
lights without StvZO
working head lights, rear rh.

working head lights, rear lh.
X1:308
X1:304
werfer ohne StvZO
X1:303
13 23
X1:311
X1:310
X1:319
X1:312
X58:5 X1:309
X61:3 X1:320
X1:313
01
X60:1 X1:321
X1:314
X61:1 X1:322
01
S14
X1:84
X59:5
X60:3
X59:3
X58:3
Warnblinkschalter 14 24
X59:2
X58:2
6:2 switch, hazard light
0,125A
0,125A
BEL MESX BLW

E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 4:19 E08 1 E09 1 E10 1 E11 1
+
2 2 86 2 2 2 2 86 2 2 2 2 H06 2 2 2 2
4,6A
4,6A
4,6A
4,6A
K06 K16

X61:2
X1:324 X61:4
X1:316 X59:6
X1:316 X59:6
X59:6
X1:315 X58:6
X1:315 X58:6
X58:6
X60:2
X1:323 X60:4
85 85
X1:315
X1:316
X3:1
X1:323
X1:324
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A
4,6A
4,6A
7:20 9:1
31
8:10 Schluleuchte links 8:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
Anschlu Arbeitsscheinwerfer
Scheinwerfer rechts parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
head light RH Parkleuchte rechts Blinkleuchte HL
parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schluleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH
16.11.2005
1 1 582 702 09
Vogt ZA Beleuchtung und StvZO
16.11.2005
Seis opt. illumination and StvZO 008
F42:H 10:13 F41:5 10:13
X3:6
2:11 K30 2:11 K32:87 10:2
X3:7
K32:86 K32 30 STV2
X3:8 8:13
2:20 9:2 8:13 STV1
87 87a
X3:3
G H A B C E F
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3
5 6
F42 10:8
F130 9:9 F130 F130 10:7
9:14
socket operator platform
A12
1,75A
0,83A
Steckdose Fahrerst.
15
K141 30 1 B51 + + 30 01W 7 2 01W 7 2
+ + B51 1 S163 5 1 S38 5
01 01 E72
9:16 E29 E70
1
87 87a 2 2 2 1
31 S21 5 4 S20 5 4
Radio
night illumination
radio
Nachtleuchte
inside light, cabin
3,8A
3,8A
1 Tachographenmodul
Steckdose Kabine
Kontrolleuchte
E71 1
Innenleuchte
module, tachograph
socket cabin
indicator
XS
+ R80 A2+A3
X3:17
X55:1
X56:1
X55:3
X56:3
X55:4
X56:4
4,6A
4,6A
4,6A
4,6A
2 4 6 A1 XS
3:16 P09 +
12V 2 SPEED TAC A16 E27 1 E28 1 E23 1 E25 1
Heizung Heckscheibe
1 B3

12V
heating rear screen
switches interior lights
+ 7,8,9 2 B4 2 2 2 2
Schalter Innenleuche
A01 5 3 C3
only at handrail/Rops/sunroof
Nur bei Gelnder/Rops/SD
A5+A6
S45 TK
4 1
A51
3
5A
86 S86 + 3 2 5 + + S158 I 15 +
K32 E32
K141
X3:16
X3:15
M05 M M M04 M M
31
3 min
M07
Abfallverzgert
M06 4
GA
KA
2,9A
85
4,7A
ZA
X55:2 X56:2 option
5:17
5:16
10:18
Relais Kabine Trkontaktschalter Frequenzmodul Tachograph KABINE 31
relais cabin door switch module, frequency tachograph Schalter Nachtleuchte
switch, night illumination
X3:1
X3:2
Schalterbel.
switch illum.
8:20 31 31 10:1
9:6 Wascher hinten Wascher vorn 9:2 Arbeitsscheinwerfer vorn

washer rear washer front working head lights, front
Wischer hinten Wischer vorne Arbeitsscheinwerfer hinten Rundumkennleuchte

