Service Training Overview

Service Training
Single Drum Rollers

BW 156/177 D-3/DH-3/PDH-3
BW 156/177 D-3/DH-3/PDH-3
008 098 14 Edition 04/2000

Service Training
Table of contents
Foreword A1
Documentation A2
General A4
List of components B1
Technical data B2
Maintenance B 26
Maintenance table B 27
Cummins Diesel engine C1

External engine parts Cummins 4B 3.9-C C3
External engine parts Cummins 4BT 3.9-C C5
Adjusting the valve clearance C 11
Changing the injection pump C 12
Travel system D1
Brake control D4
Travel pump D5
Multi-function valve D 13
Charge pressure relief valves D 15
Flushing valve D 16
Drum drive motor D 17
Axle drive motor D 21
Drum drive motor (51D110 + GFT17) DH/PDH versions D 23
Trouble shooting travel system DTr 1
BW 156/177 D-3/DH-3/PDH-3
BW 178/179 D-3/DH-3/PDH-3
Service Training
Vibration E1
Vibration pump E3
Control E6
High pressure relief valves E6
Charge pump E7
Vibration motor E8
Drum E 11
Trouble shooting vibration system ETr 1
Steering F1
Steering pump F3
Steering valve F5
Articulated joint F7
Trouble shooting steering system FTr 1
Electrical system G1
Power supply G2
Starting G4
Fault monitoring board G7
Function diagram fault indicator G 10
Brakes G 11
Travel speed range selector G 14
Vibration G 18
BW 156/177 D-3/DH-3/PDH-3
BW 178/179 D-3/DH-3/PDH-3
Service Training
Foreword
This training manual was specially written for the new single drum rollers BW 156 D-3 to BW 179 PDH-
3 of generation 3. This range of single drum rollers is the consistent further development of the product
range BW 142 D-2 to BW 172 PD-2 and represents a perfect adaptation to the presently highest
technical standards.
Today single drum rollers of series BW 156 and BW 179 can be found on construction sites all over the
world. These machines are mainly used in earth construction, for the preparation and sealing of sanitary
landfill sites and, as AD-versions, for the compaction of bituminous wear courses.
During the development of this new generation of single drum rollers special attention was paid to the
necessities and requirements of customers and operating personnel.
Also in the future we will obviously undertake everything possible to increase the benefits for our
customers and we therefore would like to ask you to inform us about your ideas and suggestions.
The introduction of new or enhanced products obviously emphasizes the necessity of training for all
persons who are responsible for a trouble free service support for these products.
For this reason we have revised these training documents. They should help the trainer to pass the
necessary information on to the persons attending the training course in an easy to understand way.
This documentation is by no means complete. Technical data and details, which were not yet available
at the time this manual was written or which have changed since the introduction of this manual, must
be explained by the trainer during the training session.
These training documents are not subjected to a regular updating service. However, all important
changes to the machine will be included during a revision.
The chapter „Documentation“ contains notes on further documents, which are additionally available for
this machine. The currently valid operating and maintenance instructions and the latest electric and
hydraulic diagrams are part of this training manual.
BW 156/177 D-3/DH-3/PDH-3 -A1-

BW 178/179 D-3/DH-3/PDH-3
Service Training
Documentation
For the single drum rollers BW 156 D-3 to BW 179 PDH-3 the following documents are available:
1. Operating and maintenance instructions

Machine type Catalogue-No.: from serial-number to serial-number
BW 156 D-3 008 140 20 101 580 00 0101
BW 156 DH-3 008 140 20 101 580 03 0101
BW 156 PDH-3 008 140 20 101 580 02 0101
BW 177 AD-3 008 140 20 101 580 11 0101
BW 177 D-3 008 140 20 101 580 10 0101
BW 177 DH-3 008 140 20 101 580 14 0101
BW 177 PDH-3 008 140 20 101 580 13 0101
BW 178 D-3 008 140 20 101 580 70 0101
BW 178 DH-3 008 140 20 101 580 73 0101
BW 178 PDH-3 008 140 20 101 580 72 0101
BW 179 D-3 008 140 20 101 580 80 0101
BW 179 DH-3 008 140 20 101 580 83 0101
BW 179 PDH-3 008 140 20 101 580 82 0101
2. Spare parts catalogue

BW 156 D-3 008 153 00 101 580 00 0101
BW 165 DH-3 008 153 03 101 580 03 0101
BW 156 PDH-3 008 153 02 101 580 02 0101
BW 177 AD-3 008 153 11 101 580 11 0101
BW 177 D-3 008 153 10 101 580 10 0101
BW 177 DH-3 008 153 14 101 580 14 0101
BW 177 PDH-3 008 153 13 101 580 13 0101
BW 178 D-3 008 153 70 101 580 70 0101
BW 178 DH-3 008 153 73 101 580 73 0101
BW 178 PDH-3 008 153 72 101 580 72 0101
BW 179 D-3 008 153 80 101 580 80 0101
BW 179 DH-3 008 153 83 101 580 83 0101
BW 179 PDH-3 008 153 82 101 580 82 0101
3. Electric circuit diagram*

Drawing-No.: for machine
582 700 38 for single drum rollers with new control board
582 700 48 for single drum rollers with new control board from BJ 02/99
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BW 178/179 D-3/DH-3/PDH-3
Service Training
4. Hydraulic diagram*
BW 156 D-3 058 120 124 101 580 00 0101
BW 156 DH-3 058 120 136 101 580 03 0101
BW 156 PDH-3 058 120 136 101 580 02 0101
BW 177 AD-3 058 120 124 101 580 11 0101
BW 177 D-3 058 120 124 101 580 10 0101
BW 177 DH-3 058 120 136 101 580 14 0101
BW 177 PDH-3 058 120 136 101 580 13 0101
BW 178 D-3 058 120 187 101 580 70 0101
BW 178 DH-3 058 120 136 101 580 73 0101
BW 178 PDH-3 058 120 136 101 580 72 0101
BW 179 D-3 058 120 187 101 580 80 0101
BW 179 DH-3 058 120 136 101 580 83 0101
BW 179 PDH-3 058 120 136 101 580 82 0101
5. Repair instructions
Catalogue-No.: Component Part-No.
6. Service Information
Remark:
* These documents are part of this training manual
BW 156/177 D-3/DH-3/PDH-3 -A3-

BW 178/179 D-3/DH-3/PDH-3
Service Training
General
The new single drum rollers BW 156 D-3 to BW 179 PDH-3 from BOMAG are mainly further
developments of their predecessors BW 142 D-2 to BW 172 DH-2.
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 driver’s 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 board 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
offers clear vision to all sides.
BW 156/177 D-3/DH-3/PDH-3 -A4-

BW 178/179 D-3/DH-3/PDH-3
Service Training
Important characteristics of the new generation of single drum rollers are
• strong ROPS/FOPS according to SAE-standard
• wear free service brake by closed hydrostatic travel circuits
• multi-disc brakes in planetary gears as parking and emergency brakes
• high stability due to low centre of gravity and the use of an articulated joint
• operating afety due to the use of monitoring boards for all important system data
• automatic engine shut-down at too high coolant temperature, too low hydraulic oil level (when
reaching the lowest permissible level the engine will be shut down after 20 seconds) and too low
engine oil pressure.
The machines of product ranges BW 156 D-3 to BW 179 PDH-3 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.
BW 156/177 D-3/DH-3/PDH-3 -A5-

BW 178/179 D-3/DH-3/PDH-3
Service Training
List of components
1 Drum
2 Drum drive motor
3 Front frame
4 Articulated joint
5 Operator’s stand
6 Hydraulic oil tank
7 Hydraulic oil cooler
8 Radiator
9 Engine oil filter
10 Cummins engine 4B3.9 (BW 156 D-3/PD-3); 4BT 3.9 (BW 179 D-3/PD-3)
11 Wheels (with axle and axle drive motor)
12 Vibration pump
13 Travel pump
14 Hydraulic oil filter
15 Hand pump for hood
16 Accumulator for the absorption of vibrations in the steering
17 Fuel filter
18 Steering/charge pump
19 Colling blower
20 Operator’s seat
21 Steering wheel with steering valve
22 Vibration motor
23 Generator
24 Starter
BW 156/177 D-3/PD-3 -B1-

BW 178/179 D-3/PD-3
Service Training
BW 156 D-3
Engine
Manufacturer Cummins
Type 4 B 3.9-C
Cooling Water
Rated power ISO 9249 kW 56
-1
at nominal speed min 2200
-1
Low idle speed min 700 - 950
-1
High idle speed min 2280 - 2330
spec. fuel consumption g/kWh approx. 246
Starter voltage/power V/kW 12/2,9
Valve clearance (inlet) mm 0,254
Valve clearance (outlet) mm 0,508
Injection valve opening pressure bar 245 - 253
Travel pump
Manufacturer Sauer
Type 90 RO 55
System Axial piston
Control Swash plate
3
Displacement cm /rev. 55
High pressure limitation bar 435 +/- 15
Charge pressure bar 25 +/- 1
Travel motor (drum)
Manufacturer Poclain
Type MSE 08
System Radial piston
3
Operating pressure, max. bar 435 +/- 15
Leak oil quantity, max l/min 2
BW 156/177 D-3/PD-3 -B2-

BW 178/179 D-3/PD-3
Service Training
BW 156 D-3
Travel motor (axle)
Manufacturer Sauer
Type 51 D 110
System Axial piston
3
Displacement, range 1 cm /rev. 110
3
Displacement, range 2 cm /rev. 55,3
Axle
Manufacturer Clark-Hurth
Type 172
Transmission ratio i = 27
Vibration pump
Manufacturer Sauer
Type 42 R 028
System Axial piston
3
High pressure limitation/
vibration starting pressre bar 365 +/- 35
Vibration motor
Manufacturer Sauer
Type MMF 025
System Swash plate
3
Frequency Hz 30/41
Amplitude mm 1,75/0,90
BW 156/177 D-3/PD-3 -B3-

BW 178/179 D-3/PD-3
Service Training
BW 156 D-3
Steering pump
Manufacturer Bosch
Type HY/ZFS11/22,5
System Gear pump
3
Displacement cm /rev. 22,5
max. steering pressure bar 435 +/- 15
Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve
Filling capacities
Coolant (50% water/50% anti-freeze) l 15

Engine oil 15W/40 l 10,9
Hydraulic oil HV46 l 60
Axle SAE 90 l 5,5
Planetary gear (axle) SAE 90 l/side 1
Vibrator housing 15W/40 l/side 2,3
BW 156/177 D-3/PD-3 -B4-

BW 178/179 D-3/PD-3
Service Training
BW 156 DH-3 BW 156 PDH-3
Engine
Manufacturer Cummins Cummins

Type 4 B 3.9-C 4 B 3.9-C
Cooling Water Water
Rated power ISO 9249 kW 56 56
-1
at nominal speed min 2200 2200
-1
Low idle speed min 700 - 950 700 - 950
-1
High idle speed min 2280 - 2330 2280 - 2330
spec. fuel consumption g/kWh 246 246
Starter voltage/power V/kW 12/2,9 12/2,9
Valve clearance (inlet) mm 0,254 0,254
Valve clearance (outlet) mm 0,508 0,508
Injection valve opening pressure bar 245 - 253 245 - 253
Travel pump
Manufacturer Sauer Sauer

Type 90 RO 55 90 RO 55
System Axial piston Axial piston
Control Swash plate Swash plate
3
Displacement cm /rev. 55 55
High pressure limitation bar 435 +/- 15 435 +/- 15
Charge pressure bar 25 +/- 1 25 +/- 1
Travel motor (drum)

Type 51 C 060 51 C 060
3
Displacement, range 1 cm /rev. 60 60
3
Operating pressure, max. bar 435 +/- 15 435 +/- 15
Leak oil quantity, max l/min 2 2
BW 156/177 D-3/PD-3 -B5-

BW 178/179 D-3/PD-3
Service Training
BW 156 DH-3 BW 156 PDH-3
Reduction gear (drum)
Manufacturer Lohmann + Stolterfoth Lohmann + Stolterfoth

Type GFT 17 GFT 17
Reduction ratio i = 53,95 i = 53,95
Travel motor (axle)

Type 51 D 110 51 D 110
Displacement, range 1 cm3/rev. 110 110
Displacement, range 2 cm3/rev. 31,4 31,4
Axle
Manufacturer Clark-Hurth Clark-Hurth

Type 172 172
Reduction ratio i = 27 i = 27
Vibration pump

Type 42 R 028 42 R 028
3
Vibration starting pressure bar 365 +/- 35 365 +/- 35
Vibration motor

Type MMF 025 MMF 025
System Swash plate Swash plate
3
Frequency Hz 30/41 30/41
Amplitude mm 1,75/0,90 1,65/0,80
BW 156/177 D-3/PD-3 -B6-

BW 178/179 D-3/PD-3
Service Training
BW 156 DH-3 BW 156 PDH-3
Steering pump
Manufacturer Bosch Bosch

Type HY/ZFS11/22,5 HY/ZFS11/22,5
System Gear pump Gear pump
3
Displacement cm /rev. 22,5 22,5
max. steering pressure bar 200 +/- 10 200 +/- 10
Steering valve
Manufacturer Danfoss Danfoss

Type OSPC 500 ON OSPC 500 ON
System Rotary spool valve Rotary spool valve
Filling capacities
Coolant (50% water/50% anti-freeze) l 15 15

Engine oil 15W/40 l 10,9 10,9
Hydraulic oil HV46 l 60 60
Axle SAE 90 l 5,5 5,5
Planetary gear (axle) SAE 90 l/side 1 1
Reduction gear (drum) SAE 90 l approx. 2,5 approx. 2,5
Vibrator housing 15W/40 l/side 3,2 3,2
BW 156/177 D-3/PD-3 -B7-

BW 178/179 D-3/PD-3
Service Training
BW 177 AD-3
Engine
Type 4 B 3.9-C
Cooling Water
-1
-1
-1
spec. fuel consumption g/kWh 246
Travel pump
Manufacturer Sauer
Type 90 RO 55
System Axial piston
Control Swash plate
3
Travel motor (drum)
Type MSE 08
3
BW 156/177 D-3/PD-3 -B8-

BW 178/179 D-3/PD-3
Service Training
BW 177 AD-3
Travel motor (axle)
Manufacturer Sauer
Type 51 D 110
System Axial piston
3
3
Axle
Type 172
Vibration pump
Manufacturer Sauer
Type 42 R 028
System Axial piston
3
Vibration starting pressure bar 365 +/- 35
Vibration motor
Manufacturer Sauer
Type MMF 025
System Swash plate
3
Frequency Hz 30/38
BW 156/177 D-3/PD-3 -B9-

BW 178/179 D-3/PD-3
Service Training
BW 177 AD-3
Steering pump
Manufacturer Bosch
Type HY/ZFS11/22,5
System Gear pump
3
Steering valve
Type OSPC 500 ON
Filling capacities

Axle SAE 90 l 5,5
BW 156/177 D-3/PD-3 - B 10 -
BW 178/179 D-3/PD-3
Service Training
BW 177 DH-3 BW 177 PDH-3
Engine

Type 4 B 3.9-C 4 B 3.9-C
Cooling Water Water
-1
-1
-1
Travel pump

Type 90 RO 55 90 RO 55
3
Travel motor (drum)

Type 90 RO 55 90 RO 55
3
3
BW 156/177 D-3/PD-3 - B 11 -
BW 178/179 D-3/PD-3
Service Training
BW 177 DH-3 BW 177 PDH-3

Type GFT17 GFT17
Travel motor (axle)

Type 51 D 110 51 D 110
Displacement, range 1 cm3/rev. 110 110
Displacement, range 2 cm3/rev. 59,6 59,6
Axle

Type 172 172
Vibration pump

Type 42 R 028 42 R 028
3
Vibration motor

3
Amplitude mm 1,25/2,0 1,7/1,2
BW 156/177 D-3/PD-3 - B 12 -
BW 178/179 D-3/PD-3
Service Training
BW 177 DH-3 BW 177 PDH-3
Steering pump

3
Steering valve

Filling capacities

Engine oil 15W/40 l 10,9 10,9
Axle SAE 90 l 5,5 5,5
Planetary gear (axle) SAE 90 l/side 1 1
Reduction gear (drum) SAE 90 l 2,5 2,5
Vibrator housing 15W/40 l/side 3,2 3,2
BW 156/177 D-3/PD-3 - B 13 -
BW 178/179 D-3/PD-3
Service Training
BW 178 D-3
Engine
Type 4 BT 3.9-C
Cooling Water
-1
-1
-1
Travel pump
Manufacturer Sauer
Type 90 RO 55
System Axial piston
Control Swash plate
3
Travel motor (drum)
Type MSE 18 - 2C
3
3
BW 156/177 D-3/PD-3 - B 14 -
BW 178/179 D-3/PD-3
Service Training
BW 178 D-3
Travel motor (axle)
Manufacturer Sauer
Type 51 D 110
System Axial piston
3
3
Axle
Type 172
Vibration pump
Manufacturer Sauer
Type 42 R 028
System Axial piston
3
Vibration motor
Manufacturer Sauer
Type MMF 025
System Swash plate
3
Frequency Hz 30/38
BW 156/177 D-3/PD-3 - B 15 -
BW 178/179 D-3/PD-3
Service Training
BW 178 D-3
Steering pump
Manufacturer Bosch
Type HY/ZFS11/22,5
System Gear pump
3
Steering valve
Type OSPC 500 ON
Filling capacities

Axle SAE 90 l 5,5
BW 156/177 D-3/PD-3 - B 16 -
BW 178/179 D-3/PD-3
Service Training
BW 178 DH-3 BW 178 PDH-3
Engine

Type 4 BT 3.9-C 4 BT 3.9-C
Cooling Water Water
-1
-1
-1
Travel pump

Type 90 RO 55 90 RO 55
3
Travel motor (drum)

Type 51 C 060 51 C 060
3
3
BW 156/177 D-3/PD-3 - B 17 -
BW 178/179 D-3/PD-3
Service Training
BW 178 DH-3 BW 178 PDH-3

Type GFT 17 GFT 17
Axle

Type 172 172
Travel motor (axle)

Type 51 D 110 51 D 110
3
3
Displacement, range 2 cm /rev. 31,4 31,4
Vibration pump

Type 42 R 028 42 R 028
3
Vibration motor

3
Amplitude mm 1,35/2,1 1,1/1,75
BW 156/177 D-3/PD-3 - B 18 -
BW 178/179 D-3/PD-3
Service Training
BW 178 DH-3 BW 178 PDH-3
Steering pump

3
Steering valve

Filling capacities

Motoröl 15W/40 l 10.9 10.9
Axle SAE 90 l 5,5 5,5
Planetary gear (axle) l/side 1 1
Reduction gear (drum) l 2,5 2,5
Vibrator housing l/side 3,2 3,2
BW 156/177 D-3/PD-3 - B 19 -
BW 178/179 D-3/PD-3
Service Training
BW 179 D-3
Engine
Type 4 BT 3.9-C
Cooling Water
-1
-1
-1
Travel pump
Manufacturer Sauer
Type 90 RO 55
System Axial piston
Control Swash plate
3
Travel motor (drum)
Type MSE 18 - 2C
3
3
BW 156/177 D-3/PD-3 - B 20 -
BW 178/179 D-3/PD-3
Service Training
BW 179 D-3
Travel motor (axle)
Manufacturer Sauer
Type 51 D 110
System Axial piston
3
3
Axle
Type 172
Vibration pump
Manufacturer Sauer
Type 42 R 028
System Axial piston
3
Vibration motor
Manufacturer Sauer
Type MMF 025
System Swash plate
3
Frequency Hz 30/38
BW 156/177 D-3/PD-3 - B 21 -
BW 178/179 D-3/PD-3
Service Training
BW 179 D-3
Steering pump
Manufacturer Bosch
Type HY/ZFS11/22,5
System Gear pump
3
Steering valve
Type OSPC 500 ON
Filling capacities

Axle SAE 90 l 5,5
BW 156/177 D-3/PD-3 - B 22 -
BW 178/179 D-3/PD-3
Service Training
BW 179 DH-3 BW 179 PDH-3
Engine

Type 4 BT 3.9 C 4 BT 3.9 C
Cooling Water Water
-1
-1
-1
Travel pump

Type 90 RO 55 90 RO 55
3
Travel motor (drum)

Type 51 C 060 51 C 060
3
3
BW 156/177 D-3/PD-3 - B 23 -
BW 178/179 D-3/PD-3
Service Training
BW 179 DH-3 BW 179 PDH-3

Type GFT 17 GFT 17
Axle

Type 172 172
Travel motor (axle)

Type 51 D 110 51 D 110
3
3
Displacement, range 2 cm /rev. 31,4 31,4
Vibration pump

Type 42 R 041 42 R 041
3
Vibration motor

3
Amplitude mm 1,35/2,1 1,7/1,0
BW 156/177 D-3/PD-3 - B 24 -
BW 178/179 D-3/PD-3
Service Training
BW 179 DH-3 BW 179 PDH-3
Steering pump