windscreen wiper, rear windscreen wiper, rear working head lights, rear rotary beacon
16.11.2005
1 1 582 702 09
Vogt ZA Kabine, Beleuchtung, Radio, Tachograph
16.11.2005
Seis opt. cabin, headlights, radio, tachograph 009
9:20 K32:87 9:19 F41:5
Potential 15 aus Kabine
9:17 F130 9:4
F42:H
F42 Potential 15 aus Kabine
9:9
F31 D Potential 30 aus Kabine
F40 A F15 B
BOX2 BOX2
20A 20A 5A
4 1 2
2.5qmm
Bedienteil Kabinenheizung/Klimaanlage
1 2 3 12 11 13 14 16
X53:B X53:C controlunit cabheater /air conditioning X54:4 X54:3 X54:2
0123 4 3 2 5 7 11 3 10 1
S44 A72
Schaltuhr Heizung
Steuergert
heater timer
control unit
6 11 12 1 Regel aus = 0,4A
S28
Schalter Kabinenlfter
E30 Kleine Stufe = 0,67A
switch blower cabin X54:6 X54:11 X54:12 X54:1 Zusatzheizung mittleter Stufe = 1,0A
add. heater groe Stufe = 1.9A
X3:13 Power Stufe = 2,8A
Anlaufstrom beim Start = 8,3A
2 6 8 9 4 12
X53:M
X53:H
X53:L
K09 30
X3:14
temperature sensor air conditioning
Thermofhler Klimaanlage
2:8
87 87a X1:167 5 9 10 6 8 7 4 15
2.5qmm
temperature sensor heating unit
X3:11
X3:10
X3:12
X3:9
X1:169 X18:1
X19:1
Thermofhler Heizung
B131
B103 1
X17:1 X1:163
X17:2 X1:165
X17:3 X1:166
1
_t _t
2
berwachung Khlmitteldruck
2
monitoring coolant pressure
X19:2
X20:1 X18:2
B104 4
P
LP 3 HP X77:1
1A
X20:4
ge rt or ge rt or
X20:3
Y138 1 1
X1:170 9:19
V06 Y14 KABINE 31
M09 M M09 M
Kabinenlfter 2 2
br br
X20:2
X77:2
Y15 1 2
X17:4 V04 X1:168
3,5A
2 1
X1:164
9:20 31 31
Kabinenlfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit
Vogt
1 1 582 702 09
Seis ZA Kabinenheizung, Klimaanlage, Zusatzheizung
16.11.2005
Seis opt. cabinheater, air conditioning, add. heater 010
Name Bl. Pf. Benennung title TYP
005 4 MAX. 1,67A
A02 008 17 Blinkrelais indicator relay

A05 003 17 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer MODUL
A12 009 5 Radio Radio
A13 003 3 Steuergeraet Heizung Control unit, heating
A15 004 16 Ueberwachungsmodul monitoring module
A16 009 7 Elektronik Tachograph Electronic system, tachograph
A51 009 6 Platine Frequenzanzeige Circuit board,frequenzy meter
A68 005 10 Modul Sitzkontakt Modul seat contact MAX. 0,12A
A72 010 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A83 006 6 Elektronik Messtechnik electronic measurementequipment
A87 007 15 USBCAN Schnittstelle BCM USBCAN Interface BCM
Seis
16.11.2005
Vogt
16.11.2005
B03 004 15 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B06 004 17 Druckschalter Motoroel Pressure switch, engine oil
B11 003 9 Signalhorn Warning horn MAX.5A
B11 003 11 Signalhorn Warning horn MAX.5A
B13 004 2 Naeherungsinitiator Fahrhebel links Proximity switch, travel lever, lh.
B14 004 6 Naeherungsinitiator Fahrhebel rechts Proximity switch, travel lever, rh.
B21 004 14 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B30 004 16 Temperaturschalter Motoroel Temperature switch, engine oil
B51 009 5 Lautsprecher Radio Speaker radio
B51 009 6 Lautsprecher Radio Speaker radio
B55 004 17 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B60 003 14 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 006 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 006 8 Beschleunigungsaufnehmer Acceleration sensor
B62 006 10 Beschleunigungsaufnehmer Acceleration sensor
B103 010 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 010 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B113 003 3 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B124 004 19 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 010 10 Temperaturschalter Heizung Temperature switch, heating
E08 008 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 008 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 008 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 008 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 008 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 008 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 008 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 008 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
component listing
E16 008 2 Scheinwerfer links Head light, lh. MAX. 4,6A