3
Steering valve

Filling capacities

Motoröl 15W/40 l 10.9 10.9
Axle SAE 90 l 5,5 5,5
Planetary gear (axle) l/side 1 1
Reduction gear (drum) l 2,5 2,5
Vibrator housing l/side 3,2 3,2
BW 156/177 D-3/PD-3 - B 25 -
BW 178/179 D-3/PD-3
Service Training
Maintenance
Single drum rollers of series BW 156 D-3 to BW 179 PDH-3 are heavy-duty machines for extremely
difficult applications in earth work. To be able to meet these demands the machine must always be
ready to be loaded up to its limits. Apart from this all safety installations must always be fully functional.
Thorough maintenance of the machine is therefore mandatory. It not only guarantees a remarkably
higher functional safety, but also prolongs the lifetime of the machine and of important components.
The time required for thorough maintenance is only minor when being compared with the malfunctions
and faults that may occur if these instructions are not observed.
The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance
interval all the work for shorter preceding intervals must also be performed. During the 2000 hour
interval you must also perform the maintenance work for the 250, 500 and 1000 hour intervals.
It should also be clear, that with the 2500 hours interval only the work for the 10, 250 and 500 hour
intervals must be performed.
For maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and
lubricants (oils, fuels, grease etc.).
These training documents include an operation and maintenance manual. Please refer to these
instructions for the individual maintenance intervals and the description of the individual maintenance
tasks.
BW 156/177 D-3/PD-3 - B 26 -
BW 178/179 D-3/PD-3
Service Training
Maintenance table
Running-in inspect.
1000 op. hours

2000 op. hours
10 oper. hours
50 oper. hours
(50 op. hours)
250 op. hours

500 op. hours
as required
Maintenance work Comment
Tighten all bolted connections on air intake, X

exhaust, oil sump and engine mounts
Retighten the bolted connections on the X
machine
Retighten the wheel studs X
Change the oil in the axle X
Change the oil in the planetary drives X
Change the oil in the axle reduction gear X
Change the oil in the drum drive reduction X
gear
Change the oil in the vibrator housings see note X X X
drives
Check the engine oil level Dipstick mark X X X X X X
Check the water separator X X X X X X
Check the fuel level approx. 125 l X X X X X X
Check the hydraulic oil level Inspection glass X X X X X X
Check the coolant level X X X X X X
Check the V-belt X X X X X X
Check the water level only AD-version X X X X X X
Check the tire pressure BW 156 = 1.9 bar X X X X X
BW 177 = 1.4 bar
BW 178 = 1.6 bar
BW 179 = 1.6 bar
BW 156/177 D-3/PD-3 - B 27 -
BW 178/179 D-3/PD-3
Service Training
Running-in inspect.
1000 op. hours

2000 op. hours
10 oper. hours
50 oper. hours
(50 op. hours)
250 op. hours

500 op. hours
as required
Adjust the scrapers X X X X X

Change engine oil and oil filter min. 1 x per year X X X X
Clean the cooling fins on engine oil and X X X X
hydraulic oil cooler
Check the oil level in the axle X X X X
Check the oil level in the planetary gear of X X X X
the axle
Check the oil level in the vibrator housings X X X X
Check the oil level in the drum drive gear DH and PDH X X X X
Darin the sludge from the fuel tank X X X
Battery maintenance Grease the poles X X X
Change the fuel filter X X X
Check V-belt tension, idler pulley and X X X
blower hub
Change the oil in the drive axle min. 1 x per year X X
Change the oil in the planetary drive min. 1 x per year X X
Change the oil in the vibrator housings min. 1 x per year X X
drives
Change the oil in the drum drive gear min. 1 x per year X X
Check the engine mounts X X

Check the fastening of the axle on the X X
frame
Tighten the wheel nuts X X
Check the ROPS X X X
BW 156/177 D-3/PD-3 - B 28 -
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Service Training
Running-in inspect.
1000 op. hours

2000 op. hours
10 oper. hours
50 oper. hours
(50 op. hours)
250 op. hours

500 op. hours
as required
Check and adjust the valve clearance intake = 0.254 mm X X

(on cold engine) CUMMINS exhaust = 0.508
mm
Change hydraulic oil and breather filter min. every 2 years X X
Change the hydraulic oil filter min. every 2 years X X
and after repairs in
the hydraulic
system
Change the coolant min. every 2 years X X
Clean, replace the combustion air filter X
Clean the water sprinkler system X
Water sprinkler system, maintenance in X
case of frost
Adjust the parking brake X
Bleed the fuel system X
Change the tires X
Change the fresh air filter for the cabin X
Retighten all bolted connections Observe the X
tightening torques!
Engine conservation Before longer X
periods of standstill
BW 156/177 D-3/PD-3 - B 29 -
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Note:
When changing filters use only the original filters specified in the operating and maintenance
instructions for this machine. The installation of incorrect filters (e.g. insufficient pressure resistance)
can lead to severe damage on engine or hydraulic components.
The coolant for the water cooled engine must always be mixed with 40 to 50% anti-freeze additive (even
under hot environmental conditions) as a preventive measure against corrosion and cavitation.
However, the additive proportion must not exceed 60%, since this would have an adverse effect on the
cooling ability of the coolant.
Oil change intervals in the vibrator housings: after 50 h, after 500 h, after 1000 h and then every 1000 h.
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Diesel engine
The new single drum rollers of product range BW 156/179 D-3/PD-3 are powered by Cummins diesel
engines of series B. This automotive engine is characterized by the following features:
• low weight,
• compact design,
• low specific fuel consumption,
• low noise development,
• low exhaust emissions,
• simple, but effective constructive design with simple installation characteristics.
The engines used in these single drum rollers have the following designations:
• BW 156 D-3/PD-3 4B3.9
• BW 179 D-3/PD-3 4BT3.9
The engine 4B3.9 is an aspirating engine with a power of 56 kW.
The engine 4BT3.9, in contrast, is fitted with a turbo charger and has a power of 75 kW.
The 4-cylinder four stroke engines are water cooled.
The combustion method with direct fuel injection enables the use of a less expensive casting for the
cylinder head, highest possible utilization of fuel and minimum heat transfer to the coolant.
This in turn enables the use of more effective, quieter cooling fans and smaller, but more effective
radiators.
The extremely economical fuel consumption was achieved by the following design measures:
• small exhaust channels with minimum cooling,
• as a measure to improve the rate of efficiency the combustion chambers were specially shaped for
direct fuel injection,
• excellent mixing of fuel and air due to the helical flow out of the intake channel,
• alloyed trough head shaped pendulum shaft pistons,
• specially formed exhaust manifold for effective utilization of exhaust pulses in the turbo charger.
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The crankshaft is made of forged steel and has inductively hardened transition radii at the bearing
journals. The crankshaft is designed for considerably higher loads.
Due to the use of modern design methods the number of individual engine elements could be
considerably reduced. The relatively low number of parts per engine results in a lower problem
frequency and therefore a higher reliability. Apart from that, the expenses for the storage of spare parts
and maintenance activities can be reduced. In most cases O-rings are used as seals.
The water pump is a plug-type unit, which is installed at the front end of the cylinder block.
The lubrication oil pump is installed in the cylinder block in a similar way. It delivers the engine oil from
the oil sump to the individual lubrication points.
Excellent emission values and high availability of engine power are achieved by the following features:
• wet cylinder liners installed and support at half stroke height for noise reduction and avoidance of
cavitation,
• pendulum shaft pistons for high durability and long lifetime,
• improved piston cooling to prolong the lifetime and reduce the oil consumption,
• lubrication oil temperature control to assure immediate oil supply during starting and to maintain the
optimal operating temperature during operation,
• lubrication oil system components avoiding the complete drainage of the lubrication oil circuit after
stopping the engine, thereby assuring quick increase of oil pressure during starting,
• excellent lubrication oil filtration with main flow filter for the protection of moving engine components.
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External engine parts Cummins 4B 3.9-C
(BW 156 D-3/DH-3/PDH3, BW 177 AD-3/DH-3/PDH-3)
4 3
Fig. 1 Air intake side 4B 3.9-C
1. Fuel filter
2 Water separator
3 Oil dipstick
4 Fuel lift pump
5 Oil filler neck
6 Injection pump
7 Engine solenoid (behind injection pump)
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1 2
5 4
Fig. 2 View starter side 4B 3.9-C
1 Generator
2 Coolant temperature sensor
3 Water pump
4 Coolant inlet port
5 Engine oil filter
6 Starter
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External engine parts Cummins 4BT 3.9-C
(BW 178 D-3/DH-3/PDH3, BW 179 D-3/DH-3/PDH-3)
7
1
5 4 3
Fig. 3 Injection pump side 4BT 3.9-C
1 Fuel filter
2 Water separator
3 Oil dipstick
4 Fuel lift pump
5 Oil filler neck
6 Injection pump
7 Engine solenoid (behind injection pump)
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2
1 3
10 9
Fig. 4 View starter side 4BT 3.9-C
1 Exhaust outlet turbo charger

2 Turbo charger
3 Lubrication oil line to turbo charger
4 Fresh air intake
5 Coolant outlet port
6 Generator
7 Coolant inlet
8 Lubrication oil filter
9 Lubrication oil return from turbo charger
10 Starter
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9
10 6 9 11
12
6
3
5
8
4
1 10 9
7 2
11
Fig. 5 Fuel system
1 Fuel from fuel tank

2 Fuel lift pump
3 Fuel line to fuel filter
4 Fuel-water separator
5 Fuel filter
6 Low pressure supply line
7 Additional turbo charger control line
8 Injection pump
9 Fuel return line
10 High pressure line
11 Injection nozzle
12 Fuel return to fuel tank
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Filter
By-Pass
Valve
to filter
from
Main flow Filter
filter, oil cooler Main closed
closed open oil channel
Oil
sump
Pump
Lub. oil open

cooler pump
Filter-by-pass
Pressure control valve valve
Oil supply
Oil drain
Fig. 6 Lubrication system
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to the valves from main oil

channel
Main oil
channel to cam
shaft
to piston
cooling nozzle
from oil cooler
to conrod
bearing
Rocker arm
block
Oil slot
Crank
journal
Crankshaft
Main journal Head
gasket
Trough
Rocker arm
shaft Rocker arm
Rocker arm
bore
Main oil channel
Fig. 7 Lubrication of power components
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5 4
3
10
11
8
6
7 9
12
13
Fig. 8 Cooling system
1 Coolant inlet (from radiator)

2 Coolant pump
3 Coolant flow along oil cooler
4 Coolant flow around cylinder
5 Coolant to cylinder head
6 Coolant to thermostat housing
7 Coolant to cylinder block
8 Thermostat
9 Coolant flow along injection nozzle
10 Coolant diversion, by-pass to radiator closed
11 Coolant flow to pump inlet
12 Coolant return to radiator
13 By-pass to radiator open
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Adjusting the valve clearance
Nominal value:
Inlet valve: 0,25 mm

Outlet valve: 0,51 mm
• Set cylinder 1 to injection TDC
4 3 2 1
Out In Out In
Flywheel side
Fig. 9
• Turn the crankshaft 360° further
4 3 2 1
Out In In Out
Flywheel side
Fig. 10
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Changing the injection pump
Preparation:
• Thoroughly clean the area around the injection pump.
• Disconnect the fuel line to the pump.
• Disassemble the control linkage.
• Disassemble the control air line for the fuel-air mix.
• Remove the oil lines.
Note:
Dirt or water in the fuel system can lead to engine damage. A small dirt particle or a few drops of water
in the injection system can damage your engine.
You should therefore thoroughly clean all surfaces of the injection pump, including all line connections
and fittings that have to be disassembled. Clean the areas around the cover for the injection pump gear,
so that no dirt can fall into the crankcase.
Disassembly
Find the top dead centre for cylinder 1. Press the pin for the top dead centre into the bore in the camshaft
gear while slowly turning the engine.
The gear needed for this purpose (special tool, Cummins part-no. 3824591) is inserted into the flywheel
housing and meshes with the flywheel ring gear. The engine can now be cranked with a 1/2“ reversible
ratchet.
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Note:
After finding the top dead centre pull the pin back out.
• Take the cover off the gear housing. Unscrew the nut with the washer from the pump shaft.
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• Pull the injection pump drive gear from the shaft.
• Unscrew the four fastening nuts from the injection pump.
• Take the injection pump off.
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Assembly
Note:
Make sure that cylinder 1 is in top dead centre position.
The fuel injection pump is fitted with an adjustment pin (1) in the governor housing to fix the pump shaft
relative to the top dead centre of cylinder 1. After the installation of the pump this pin must be turned
around and inserted into the housing (2).
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• Unscrew the plug.
• Take the adjustment pin out.
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Note:
If the adjustment tooth does not correspond with the slot in the adjustment pin the injection pump must
be turned, until both parts match.
• Turn the adjustment pin around, so that the slot can be pushed over the adjustment tooth in the
pump.
• Push the adjustment pin in and lock it with the plug.
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Note:
If the O-ring of the fastening flange has a coloured stripe it can no longer be used. Replace it by a new
one. Do not cover the new O-ring with lubricant. Lubricate the seat area in the timing gear housing.
• Lubricate the fastening flange on the injection pump with clean engine oil.
Caution:
The inner diameter of the injection pump drive gear and the outer diameter of the shaft must be
clean and dry before assembling the parts. Gear and shaft should be cleaned with a fuel free
cleansing agent. Negligence may cause slipping of the gear on the shaft.
Note:
The shaft has a key way for a woodruff key, however, this key is not needed. An alignment of the control
marks is not necessary for this pump type.
• Slide the pump shaft through the gear and locate the fastening flange of the pump on the stud.
• Move the pump forward, until fastening flange and O-ring are correctly positioned in the timing gear
housing.
• Turn the screws for the bracket in by hand. Do not attempt to pull the pump flange into the timing gear
housing with the nuts, since this may damage the housing.
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• Tighten the fastening nuts.
Tightening torque:
Fastening nuts: 44 Nm
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• Screw the fastening nut for the injection pump drive gear on with the washer and tighten it.
Tightening torque 10 to 15 Nm
Note:
Do not exceed the specified tightening torque. This is not the final tightening value for the fastening nut.
• Pull the adjustment pin out.
• Unscrew the plug from the injection pump. Turn the pin around and screw the plug back in with a new
seal ring.
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Tightening torque: 24 Nm
• Tighten the fastening nut for the injection pump drive gear.
Tightening torque: 178 Nm
• Reinsert the cover into the timing gear housing and fasten it.
• Reconnect fuel and oil lines. Fasten control lines for fuel-air mix, control linkage and engine shut-
down solenoid.
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Tightening torques High pressure fuel lines 30 Nm
Low pressure fuel fittings 15 Nm
• Bleed fuel injection pump and high pressure lines (see operating instructions)
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Travel system
vibration cuircuit charge ports

from charge pressure filter
releasing of brake
1 Travel pump
2 Axle drive motor
3 Drum drive motor
(Poclain)
Fig. 1 Hydraulic diagram travel system BW 156 D-3, 177 D-3/AD-3
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Charge supply, vibration

Releasing the brake
1 Travel pump
2 Axle drive motor
3 Drum drive
motor (Sauer 51D)
Fig. 2 Hydraulic diagram travel system BW 156/177/178/179 DH-3/PDH-3
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The travel system of the single drum roller product range BW 156/177/178/179 D/PD-3 and DH/PDH-3
is a closed hydrostatic circuit. The circuit consists mainly of
• the travel pump with control and safety elements,
• the drum drive motor with integrated multi-disc brake,
• the axle drive motor
• the charge pump (steering pump)
• the hydraulic oil filter in the charge circuit
• the hydraulic oil filter in the return flow to the tank
• and the pressure resistant connecting hoses
Travel pump and vibration pump are joined together to a tandem pump unit. 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 parallel arranged motors on drum and rear axle. The pressure
in the closed travel circuit generated by the resistance of drum and drive wheels is limited by the high
pressure limitation in the pump to maximum 435 bar.
A flushing valve in the axle drive motor flushes a certain quantity of oil out of the closed circuit when the
machine is driving. This prevents the travel circuit from overheating.
Leakage in the individual components and flushing quantities are replaced by the charge circuit through
the boost check valves in the travel pump.
The charge pump draws the hydraulic oil out of the hydraulic oil tank and delivers it through the hydraulic
oil filter to the boost check valves in the travel pump, to the vibration pump and to the control valves for
the brakes (drum drive motor and wheel drives) as well as to the travel speed range selector valve (BW
156/177 D-3 only axle drive motor; all other machines drum drive motor and axle drive motor).
Apart from supplying the closed travel and vibration circuits with cool and filtered oil as compensation
for leaks and flushing quantities, the charge circuit is also used to operate (release) the brakes and to
change the speed ranges in the travel motors.
The axle drive motor of the BW 156/177 D-3 and both travel motors on all other machine types the
displacement can be reduced to half. This allows to drive the machine in different speed ranges without
having to change the pump displacement (BW 156/177D-3, BW 177 AD-3 two speed ranges; BW 178/
179 D-3 four speed ranges; DH/PDH-versions (machines with ASC) three speed ranges). However, the
higher speed ranges works with a reduced torque.
With this control the machine can be optimally adapted to the actual operating conditions.
On machines with ASC the torque in the individual travel speed ranges is adapted automatically (see
chapter ASC).
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Brake control
During operation the closed hydrostatic travel circuit has the function of a service brake. When moving
the travel lever from full forward or reverse position towards neutral, the travel pump will follow towards
zero position relative to the movement of the travel lever. The oil flow is thereby reduced and the
machine is hydraulically braked. When moving the travel lever to neutral position, the pump will also
return to neutral, the supply of oil is interrupted and the hydraulic circuit brakes the machine to standstill.
However, since minor leaks cannot be avoided in any hydraulic circuit and such minor leaks will cause
creeping of the machine when it is parked on a slope with the engine running, the machine is additionally
equipped with multi-disc brakes in drum drive and both wheel drives. When engaging the travel lever
in neutral position the multi-disc brakes will close and the machine can be parked on slopes with the
engine running and without the risk of creeping.
However, these parking brakes can also be operated via a 3/2-way solenoid valve. In de-energized
condition the multi-disc brakes in the travel drives are unloaded. The charge pressure to the brakes is
interrupted and the oil from the brake housings flows as leak oil back into the tank. With the travel lever
in braking position the brakes are operated by the proximity switch.
If the brake solenoid valve is supplied with current while the engine is running and the brake is open,
the connection of the brake line to the tank is interrupted and oil from the charge circuit is guided to the
brake pistons. The oil pressure works against the spring force of the brake spring and relieves the brake
discs.
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Travel pump
The travel pump is a swash plate operated Sauer-Sundstrand axial piston pump with variable
displacement for hydrostatic power transmission in a closed hydraulic circuit.
to vibration circuit charge port

brake, travel speed range selector
Fig. 3 Hydraulic diagram for travel pump
1 Travel pump
2 Control
3 Charge pressure relief valve
4 Check valves
5 Multi-function valves
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The pump flow is proportional to the drive speed (engine speed) and the infinitely adjustable
displacement. By altering the position of the swash plate the pump flow can be adjusted from “0" to
maximum pump displacement. When changing the swash plate position through neutral both the oil
flow direction and the travel direction of the machine will change.
All valves as well as the safety and control elements required for pump operation in a closed circuit are
integrated in the pump. However, this does not apply for the charge pump. This pump is an integral
part of the vibration pump.
7 1
6 5
Fig. 4 Travel pump
1 Control lever
2 Drive shaft
3 Bearing for swashing cradle
4 Pistons with slipper pads
5 Cylinder block
6 Valve plate
7 Control piston
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2
4
5
1 3
10 9
8
11
Fig. 5 Cross-section of travel pump
1 Holder for swashing cradle