E17 008 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
Bauteilliste
E23 008 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 009 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 008 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 009 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 008 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 009 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 008 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 009 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 009 4 Innenleuchte Kabine Inside light, cabin 1,75A
E30 010 13 Heizgeraet Heating unit
E32 009 19 Kennleuchte Warning light 5A
E70 009 15 Nachtleuchte Night lamp 0,83A
E71 009 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 009 16 Beleuchtung Bedienschalter illum. Switches
F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A

F03 005 18 Sicherung Vibration Fuse, vibration MAX. 1,23A
F07 008 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 008 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 008 6 Sicherung Park u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 008 8 Sicherung Park u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 008 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F14 002 18 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 15A
F15 010 18 Sicherung Heizgeraet Fuse, heating unit BOX2
F18 008 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 008 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 008 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 003 9 Sicherung Signalhorn Fuse, warning horn 10A
F24 004 10 Sicherung Ueberwachungsmodul Fuse, monitoring module 10A
F25 004 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F31 010 3 Sicherung Kabinenluefter Fuse, cabin ventilator
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 010 13 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
F41 009 19 Sicherung Rundumkennleuchte Fuse, rotary beacon
F42 009 4 Sicherung Kabineninnenleuchte Fuse, inside light cab
F43 009 10 Sicherung Wischermotor hinten Fuse, wipermotor rear
1
F44 009 13 Sicherung Wischermotor vorn Fuse, wipermotor front

F48 002 3 Sicherung Gluehanlage Fuse, glow plug system 125A
F84 006 5 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
FM4 006 11 Platinensicherung Multifuse
F105 002 16 Sicherung Motordrehzahl Fuse, motor speed 20A
6
F130 009 15 Sicherung Nachtleuchte Fuse, night lamp

F143 009 2 Sicherung Heckscheibenheizung fuse rear screen heating unit
F144 009 20 Sicherung Kabinensteckdose Fuse cabinsocket
F146 006 4 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30)
582 702 09
F148 006 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15)
G01 002 4 Batterie Battery 103A

G02 002 5 Generator Generator
G03 002 3 Batterie Battery 103A
101
H06 008 15 Meldeleuchte Warnblinker Indicator light, hazard light

H07 004 10 Warnsummer Betriebsstoerung Warning buzzer, breakdown MAX. 0,12A
H14 004 8 Warnsummer Rueckwaertsfahrt Backup alarm buzzer MAX. 0,12A
K04 005 18 Schrittrelais Vibration Toggle relay, vibration MAX. 1,23A

K05 004 3 Relais Startstrom Relay, starting current BOSCHW
K06 008 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW
K14 003 5 Relais Vorgluehen Relay, glow plug system BOSCHL
K16 008 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K22 004 9 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K26 004 6 Relais Rueckfahrwarneinrichtung Relay, back up alarm BOSCHW
K32 009 2 Relais Kabine Relay, cabin BOSCHW
K35 002 16 Relais Selbsthaltung Relay, holding contact BOSCHW
K36 002 7 Relais Bremskontrolle Relay, brake control BOSCHW
Seis
16.11.2005
Vogt
16.11.2005
K48 004 2 Relais Fahrhebel 0Stellung Relay, travel lever 0position BOSCHW
K61 002 5 Relais Ladekontrolle Relay, charge control BOSCHW
K114 002 14 Relais Motordrehzahl Relay, engine rpm BOSCHW
K141 009 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
M01 002 11 Starter Starter 2.3 KW

M04 009 13 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 009 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 009 14 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 009 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 010 3 Kabinenluefter Cabin ventilator
M09 010 4 Kabinenluefter Cabin ventilator
P04 003 19 Geschwindigkeitsanzeige Speedometer

P07 006 15 Omegameter Omegameter
P09 009 8 Frequenz und Geschwindigkeitsanzeige Frequency and Speedometer
P11 006 14 Drucker Printer
P15 007 16 BCM 03 Bildschirm BCM 03 terminal
P16 006 16 Diagnose, Variomatic Diagnostics, varimatic
P33 006 18 Opus 21 Opus 21
R03 004 12 Geber Tankanzeige Sender, level gauge

R10 002 6 Parallelwiderstand Parallel resistor 82 OHM
R19 002 2 Heizflansch heater flange 167A
R20 006 17 Widerstand Resistor 60OHM
R24 007 15 Widerstand Resistor 120 OHM
R25 007 15 Widerstand Resistor 120 OHM
R80 009 2 Heizung Heckscheibe heating rear screen
component listing
S00 002 10 Startschalter Starter switch

S01 002 18 Schalter NOT AUS Switch, emergency off
Bauteilliste
S03 003 9 Taster Signalhorn Push button, warning horn

S13 005 13 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 008 15 Warnblinkschalter Switch, hazard light
S15 008 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 009 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 009 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 010 17 Schalter Kabinenheizung Switch, cabin heating
S30 002 3 Batterietrennschalter Switch, battery disconnect
S35 005 15 Vibrationsschalter klein/gross Switch, vibration low/high
S37 008 18 Schalter Blinker Switch, indicator
S38 009 19 Schalter Kennleuchte Switch, warning light
S42 005 3 Stufenumschalter schnelllangsam Speed range selector, fastslow
S42 005 7 Stufenumschalter schnelllangsam Speed range selector, fastslow
S44 010 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 009 4 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 008 4 Schalter Arbeitsbeleuchtung Switch, working lights
S58 005 13 Schalter Aetherstartanlage Push button, ether starting unit
S86 009 4 Schalter Tuer, links Switch door, lh.
S120 002 14 Schalter Motordrehzahl Switch, engine speed
S158 009 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 009 16 Schalter Heckscheibenheizung switch rear screen heating unit
V01 002 6 Diode Diode 4UF004

V02 005 6 Diode Diode MAX. 1,23A
V04 010 8 Diode Diode FE5B
V06 010 9 Diode Diode
V47 002 15 Diode (A7) Diode (A7) FE5B
X1:1 002 5 WAGO,EKasten WAGO,EBOX

X1:2 008 10 WAGO ZENTRALELEKTRIK WAGO EBOX
2

6

582 702 09

102

X1:69 004 13 WAGO,EKASTEN WAGO, Ebox
Seis
16.11.2005
Vogt
16.11.2005

component listing

Bauteilliste

3

X1:15A 002 10 WAGO,EKasten WAGO,EBOX
X1:15E 002 10 WAGO,EKasten WAGO,EBOX
6

582 702 09

103

X1:18A 008 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:18E 008 2 WAGO ZENTRALELEKTRIK WAGO EBOX
Seis
16.11.2005
Vogt
16.11.2005

component listing

Bauteilliste

X2:47 006 18 WAGOMESSTECHNIK Wagomeasurement equip.
4

6

582 702 09

104

X3:1 008 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 009 10 STECKER KABINE/ROPS conn. cabin/ROPS
Seis
16.11.2005
Vogt
16.11.2005

X4:A 006 14 KABINENST. MESST. con. measurem.equipm.
X4:B 006 14 KABINENST. MESST. con. measurem.equipm.
X4:C 006 14 KABINENST. MESST. con. measurem.equipm.
X4:D 006 14 KABINENST. MESST. con. measurem.equipm.
X4:E 006 15 KABINENST. MESST. con. measurem.equipm.
X4:F 007 18 KABINENST. MESST. con. measurem.equipm.
X4:G 007 18 KABINENST. MESST. con. measurem.equipm.
X4:M 007 16 KABINENST. MESST. con. measurem.equipm.
X4:N 007 15 KABINENST. MESST. con. measurem.equipm.
X6:1 005 14 DEUTSCH DEUTSCH connector
XS 009 1 Steckdose Socket
XS 009 20 Steckdose Socket
X10:2 004 12 AMP SUPERSEAL AMP connector
component listing
X10:3 004 12 AMP SUPERSEAL AMP connector

Bauteilliste

X14:A 005 13 DEUTSCH DEUTSCH connector
X14:B 005 13 DEUTSCH DEUTSCH connector
X17:1 010 3 STECKER LFTER HKL conn. blower
X18:1 010 10 STECKER THERMOFHLER conn. sender temp.
X18:2 010 10 STECKER THERMOFHLER conn. sender temp.
X19:1 010 7 STECKER EISSCHUTZ HKL conn. antiice aircond.
X19:2 010 7 STECKER EISSCHUTZ HKL conn. antiice aircond.
X20:1 010 7 STECKER DRUCKSCH. KLI conn. pressuresitch aircond.
X21:1 004 17 STECKER KHLMITTEL connector coolant sensor
X21:2 004 17 STECKER KHLMITTEL connector coolant sensor
X36:A 002 4 EINSPEISUNG SCHALTKAS supply ebox
X36:B 002 4 EINSPEISUNG SCHALTKAS supply ebox
X37:A 002 10 ST. ZNDSCHLO EKAST connector ignition switch
X37:B 002 11 ST. ZNDSCHLOSS EKAS connector ignition switch, ebox
X38:A 002 11 ST.STARTER EKASTEN connector starter ebox
X42:1 006 18 STECKER ADAPTER BOP conector adapter BOP
X44:1 006 13 MESX STECKER MESX Stecker
5