2 Sliding block
3 Servo piston
4 Servo lever
5 Servo valve
6 Feed-back device
7 Bearing for swashing cradle
8 Guide for swashing cradle
9 Swashing cradle
10 Swashing lever
11 Charge pump (not for Bomag)
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Fig. 6 Travel pump, rotating assembly
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2 3 4 5 6
1
8 6 7
Fig. 7 Cross-section of travel pump, function
1 Drive shaft
2 Drive shaft bearing
3 Swashing cradle
4 Pistons with slipper pads
5 Cylinder block
6 Multi-function valves
7 Charge pump (not for Bomag)
8 Valve plate
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Description of function
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling and transfers the rotary
motion to the cylinder block (5) via a splined connection.
The cylinder block rotates with the drive shaft (1), thereby carrying the working pistons (4). The pistons
rest with their slipper pads on the sliding face of the swashing cradle (3). When actuating the swash
plate out of neutral position to one of the two possible flow directions, the working pistons perform a full
stroke movement in the cylinder block with every complete revolution.
The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.
During a complete rotation of the cylinder block each piston moves through the bottom and top dead
centre back to its initial position. Between those two dead centres the piston performs a complete
stroke.
During this stroke movement the appropriate amount of fluid with respect to piston area and stroke
length is drawn in through the two control slots in the valve plate (8) and displaced into the pressure side.
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Mechanical-hydraulic displacement control MA
The mechanical – hydraulic displacement control (servo control) converts the mechanical input signal
on the control lever (1) into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (8) and thereby the displacement of the travel pump
as well as the swashing direction and obviously also the flow direction of the pressure fluid.
The pump flow from the variable displacement pump is proportional to te magnitude of the mechanical
input signal. A mechanical feedback device ensures a fixed relation between the mechanical input
signal and the swashing angle of the swash plate.
A mechanical device (spring) avoids damage to the servo control caused by a too fast actuation of the
control lever.
Advantages and specialities of the control unit
Fig. 8 Displacement control
1 4/3-way valve
2 Control lever
3 Neutral adjstment spring
4 Nozzle (0.8 mm)
5 Check valve
The displacement of the pump is controlled with the travel lever via the travel control cable and the pump
control lever. This requires only little force and a small actuating distance.
The mechanical protection of the control enables quick alteration of the input signal.
High quality fits result in a precise response to the input signal.
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Servo cylinder
Control piston
Sliding block
Servo arm
Fig. 9 Control piston
Due to the spring-type centering device in the control the swash plate will return to neutral position,
interrupt the pump flow rate and brake the machine under the following conditions:
• when shutting the engine down,
• if the external control cable comes loose,
• in case of a charge pressure failure.
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Multi-function valve
High pressure limitation
Pumps of series 90 are equipped with a follower valve, which activates a pressure override and a
pressure relief valve, one after the other.
When the adjusted pressure value is reached, the pressure override will return the pump very quickly
back towards neutral, thereby limiting the system pressure. The average response time is less than 90
ms.
In case of an extremely quick pressure increase the function of the high pressure relief valves is utilised
as an additional safety. In such a case the pressure override works as a pre-control unit for the control
piston of the pressure relief valve. The pressure relief valve, the pressure setting of which is higher than
the pressure level of the pressure override valve, is actuated if the pressure increase is so fast, that the
pressure override valve cannot return the pump quick enough back to neutral.
Pressure override and high pressure relief valve are arranged together in the multi-function valve inside
the pump case. This so-called multi-function valve is a further developed and improved kind of pressure
limitation.
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
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The pressure override function limits the pressure without overheating the system, whereas the high
pressure relief valve eliminates suddenly appearing pressure peaks.
Since the pressure relief valve responds only in case of a very quick pressure increase, the heat
development is only limited a relatively short period of time.
Function of the pressure override
If the adjusted pressure of the pressure override is exceeded, pressure fluid will flow through a
restriction in the control piston, causing a pressure increase on the servo side. Here the pressure is
normally lower.
The low pressure relief valve limits this pressure to an appropriate level.
The pressure override valve overrides this signal of the displacement control and equalizes the
pressures on both sides of the control cylinder. The resetting torques of the swash plate change the
displacement, until the system pressure has dropped to or below the adjusted pressure.
Note:
The multi function valves must be tightened with a torque of 89 Nm!
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Charge pressure relief valve
The charge pressure relief valve is a direct acting valve with a fixed adjustment and belongs to the group
of safety elements in the closed circuit. This valve limits the pressure in the charge circuit to the value
determined by the setting of the valve (approx. 25 +/- 1 bar).
The charge circuit has the function to replace leakages and flushing quantities in the closed travel and
vibration circuits and to supply the necessary pilot oil for the controls on travel and vibration pumps, the
travel speed range selection and to release the multi-disc brakes in the travel system.
Since cooled ad filtered oil can only enter into the closed circuit on the low pressure side, the pressure
in the low pressure side is identical with the pressure in the charge circuit.
With the machine at standstill on level ground and the engine running, both sides of the closed circuit
are under charge pressure.
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Flushing valve
Fig. 11 Cross-section of flushing valve
1 Flushing spool
2 Flushing pressure relief valve
The flushing valves are integrated in the axle drive motor, or on DH/PDH machines, also in the drum
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 flushed out oil quantity 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.
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Drum drive motor
On single drum rollers of generation “3" both the drive wheels as well as the drums are driven by
hydraulic motors.
2 3
4
1
8 7 6 5
Fig. 12 Radial piston motor (Poclain)
1 Drive shaft with output flange

2 Piston with roller
3 Oil distributor
4 Brake piston
5 Multi-disc brake
6 Cylinder block
7 Cam ring
8 Bearing plate
The drum drive motor is a radial piston motor (BW 156/177 D-3 Poclain MSE 08 / BW 178/179 D-3
Poclain MSE 18), the displacement of which can be altered between two fixed points.
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The motor consists of
• the outer three-piece housing,
• the flat distributor,
• the cylinder block with the working pistons,
• the output shaft and
• the brake.
The motor housing consists of
• the bearing section (drive shaft bearings),
• the torque module (cam race) and
• the oil distributor.
The flat distributor guides the pressure oil to the working pistons in the cylinder block. The working
pistons inside the cylinders are pressed with their rollers against the cam race of the torque module and
roll along the cam profile. This transforms the axial movement of the pistons to a radial movement of
the cylinder block. This rotary movement of the cylinder block is transferred via a splined connection to
the output shaft and from there to the drum.
The function of the radial piston motor is described hereunder. The piston positions mentioned in the
description are shown in the corresponding illustration.
The movement of a piston along the cam race must be examined during various phases of the rotation.
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2
3
Fig. 13 Function of radial piston motor
Piston position 1:
The oil enters into the oil distributor under pressure, flows through the distributor and presses against
the piston. This is the start of a rotation. Due to the pressure on the back of the piston the roller will
move along the cam, thereby causing a rotary movement of the cylinder block.
Piston position 2:
At this point the oil flow to the piston has reached its largest cross section. The piston continues his travel
along the cam race towards the valley between two cams. The opening cross section decreases with
continuing rotary movement.
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Service Training
Piston position 3:
Once the piston has reached the deepest point the oil flow to the piston is cut off. The piston is no longer
driven. It has reached its dead centre. Another piston must now be driven to move the previous piston
out of dead centre position.
Piston position 4:
By driving other pistons the previous piston is moved out of dead centre position. The oil behind the
piston is connected with the low pressure side and the retracting piston presses it back to the pump.
Piston position 5:
The oil supply back to the pump comes close to an end, the connecting bore between cylinder and low
pressure side closes slowly. The piston will now reach its second dead centre position. This point is
the start of a new working cycle.
Changing the flow direction of the oil will also change the sense of rotation of the motor.
The output shaft is resting in two taper roller bearings. It transmits the rotary movement via the drive
disc and the rubber elements to the drum.
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Service Training
Axle drive motor and drum drive motor DH/PDH-versions
The wheel drive motor is a swash plate controlled Sauer-Sundstrand axial piston motor (series 51 D
110) in with variable displacement. The DH/PDH-versions use the same motor as drum drive motor
(only with a different connecting housing).
5 7 8
6
9
11
10
4
2
Fig. 14 Axial piston 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
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Service Training
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle
position of the cylinder block to the output shaft.
With a large angle position the motor works with maximum displacement, slow speed and high torque.
When swashing the cylinder block to minimum angle the motor will work with minimum displacement,
high speed and low torque.
The displacement is changed by a control piston, which is tightly connected with the valve segment. To
change the displacement oil from the charge circuit is guided to the corresponding control piston side
via a 4/2-way solenoid valve.
Function
The motor is connected with the travel pump via the high pressure ports A and B. High pressure
hydraulic oil flows through the corresponding high pressure port to the back of the working pistons.
Since the pistons are arranged under an angle to the output shaft, the pressurized pistons will perform
a stroke movement and cause a rotation of the connected output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. The continuing rotation forces the piston back into the cylinder block. This presses
the oil in the cylinder chamber through the low pressure side back to the pump.
A synchronizing shaft with spherical rollers ensures uniform rotation of output shaft and cylinder block.
The spherical heads of the pistons move in journal bearings, which are pressed into the output shaft.
For the connection between output shaft and pistons no other parts are required. The output shaft is
resting in two taper roller bearings.
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Service Training
Drum drive (51D110 + GFT17) DH/PDH-versions
On the DH/PDH-versions the drum is driven by a fast rotating axial piston motor 51D110 from Sauer
and a reduction gear GFT17 from Lohmann + Stolterfoth.
The function of the axial piston motor is identical with the function of the axle drive motor and does
thereofre not need to be explained in detail.
A reduction gear with a reduction ratio of i = 53.95 reduces the high output speed to the final rotational
speed of the drum.
2 3
1 4
5 6 7
8
15
14 9
13
12 10
11
Fig. 15 Drum drive
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Service Training
1 Fastening to front frame
2 Fixed housing section = planet carrier stage 2
3 Fastening to drum
4 Ball bearing
5 Locating pin for bearing
6 Planet gear stage 2
7 Rotating housing = hollow wheel stages 1 and 2
8 Planet carrier stage 1
9 Planet gear stage 1
10 Drive shaft = sun gear stage 1
11 Hollow shaft = receptacle for motor output and brake shaft
12 Brake discs
13 Brake piston
14 Brake spring
15 Brake releasing port
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Service Training
Trouble shooting travel circuit
The following description of trouble shooting steps contains a small selection of possible faults, which
may occur during operation of the machine. This list is by no means complete, however, the description
should help you to become acquainted with a systematic trouble shooting procedure.
The problems and trouble shooting steps described in this training manual are identical with the
problems and trouble shooting steps in the operating and maintenance instructions for this machine.
However, in this manual we have tried to describe the individual steps in more detail, in order to explain
why certain trouble shooting steps should be applied and why certain preparations must be made before
certain tests or measurements can be performed.
After this training session the persons attending the course should be able to apply the correct trouble
shooting steps, even if the actual problem is not described in this manual.
BW 156/177 D-3/PD-3
BW 178/179 D-3/PD-3 - DTr 1 -
Service Training
Machine drives with travel lever in „NEUTRAL“
Check neutral
position Fig. F1
no Adjust the travel

OK ? cable Fig. F2
yes
Check mechanical ‚0‘-

position Fig. F3
no Adjust the mechanical

OK ?
0-position Fig. F4
yes
Check the servo

control Fig. F5
no Replace the servo

OK ? control
yes
Replace the travel

pump
Trouble shooting single drum rollers generation 3 DTr 2

Service Training
Check the control Machine does not drive (to both directions)
cable (torn/
detached)
no Replace / attach the

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

OK ? and moveability
yes
Replace the
Check high no steering/charge
pressure Fig. 9 OK ?
pump
yes
no
OK ?
yes
Check magnetic coil of Check charge pressure

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

pressure Fig. F11 brake Fig. F8
Repair the
component after
no no the disconnection
OK ? OK ? of which the
Replace the brake charge pressure is
valve correct OK
yes yes
Mechanical fault in
axle, drum

Service Training
Testing of individual components
Check the drum drive

motor Fig. F12
yes Check flushing valve on drum

Pressures drive motor (axial piston
OK ? motor), Fig. F14
no
Check axöle drive motor /
travel pump Fig. F13 no
OK ?
Replace the
yes flushing valve
Check the flushing valve yes
on axle drive motor, Pressures
Fig. F14 OK ?
Replace/repair the drum

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

yes
drive motor
Replace / repair the
travel pump

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

speed Fig. F15
no Perform trouble shooting

OK ? on diesel engine
yes
Check travel cable for

play and wear
no Adjust / replace the

OK ? travel cable
yes
Continue with
„machine does not
drive“ from „check
charge pressure“
Hydraulic oil overheating (> 90°C)
Check the
thermostat valve
Fig. F16
Thermostat no Replace the

opens ? thermostat valve
yes
Check the multi-function

valves Fig. F17
Check hoses for kinks /

Valves check components for
no
heating up ? excessive development
of heat
yes
Clean/replace the
respective multi-
function valve