6

582 702 09

105

Seis
16.11.2005
Vogt
16.11.2005

X46:A 006 19 STECKER BOP Connector BOP
X46:B 006 18 STECKER BOP Connector BOP
X46:D 006 18 STECKER BOP Connector BOP
X46:E 006 19 STECKER BOP Connector BOP
X46:F 006 18 STECKER BOP Connector BOP
X47:A 006 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 006 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:C 006 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X48:1 006 8 STECKER AUFN. VORNE conn. sender front
X49:1 006 10 STECKER AUFN. HINTEN conn. sender rear
X53:B 010 3 STECKER LFTERSCHALTE conn. blowerswitch
X53:C 010 4 STECKER LFTERSCHALTE conn. blowerswitch
X53:H 010 4 STECKER LFTERSCHALTE conn. blowerswitch
X53:L 010 3 STECKER LFTERSCHALTE conn. blowerswitch
X53:M 010 3 STECKER LFTERSCHALTE conn. blowerswitch
X54:1 010 11 STECKER HEIZSTEUERUNG conn. heating controller
component listing

X55:1 009 11 STECKER WISCHER HINTE connector wiper rear
Bauteilliste

X56:1 009 14 STECKER WISCHER VORNE conn. wiper front
X58:2 008 17 STECKER STVZO VL Con. STVZO FL
X59:2 008 19 STECKER STVZO VR Con. STVZO FR
X60:1 008 18 STECKER STVZO HL Con. STVZO BL
X61:1 008 19 STECKER STVZO HR Con. STVZO BR
X74:1 006 14 STECKER DRUCKER con. printer
X75:2 007 16 SUBD STECKER BCM INT con. SUBD BCM
X75:7 007 15 SUBD STECKER BCM INT con. SUBD BCM
X76:1 007 17 STECKER VERS. BCM con. Powersup. BCM
X76:2 007 17 STECKER VERS. BCM con. Powersup. BCM
X77:1 010 13 STECKER PUMPE STANDHE Conn. pump add. heater
6
X77:2 010 13 STECKER PUMPE STANDHE Conn. pump add. heater
Y01 002 12 Magnetventil Startmehrmenge Solenoid valve, start boost fuel MAX. 3.9A
Y04 004 5 Magnetventil Bremse Solenoid valve, brake MAX. 1,8A
Y07 005 14 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high MAX. 2,5A
6
Y08 005 16 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low MAX. 2,5A
Y13 002 18 Hubmagnet Motor Shut off solenoid, engine MAX. 3.8A
Y14 010 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 010 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
582 702 09
Y30 005 6 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front MAX. 1,67A
Y31 005 3 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y31 005 8 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y120 002 16 Magnetventil Motordrehzahl hoch Solenoid valve, rpm engine high
Y138 010 10 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
106
Y140 006 10 Magnetventil Erreger auf solenoid valve exciter up

Y141 006 11 Magnetventil Erreger ab solenoid valve exciter down
X38
X36 X37
Nur bei StvzO

only acc. To StvZO illumination
A02 R10 K05
K11 K16 K06
K36 K22
Nur bei Klimaanlage

K09 K35
only acc. to aircond.
K48
K61
A68 K114
K26
Nur wenn Sitzkontakt angebaut

only acc. if seatswitch is assembled
Nur wenn kein Sitzkontakt angebaut

K04 only acc. if no seatswitch is assembled
Gez.: 19.10.2005 Seite: 1 von: 2

Name: Vogt bersicht Schaltkasten BW 177...219 D-4/D-40 page: 1 from: 2
582 702 09
Gepr.: 19.10.2005 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box BW 177...219 D-4/D-40 Replaces: Sheet No.: 201
Nur bei VM8
only acc. To VM8
F1 F2
CAN 1
CAN 1 OPUS 21
A83
Messtechnik Steuerung
CAN 3 BCM
Gez.: 19.10.2005 Seite: 2 von: 2

Name: Vogt
bersicht Schaltkasten-Tr BW 177...219 D-4/D-40 page: 2 from: 2
582 702 09
Name: Seis
overview e-box door BW 177...219 D-4/D-40 Replaces: Sheet No.: 201
WAGO smart DESIGNER 4.1
1 05756417
2 05756421
3 2 x 05756425 "L" + 793-501
5 2 x 05756425 "L" + 05756420 + 793-501
7 05756422
8 4 x 05756423 "L" + 05756419 + 793-501
12 18 x 05756436 "R" + 05756419 + 793-501 12 Flachsicherung DIN 72581-C30 / 057 510

99
13 Flachsicherung DIN 72581-C15 / 057 510

98

00

98

98

98

97

97

98

97

98

97

97

98

97

98
Optional1 : Projektgruppe : Walzenzge-4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprft: :
Ort :
Optional4 :
Tragschiene : Absicherung D-4 Version Lieferadresse :
Optional5 : ausgewhlte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Optional7 : Gre der Bohrung : 5.20 x 25.00 [mm]
Copyright WAGO. Technische nderungen vorbehalten.

17.11.2005 07:47:59 Seite 1
30 2 x 05756436 "R" + 793-501
32 05756435
33 05756417

Artikelnummer :
Ort :
Optional4 :

17.11.2005 07:47:59 Seite 2

Artikelnummer :
Ort :
Optional4 :

17.11.2005 07:48:52 Seite 3

Artikelnummer :
Ort :
Optional4 :

17.11.2005 07:48:52 Seite 4
1 05756417
2 2 x 05756540 "R" + 793-501 + 05756536
4 2 x 05756540 "R" + 793-501
6 3 x 05756539 "R" + 793-501
9 05756537
10 4 x 05756538 "R" + 793-501
14 05756537
15 3 x 05756538 "R" + 793-501
18 05756537
19 3 x 05756540 "R" + 793-501
22 05756535 "R" + 793-501
23 05756537
24 5 x 05756540 "R" + 793-501
29 05756537
30 2 x 05756538 "R" + 793-501
32 2 x 05756539 "R" + 793-501
34 05756537
35 4 x 05756538 "R" + 793-501
39 05756537
40 4 x 05756540 "R" + 793-501
44 2 x 05756539 "R" + 793-501
46 05756537
47 05756540 "R" + 793-501
48 05756535 "R" + 793-501

Artikelnummer :
Ort :
Optional4 :
Tragschiene : Kabelbume D Version Lieferadresse :

17.11.2005 07:51:17 Seite 1
49 05756537
50 2 x 05756538 "R" + 793-501
52 05756537
53 4 x 05756540 "R" + 793-501
57 05756539 "R" + 793-501
58 05756537
59 4 x 05756540 "R" + 793-501
63 05756537
64 05756540 "R" + 793-501
65 05756535 "R" + 793-501
66 05756537
67 05756540 "R" + 793-501
68 05756535 "R" + 793-501
69 05756537
70 05756538 "R" + 793-501
71 2 x 05756540 "R" + 793-501
73 05756539 "R" + 793-501
74 05756537
75 05756417

Artikelnummer :
Ort :
Optional4 :

17.11.2005 07:51:17 Seite 2

Artikelnummer :
Ort :
Optional4 :

17.11.2005 07:51:57 Seite 3

Artikelnummer :
Ort :
Optional4 :

17.11.2005 07:51:57 Seite 4
1 05756417
2 2 x 05756540 "R" + 793-501
4 05756539 "R" + 793-501
5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501
9 05756538 "R" + 793-501
10 05756537
11 2 x 05756540 "R" + 793-501
Optional1 : Projektgruppe : Walzenzge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Messtechnik D Artikelnummer lang :
Ort :
Optional4 :
Tragschiene : Klemmenleiste X2 Lieferadresse :

16.11.2005 14:51:24 Seite 1
13 05756539 "R" + 793-501
14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501
17 05756540 "R" + 793-501
18 05756537
19 05756417