Service Training
Fig. F1:
Checking the neutral position
With the travel lever in neutral position the machine must not move, even when the engine is running.
In this condition the travel pump is centred in neutral position and both sides of the closed circuit have
identical pressure (charge pressure).
If the machine moves in this condition on flat ground you should perform trouble shooting by applying
the following steps.
• Shift the travel lever to “Neutral”-position
• Disconnect the travel cable from the pump
• Start the engine (if the machine is free of faults the machine will now stop)
• Check, whether bores in ball socket and pump control lever are in line
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Service Training
Fig. F2:
Adjusting the travel cable
• Slacken the counter nut on the travel cable bracket to adjust the travel contgrol cable
• turn the adjustment nut, until the correct neutral position (bores in line) is reached
• tighten the counter nut again
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Service Training
Fig. F3:
Checking the mechanical neutral position
The mechanical neutral position determines the mechanical position of the pump control piston. This
piston is connected with the swash plate and its position determines the position of the swash plate. If
the piston is out of neutral position the swash plate actuates the working pistons, whereby oil is being
pumped to the travel motors.
• Connect both control chambers on the pump control with a suitable hose
• Start the engine
• If the mechanical neutral position is correctly adjusted the machine will not move.
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Service Training
Fig. F4:
Adjusting the mechanical neutral position
If the machine still moves after connecting both control chambers, the mechanical neutral position of the
travel pump needs to be adjusted:
• Connect 600 bar pressure gauges to the high pressure test ports
• Pull the plug off the brake solenoid valve and block the drum
• Start the engine and run it with max. speed
• Read the pressure gauges and adjust the mechanical neutral position on the adjustment screw of he
spring pack on the control cylinder (see illustration), until identical pressure (charge pressure) is
reached on both sides.
For higher accuracy repeat the testing and adjustment procedure with two 60 bar pressure gauges.
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Service Training
Fig. F5:
Checking the servo control:
• Disassemble the servo control
• Check piston and linkages for moveability and wear
• Check the nozzles, clean if necessary
replace a defective servo control immediately.
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BW 178/179 D-3/PD-3 - DTr 6 -
Service Training
Fig. F6:
Checking the charge pressure
• Connect a 60 bar pressure gauge to the charge pressure test port
Nominal value: 25 +/-1 bar
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BW 178/179 D-3/PD-3 - DTr 7 -
Service Training
Fig. F7:
Checking the charge pressure relief valve
• Unscrew the valve and check for dirt and damage
Replace a defective charge pressure relief valve immediately.
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Service Training
Fig. F8:
Checking the leakage of the brake
A leakage in the brake housings can cause a drop in charge pressure, the brake cannot be released.
• Release the brake by shifting the travel lever out of braking position
• Disconnect the brake lines one after the other from drum drive and wheel drive motor and perform
charge pressure tests always after disconnecting a hose
Repair the motor after the disconnection of which the charge pressure was found correct.
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Service Training
Fig. F9:
Checking high pressure
• Pull the plug off the brake solenoid valve and block the drum
• Drive the machine against the closed brake, for this purpose actuate the travel lever for a moment
and read the pressure gauges
Nominal values: High pressure 435 +/-15 bar, charge pressure 25 +/- 1 bar
BW 156/177 D-3/PD-3
BW 178/179 D-3/PD-3 - DTr 10 -
Service Training
Fig. F10:
Checking the magnetic coil of the brake valve
• Start the engine and release the brake (disengage the travel lever from the braking position)
• use an appropriate meter to measure the voltage and current draw on the magnetic coil of the
solenoid valve
Nominal values: BW 178 / 179 D-3:12 V / 1,8 A;

BW 156 / 177 D-3, 156-179 DH/PDH-versions:12 V / approx. 5 A
1,8 A
BW 178 D-3
1,8 A
BW 156 / 177 D-3, 156- 179 DH / PDH-versions
BW 156/177 D-3/PD-3
BW 178/179 D-3/PD-3 - DTr 11 -
Service Training
Fig. F11:
Checking the brake releasing pressure
If the brake valve does not open, no oil from the charge circuit will be guided to the brakes and the brake
discs cannot open.
• Install a pressure test port with a 60 bar pressure gauge to the brake releasing line
• Start the engine and release the brake (disengage the travel lever from the braking position)
Read the pressure gauge, nominal value 25 +/- 1 bar (charge pressure)
Install pressure test

port here
BW 156 / 177 D-3 and 156-179 DH-/PDH-versions
Install pressure test port

to bottom connection
BW 178 / 179 D-3
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Service Training
Fig. F12:
Checking the drum drive motor
• Unscrew the high pressure hoses from the drum drive motor and close them with suitable plugs
• Perform a high pressure test (Fig. F9)
If the specified pressure values are reached after disconnecting the drum drive motor, whereas they
have not been reached while the motor was still connected, the drum drive motor is defective. If the
specified pressures are not reached, the axle drive motor or the travel pump must be defective
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Service Training
Fig. F13:
Checking axle drive motor / travel pump
• Disconnect the high pressure hoses from the travel pump
• Close the pump port with pressure resistant plugs
• Perform a high pressure test (Fig. F9)
If the specified pressure values are now reached and the drum drive motor is OK, the fault must be in
the axle drive motor. If the high pressure values are not reached, the fault must be in the travel pump.
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Service Training
Fig. F14:
Checking the flushing valves on axle drive and drum drive motor (only axial piston motor)
In case of a failure on one of the flushing valves a too high oil quantity may be flushed out and the charge
circuit may not be able to replace this quantity. The charge pressure will drop and important machine
functions will no longer be available.
• pull the valve spool out of the flushing valve
• check for moveability and damage
replace a defective flushing valve.
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Service Training
Fig. F15: back to vibration
Checking the engine speed
• Measure the engine speed with a suitable RPM-meter (e.g. digital optical RPM-meter)
Nominal value: 2300 rpm (high idle speed)
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Service Training
Fig. F16:
Checking the thermostat valve
If the hydraulic oil heats up to a too high temperature it will loose its lubrication properties, which may
cause damage to important components in the hydraulic system.
In case of a too high hydraulic oil temperature shut the engine down immediately, let the system cool
down and perform trouble shooting. Do not start to operate the machine unless the fault has been
corrected.
First check the function of the thermostat valve. Up to a temperature of 60°C all leak oil, flushing and
return flow quantities flow directly back into the tank. At 60°C the thermostat valve should start to open
and guide the hydraulic oil through the hydraulic oil cooler back to the tank.
• Feel with your hand if the hose to the hydraulic oil cooler starts to become warm after a hydraulic oil
temperature of 60°C is reached.
• If the thermostat valve does not open it must be replaced immediately.
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Service Training
Fig. F17:
Checking the multi-function valves
The opening cross-sections of the high pressure relief valves, which are part of the multi-function valves,
are very small. Hydraulic oil escaping from the high pressure side through the high pressure relief valves
(e.g. in case ofa defective pressure override, which is also part of the multi-function valve) will cause
very quick overheating of the hydraulic oil.
• Pull the plug off the brake solenoid valve
• Block drum and wheels with chocks
• Actuate the travel lever to both directions and check the multi function valves for heat development.
• If one of the valves develops excessive heat, it must be immediately replaced
Attention ! Tightening torque for multi-function valves 89 Nm
BW 156/177 D-3/PD-3
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Service Training
Vibration
The vibration system of the single drum roller product ranges BW 156/177 D-3/PD-3 and BW 178/179
D-3/PD-3 works with two different frequencies and amplitudes. This enables a perfect adaptation of the
machine to various types of soil and application profiles.
The vibratio drive is a closed hydraulic circuit. The circuit consists of:
• the vibration pump,
• the vibration motor and
• the pressure resistant connecting hydraulic hoses.
Releasing the brakes

from charge pump and
charging of travel pump Charging of
vibration pump
Fig. 1 Vibration circuit
1 Vibration pump
2 Vibration motor
BW 156/177 D-3/PD-3 -E1-

BW 178/179 D-3/PD-3
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 switching the 4/3-way solenoid valve on the pump control from neutral position to one of the two
possible directions pilot oil will flow from the charge circuit to one of the control piston sides. This moves
the swash plate inside the pump to the corresponding direction against the end stop and the pump starts
to deliver oil to the vibration motor. The vibration motor starts to rotate and drives the vibrator shaft
inside the drum.
When altering the swash plate position through neutral to the opposite side, the flow direction of the
hydraulic oil will change and the sense of rotation of the vibration motor will be reversed.
Since the end stops for the two directions have different settings, the angle positions between swash
plate and stroke direction of the pistons are different to both sides. This angle position effects the length
of the piston stroke and therefore the 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 the change-over weight will be positioned so that they add
to or subtract from the basic weight.
This results in the following constellations:
• Basic weight + change-over weight = high amplitude
• Basic weight - change-over weight = low amplitude
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
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BW 178/179 D-3/PD-3
Service Training
Vibration pump
Similar to the travel pump, the vibration pump is also a swash plate operated Sauer-Sundstrand axial
piston pump with variable displacement for operation in a closed hydraulic circuit.
The displacement of the pump is proportional to the engine speed and the chosen displacment.
When actuating the swash plate out of neutral position the displacement for the chosen travel direction
will increase from “0" to maximum displacement. Changing the swash plate position through neutral to
the opposite side will change the flow direction and the sense of rotation of the vibrator shaft.
All valves and safety elements for operation in a closed circuit are integrated in the pump.
to the brake
from charge pump and
to charging
charging of travel pump vibration pump
1 Vibration pump
2 Charge pump
3 High pressure limitation
4 4/3-way solenoid valve
Fig. 3 Vibration pump
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BW 178/179 D-3/PD-3
Service Training
Function
1 2
5 4 3
Fig. 4 Cross-section of vibration pump
1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate
BW 156/177 D-3/PD-3 -E4-

BW 178/179 D-3/PD-3
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 156/177 D-3/PD-3 -E5-

BW 178/179 D-3/PD-3
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.
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. 6 Pressure relief valve
1 From the charge pump

2 Closed circuit
3 High pressure relief valve with
integrated boost check valve
BW 156/177 D-3/PD-3 -E6-

BW 178/179 D-3/PD-3
Service Training
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. 374 bar
(pressure difference between high and low pressure side = 345 bar + charge pressure = 29 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”.
Charge pump
The charge pump for travel circuit and vibration works also as steering pump The pump is an internal
gear pump with fixed displacement.
The oil flow generated by the charge pump is joined together with the return flow from the steering valve
before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and vibration
pump.
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Service Training
Vibration motor
The vibration motor is a swash plate type axial piston motor with fixed displacement of series MMF 052
from Sauer-Sundstrand. 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
9 8 7
10
Fig. 7 Cross-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 valve
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BW 178/179 D-3/PD-3
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 365 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
Fig. 8 Circuit diagram of vibration motor
1 Vibration motor
2 Flushing valve
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BW 178/179 D-3/PD-3
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.
Fig. 9 Flushing valve
1 Flushing spool
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 156/177 D-3/PD-3 - E 10 -
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Service Training
Drum
4
14
5 9
7 13
6
10
3 8 11
12
Fig. 10 Drum cross section
1 Drum shell 8 Change-over weight

2 Vibration bearing 9 Coupling vibrat. motor - vibrat. shaft
3 Basic eccentric weight 10 Tavel 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 housing
BW 156/177 D-3/PD-3 - E 11 -
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Service Training
Trouble shooting vibration circuit
BW 156/177 D-3/PD-3
BW 178/179 D-3/PD-3 - ETr 1 -
Service Training
No vibration (travel system OK)
Check vibration
pressures Fig. V1
Charge pressure OK
Charge pressure OK Start pressure too low
Start pressure zero
Check magnetic Check coupling on
coil of vibration OK ? vibration motor
valve Fig. V4 Fig. V2
Charge pr. / start

pressure too low
Voltage / no Vibrationspumpe
current OK ? prüfen Fig. V3
yes Perform trouble Replace / repair the

shooting in electric no
OK ? vibration pump
system
yes
Check the solenoid Check flushing valve on

valve, replace if vibration motor, Fig. V7
necessary
Treplace the
no
OK ? flushing valve
yes
vibration motor
Trouble shooting single drum rollers generation 3 ETr 2

Service Training
Vibration works only with high or low amplitude
Check magnetic
oil on vibration
valve Fig. V4
Perform trouble
Voltage / no shooting in electric
current OK ? system
yes
Check the solenoid valve
no Replace the solenoid

OK ? valve
yes
Check the high pressure

relief valve for the side with
the not working amplitude,
clean / replace if necessary

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

OK ? on the diesel engine
yes
Drop in no Adjust the speed for high or

speed >10%? low frequency Fig. V5
yes
Check the vibration

pressures Fig. V1
Charge pressure OK
Operating pressure too high
Check vibrator shaft
OK ? bearings, replace if
necessary Fig. V6
all pressures
too low
Check the vibration

pump Fig. V3
no Replace / repair the

OK ? vibration pump
yes
Check flushing valve on

vibration motor Fig. V7
g.
no Replace the flushing

OK ? valve
yes
vibration motor

Service Training
Fig. V1
Checking the vibration pressures
A too low charge pressure is an early indicator for a fault (leakage) in the closed vibration circuit (if travel
system is OK). The pump cannot be operated correctly.
A too low starting pressure is an indicator for extreme leaks in the closed circuit or a defective vibration
motor coupling.
A too high operating pressure is an indicator for damaged vibration bearings or overfilling of the vibration
bearing housing.
• Drive the drum on old rubber tires
• Switch the vibration on and read the pressure gauges
Nominal values: charge pressure 25 +/- 1 bar

starting pressure 365 +/- 35 bar
operating pressure low amplitude approx. 90 +/- 15 bar
high amplitude approx. 100 +/- 15 bar
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Service Training
Fig. V2:
Checking the coupling on the vibration motor
• Disassemble the vibration motor
• Check the coupling parts between motor and shaft
• Replace defective parts
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Service Training
Fig. V3:
Checking the vibration pump
• Close the high pressure ports on the vibration pump with plugs
• Check the vibration pressures, see Fig. V2
If the pressure values are now reached whereas they were not reached while the vibration motor was
connected, the vibration motor must be faulty. If the high pressure values are not reached, the fault must
be in the pump.
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Service Training
Fig. V4:
Checking the magnetic coil of the vibration valve
• Switch the ignition on
• Switch the vibration on with high or low frequency
• Measure the voltage applied to the magnetic coil and the current draw with an appropriate meter
Nominal values: 12V / 2,5 A
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Fig. V5:
Adjusting high and low frequency
If the engine speed is correct and the drop in vibrator shaft speed is less than 10%, the corresponding
frequency can be adjusted on the vibration pump.
• Slacken the counter nut on the respective adjustment screw
• Turn the adjustment screw, until the required vibrator shaft speed is reached (the adjustment screw
for high amplitude protrudes further than the adjustment screw for low amplitude).
• Retighten the counter nut.
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Fig. V6;
Checking the vibrator shaft bearings
• Disassemble the vibration motor
• Check the moveability of the vibration bearings
• Replace defective parts
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Fig. V7:
Checking the flushing valve on the vibration motor
• Unscrew the flushing valve from the vibration motor
• Check the flushing spool for damage and moveability
• Replace a defective flushing valve
BW 156/177 D-3/PD-3
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Service Training
Steering
The single drum rollers of product ranges BW 156/177 D-3/DH-3/PDH-3 and BW 178/179 D-3/DH-3/
PDH-3 are equipped with a hydraulically operated articulated steering.
The steering system consists mainly of:
• the steering/charge pump,
• the steering valve,
• the steering cylinders and
• the pressure resistant connecting hoses.
The steering pump delivers the hydraulic oil from the tank to the steering valve and the connected
steering unit. If the steering is not operated, the complete oil flow flows through the fine filter to the
charge ports for the closed circuits for travel and vibration drive.
to the charge
ports
from steering/charge pump
Fig. 1 Steering
1 Rating pump 5 Check valve

2 Distributor valve 6 Shock valves
3 Anti-cavitation valve 7 Anti-cavitation valves
4 High pressure relief valve 8 Steering cylinder
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When turning the steering wheel the oil flow is guided through the distributor valve to the steering
cylinder.
A measuring pump in the steering unit measures the exact oil quantity corresponding to the turning
angle of the steering wheel and delives this oil to the steering cylinders.
The steering cylinders extend or retract and articulate the machine.
The steering unit is fitted with an integrated pressure relief valve. This valve is adjusted to a pressure
of 175 bar. However, since the oil flowing out of the steering system is also used for the charge system,
the charge pressure of approx. 25 bar must be added to this value. This results in a maximum steering
pressure of approx. 200 bar.
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Steering/charge pump
The steering/charge pump is a gear pump with constant displacement.
It is driven by the auxiliary drive of the diesel engine and draws the hydraulic oil directly out of the oil
tank. The oil flows then through the steering valve and the fine filter to the charge system for travel and
vibration drives or, when operating the steering, first to the steering cylinders.
9 9 6 1 7
8
2
4 5
Fig. 2 Gear pump
Function of he gear pump
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 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.
During operation of the pump the hydraulic oil is transported in these chambers 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. These tooth chambers convey the fluid to the pump outlet from where it is pressed to the
consumer. 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.
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Outer gear pumps are fitted with gap seals. In dependence on the operating pressure there will be
losses from the pressure side to the suction side. An axial pressure field presses the bearing plate on
the cover side against the front face of the gears, making sure that only a very little quantity of oil will
leak from the pressure side to the suction side when the pressure increases.
The pressure field is always under the actual system pressure.
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Steering valve
The steering valve block consists mainly of:
• the distributor valve,
• the rating pump,
• the steering pressure relief valve and
• the shock valves

1
9
3
1
4
8
6
Fig. 3 Steering valve
1 Neutral setting springs 6 Ring gear

2 Housing 7 Gear
3 Inner spool 8 Check valve
4 Outer spool 9 Pressure relief valve
5 Universal shaft
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When turning the steering wheel the oil flow from the pump is guided through the distributor valve to the
rating pump and from there to the respective steering cylinders.
The rating pump determines the exact oil quantity in dependence on the turning angle of the steering
wheel.
The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar
+ charge pressure.
The steering unit is fitted with so-called shock valves in each pressure side to the steering cylinders.
These valves are adjusted to 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 has its additional anti-cavitation valve. This anti-cavitation valve prevents
the appearance of cavitation, which may be caused by the response of the shock valves.
A check valve near the inlet port of the steering unit makes sure that no hydraulic oil will flow back to the
steering pump if the machine is articulated by sudden external forces. In such a case the steering
cylinders would try to work as pumps and deliver the oil back to the pump.
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Articulated joint
The articulated joint is the connecting link between the front frame with the drum and the rear frame with
operator’s stand, diesel engine and drive wheels.
Fig. 4 Articulated joint
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 rocker
bearings between front and rear console ensure that both frame parts of the machine can oscillate for
+/- 12° to each. This makes sure that the machine always has optimal ground contact, even under very
difficult ground conditions.
The front console is connected with the rear console by means of two vertical pins. These vertical pins
are mounted in rocker bearings.
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The fastening eyes for the steering cylinders are welded to the front console.
When turning the steering wheel the steering cylinders will extend or retract respectively, whereby the
piston rods swivel the front console around the vertical pin. The machine articulates and steers.
All bearing points on the articulated joint are maintenance free and do not require and lubrication.
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Trouble shooting steering
BW 156/177 D-3/PD-3
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Service Training
No steering / steering sticky / end stops are not reached
(travel system OK)
Check the steering

pressure Fig. L1
Check moveability of
yes articulated joint and
OK ?
steering cylinders
no
Check steering/
charge pump Fig. L2
Replace/repair the
no steering/charge
OK ?
pump
yes
Check the steering

cylinders Fig. L3
Replace the
no respective steering
OK ?
cylinder
yes
Replace/repair the
steering valve
Trouble shooting single drum rollers generation 3 FTr 2