Artikelnummer :
Ort :
Optional4 :

16.11.2005 14:51:24 Seite 2

Artikelnummer :
Ort :
Optional4 :

16.11.2005 14:51:51 Seite 3

Artikelnummer :
Ort :
Optional4 :

16.11.2005 14:51:51 Seite 4
1 05756417 1 Nur bei ZA E2 StvZO Beleuchtung
2 4 x 05756540 "R" + 793-501 2 Nur bei ZA E2 StvZO Beleuchtung
3 Nur bei ZA E2 StvZO Beleuchtung



Artikelnummer :
Optional2 : Projekt : E2 Beleuchtung Artikelnummer lang :
Ort :
Optional4 :
Tragschiene : Option E2 StvZO Beleuchtung Lieferadresse :

16.11.2005 14:48:22 Seite 1

Artikelnummer :
Optional2 : Projekt : E2 Beleuchtung Artikelnummer lang :
Ort :
Optional4 :
Tragschiene : Option E2 StvZO Beleuchtung Lieferadresse :

16.11.2005 14:48:52 Seite 2
X74 X75
X55
X56 X76 X53 X54
X5
X21
X11 X12
X59 X13
X58 X42
X20
X46 X14
X18 X77
X17 X6 X7
X22 X19 X4 X3
X8
X48 X49 X10
X36 X60
X37 X1 X61
X38 X2
X9
X44
X61
X77 X9
X21
X74 X75
X59
X76
X42 X11 X12 X8
X10
X46 X13
X56
X53
X20
X18
X5 X17 X14
X19 X55 X6 X7
X54
X58
X4 X3
X36 X1
X37 X44 X2
X38 X60
X48 X49
X22
Gez.: 19.10.2005 Seite: 1 von: 1

Name: Vogt
Steckerbersicht BW 177...219 D-4/D-40 page: 1 from: 1
582 702 09
Name: Seis Connector overview BW 177...219 D-4/D-40 Replaces: Sheet No.: 301

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Service Training

Single Drum Rollers

with Deutz engine 2012 C

Part-No. 008 097 26 11/2005

Technical data and adjustment values B1

DEUTZ diesel engine D1

BW 211 / 212 / 213 D-40

BW 211 / 212 / 213 D-40

the location of components in the machine eases maintenance work,

BW 211 / 212 / 213 D-40 -A1-

1. Operating and maintenance instructions

BW 211 / 212 / 213 D-40 -A2-

BW 211 / 212 / 213 D-40 -A3-

strong ROPS/FOPS according to SAE-standard

BW 211 / 212 / 213 D-40 -A4-

BW 211 / 212 / 213 D-40 -A5-

BW 211 / 212 / 213 D-40 -B1-

BOMAG Central Service - Technical data and adjustment values

Product type: BW 211 / 212 / 213 D-40

Travel motor, rear:

Type: 42R 041

Steering and charge pump:

BW 211 / 212 / 213 D-40 -C1-

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Engine Engine oil ACEA: E3-96/E5-02 or approx. 8,5 litres without

Diesel Winter diesel fuel approx. 150 litres

Vibration bearings Engine oil SAE 15W/40 approx. 0,8 litres

Air conditioning system Refrigerant R134A approx. 1400 g

Tires (only BW 213) Water approx. 295 litres

Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg

Engine cooling system Cooling system protection agent approx. 16 litres

The following maintenance work must be per-

After a running-in time of 30 minutes

After 250 operating hours

After 500 operating hours

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 500 operating hours

every 1000 operating hours

every 2000 operating hours

every 3000 operating hours

every 500 operating hours

These engines are characterized by the following positive features:

short and compact design,

low noise level,

almost vibration-free running,

low fuel consumption,

low exhaust emissions (EPA II),

high power reserves and

good access to all service points.

The forged crankshaft is equipped with integrated counterweights.

BW 211 / 212 / 213 D-40 -D1-

Fig. 1: Service side BFM 1013/2012

1 Oil filler neck 8 Fuel pump

BW 211 / 212 / 213 D-40 -D2-

Fig. 2: Starter side

BW 211 / 212 / 213 D-40 -D3-

Fig. 3: Lubrication oil circuit

1 Oil sump 12 Piston cooling nozzle

BW 211 / 212 / 213 D-40 -D4-