Service Training
Fig. L1:
Checking the steering pressure
• Connect a 600 bar pressure gauge to the steering pressure test port
• Turn the steering against an end stop and hold the steering wheel in this position while reading the
pressure gauge
Nominal value: 225 +/- 15 bar
BW 156/177 D-3/PD-3
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Service Training
Fig. L2:
Checking the steering/charge pump
• Install a 200 bar pressure relief valve between steering pump outlet and high pressure hose to the
steering valve
• Connect a 600 bar pressure gauge
• Start the engine (low idle speed) and read the pressure gauge
Nominal value: 200 bar (adjustment value of the integrated pressure relief valve)
If the pressure is not reached, replace or repair the steering/charge pump.
BW 156/177 D-3/PD-3
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Service Training
Fig. L3:
Checking the steering cylinders
• as a measure to check whether a steering cylinder is defective, i.e. if it has internal leakage, the
hydraulic hoses “L” and “R” can be disconnected from the steering cylinders and closed with plugs.
• Perform a steering pressure test (see Fig. L1): if the steering pressure is now reached, but is has not
been reached while the cylinders were still connected, one of the cylinders is defective. After this test
reconnect the hoses.
To find out which cylinder is defective you should proceed as follows:
• Start the engine and, if possible, steer fully to left or right and leave the machine in this position.
• If the steering has been actuated to the left unscrew the hoses from the rod side of the left hand and
from the piston side of the right hand cylinder.
• try again to steer to the same direction as before. If oil runs out from one of the cylinders this cylinder
is defective and needs to be replaced
• Repeat this procedure to the opposite side accordingly (cylinders may also leak only to ne side, e.g.
from piston to rod side)
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Service Training
Electric system
The new single drum rollers of generation 3 are, for the first time, fitted with easy to replace logic control
modules.
Simple trouble shooting can be performed by bridging the input and output potentials.
The control cabinet contains the following modules:
• Generator module (A23),
• Inclination sensor module (B57)
• Diode module
On inclinations and slopes the travel system is controlled by means of inclination sensor (B57).
The optional ASC (Anti Spin Control) enables optimal traction of tires and drum. This ensures safe
travel behaviour on difficult ground and maximum gradability on a hill.
Since the diode module is only used in the logic of the speed range selector, it is installed in a pre-
assembled unit together with the corresponding relays. Due to this measure the number of connecting
cable is reduced and the machine can be easily converted to a different equipment status.
The generator module (A23) is able to convert the different signals of various generator manufacturers
to a D+ signal. Different engines from various manufacturers can therefore be used, without having to
change the vehicle electrics for this purpose.
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Supply
Fig. 1 Power supply
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Battery
When the engine is at rest the voltage for the vehicle electrics is supplied by one or two parallel
rechargeable and low-maintenance 12 V lead batteries.
The minus pole of the battery (G01:05) is connected with vehicle ground (potential 31).
The plus pole of the battery (G01:02) is connected with potential 30 via the main fuse (F00:02).
There is a direct connection between battery (+),
• terminal B+ on the generator (G02:15) and
• starter (M01:05) (Fig. 2) terminal 30.
• Battery (-) minus to vehicle ground potential 31
Note:
Potentials 30, 31 and B+ are always directly connected with the battery. The current is only be
interrupted if the battery is empty or disconnected.
Generator
When the engine is running a 14 V generator (G02:16) supplies the vehicle electrics via terminals B+
(to potential 30) and B- (to potential 31) with current.
Terminal D+ provides a (+) or (-) signal to the generator module (A23:23). When the engine is not
running terminal D+ is negative (ground potential). The charge control in the fault monitoring unit (A15)
(Fig. 3) lights up. See section „monitoring board“.
Sockets
The machines are equipped with two sockets (XS:36/XS:39). These are connected with potential 30 and
protected by the fuses (F05).
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Starting
Fig. 2 Ignition and starting circuit
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Ignition switch (S00) in position "0" (ignition off)
The ignition switch (S00:04) is permanently supplied with current from the battery (G01) (Fig. 1) via main
fuse (F00) (potential 30) and fuse (F13:05).
In this position the connection to the coil of relay (K11:28) is interrupted and the relay drops off. The
solenoid valves (Y58:32) for fuel shut-off or (Y13:37) engine solenoid (depending on engine version) are
no longer supplied with current and the diesel engine will stop.
Ignition switch (S00) in position "1" (ignition on) with the engine at rest
In this position the coil of relay (K11:26) is supplied with current.
• Relay (K11) switches potential 30 to potential K11 (15/54). Fault monitoring unit (A15) (Fig. 3)
supplies the coil of relay (K22:40) with current, the relay switches. Current flows
• from potential K11,
• fuse (F14:37),
• the closed EMERGENCY STOP switch (S01:37),
• the closed contacts of relay (K22:37)
• to solenoid valve (Y58:32) for fuel shut-off or (Y13:37) engine solenoid.
The engine is ready for starting.
Ignition switch in position "3" (starting)
Note:
Position "2" is not used.
In this switching condition current flows from terminal 50a on ignition switch (S00:06) to the contact of
relay (K05:07).
When the travel lever is in "0" - and brake position the contact of proximity switch (B13:15) opens, the
coil of relay (K48:15) is no longer excited and the contact switches over.
Current flows
• via relay (K48:17),
• to the coil of relay (K05:09).
The contact closes and current can now flow to the starter (M01:05) terminal 50. The magnetic switch
of the starter is excited and the starter cranks the diesel engine.
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Note:
The starter (M01) is directly supplied with current by potentials B+ and 31.
After releasing the ignition key the ignition switch will automatically return to position "1".
During the starting process a signal 50a is transmitted to the fault monitoring board (A15) (Fig. 3).
During the starting process this signal avoids sounding of the warning buzzer and activation of the
automatic engine shut-down (see description of the fault monitoring unit).
For a new starting attempt the ignition must first be switched off (lock against repetitive starting).
Ignition switch (S00) in position "1" (ignition on) with the engine running
When the engine is running the generator (G02) (Fig. 1) produces current. This current flows now from
terminal D+ to the generator module (A23). The output signal MD+ supplies the operating hour meter
(P00) with current.
Furthermore, the MD+ signal is transmitted to the fault monitoring unit (A15) (Fig. 3) and the brake
control relay (K36) (Fig. 5).
The internal logic of the fault monitoring unit switches the charge control light off.
The automatic shut-off in the fault monitoring unit (A15) is activated and the warning buzzer is ready to
sound in case of a fault.
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Fault monitoring board
Fig. 3 Fault monitoring board
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Ignition on, with engine at rest
When switching the ignition on the program is set to a defined initial condition.
For self-testing all warning and control lights are switched on for a short moment.
If a fault should occur already at this state, the corresponding control light would stay on.
However, warning buzzer (H07:27) and shut-off relay (K22:44) (Fig. 2) still remain deactivated, because
there is no oil pressure yet. If the time between „ignition on“ and „engine start“ is too long, the engine
can no longer be started.
Diesel engine in operation

The fault indication is activ, warning buzzer and shut-off relay are enabled.
Within the specified time all sender signals must change to the corresponding potentail for the condition
„O.K.“ Otherwise:
• the signal fields will light,
• the warning buzzer is activated
• and the shut-off relay is switched off after a predetermined time.
Engine stalled, ignition on

The fault indication remains active, warning buzzer and shut-off relay will be activated after pre-
determined times.
In order to re-establish to a defined initial condition the ignition must be switched off for a moment before
attempting a new start.
The engine was stopped by the shut-off relay

The fault that causes the shut-down is stored and displayed.
The warning buzzer remains active. Other indications caused by the engine shut down are no longer
displayed. The operator is thereby able to recognize and rectify the problem.
Then switch the ignition off to deactivate the shut-off relay and to enable a new starting process.
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Table of fault indications

Function group Colour of indication Shut-off relay
Hydraulic oil filter (B21) red 2 minutes
Coolant temperature red 2 minutes

(B53)
Engine oil pressure red 10 seconds

(B06)
Brake closed red -
Charge control (MD+) yellow -
Air filter (B03) yellow -
Hazard light red -
Indicator on green -
Anti Spin Control ASC yellow -
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Function diagram fault indicator
Fig. 4 Fault indicator
BW 156/177 D-3/PD-3 - G 10 -
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Brakes
Fig. 5 Brake
BW 156/177 D-3/PD-3 - G 11 -
BW 178/179 D-3/PD-3
Service Training
With the engine at standstill no hydraulic pressure is available, the brake discs cannot be relieved, the
brake is automatically closed.
Travel lever in position „brake“ with the engine running

When the engine is running and the generator is intact, the generator (G02:15) (Bild 1) will transmit a
D+ signal or the generator module (A23:24) (Fig. 1) a MD+ signal to the brake relay (K36:33).
If the travel lever is in „brake“-position the coil of relay (K48:05) will not be excited.
Current flows
• via fuse (F25),
• the contacts of relay (K48:07)
• to the coil of relay (K05:09) (Fig. 2),
Starting is now possible.
Current flows also
• via fuse (F25),
• to the fault monitoring board (A15:17) (Fig. 3).
The control light „brake closed“ (H01) lights up.
Travel lever actuated

When actuating the travel lever,
• proximity switch (B13:05) will close,
• relay (K48) switches over
• and the current flow to relay (K05:09) (starting) (Fig. 2) is interrupted.
Starting of the engine is no longer possible.
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Service Training
If the diesel motor is running and the generator is intact
• the coil of relay (K36:34) is excited,
• the contact closes.
Current can now flow
• via the contacts of relay (K48:07)
• and, with the EMERGENCY STOP switch (S01:34), to solenoid valve (Y04:34).
The brake is released.

If the MD+ signal is missing, e.g. because of a snapped V-belt, a defective generator or if the engine
has been stalled, e.g. on a slope, to coil of relay (K36:34) is no longer excited. Contact (K36) will open
and interrupt the current flow to solenoid valve (Y04:34), the brake will close.
To still be able to drive the machine for a short time, e.g. after a V-belt has snapped or the generator is
defective, the contacts 30-87 of relay (K36:34) must be bridged.
BW 156/177 D-3/PD-3 - G 13 -
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Service Training
Travel speed range selector
Fig. 6 Travel speed ranges
BW 156/177 D-3/PD-3 - G 14 -
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Service Training
Reverse travel
When moving the travel lever to reverse while driving on level ground, the coil of relay (K26:05) is not
supplied with current.
Current flows
• via fuse (F26:23),
• through the closed contact (K26:07)
• to the back-up alarm buzzer (H14:11).
The back-up alarm will sound.
Forward tavel
In this position the proximity switch (B14:05) closes.
Current flows
• the closed proximity switch (B14:05),
• to the coil of relay (K26:05).
The relay switches over, the current supply for the warning buzzer (H14:11) is interrupted.
Current flows also
• to the travel speed range selector (S42:24).
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Travel speed ranges
Depending on the position of the travel speed range (S42:23) the solenoid valves (Y30:19, Y31:29)
• for both travel motors (drum and axle),
• only for the front travel motor (drum),
• only for the rear travel motor (axle),
• or for none of the motors are supplied with current.
This enables the operator to influence the gradability of the machine by changing the displacement of
the travel motors. The motor of the slipping axle is switched over to low displacement.
If the travel speed range selector switch (S42:23) is in position 1 „turtle“, none of the solenoid valves
(Y30:11/Y31:18) is supplied with current. In this switch position all motors for drum and axle work with
high displacement. The machine drives with low travel speed range (working speed).
In switch position 2 current flows
• switch (S42:23)
• to solenoid valve (Y30:19).
The drum drive motor switches to low displacement.
The current flow to solenoid valve (Y31:29) is avoided by diode (V02:22).
In switch position 3 current flows
• switch (S42:23)
• to solenoid valve (Y31:29).
The axle drive motor switches to low displacement.
The current flow to solenoid valve (Y30:19) is avoided by diode (V03:27).
BW 156/177 D-3/PD-3 - G 16 -
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Service Training
If the travel speed range selector switch (S42:23) is in position 4 „rabbit“ both solenoid valves (Y30:11/
Y31:18) are supplied with current. In this switching condition both motors for drum and axle are switched
to low displacement. The machine drives with high speed range (transport speed).
In this switch position current flows
• switch (S42:23)
• to both diodes (V02:22 and V03:27)
• to both solenoid valves (Y30:19 and Y31:29).
Drum drive motor and axle drive motor change to low displacement.
BW 156/177 D-3/PD-3 - G 17 -
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Service Training
Vibration
Fig. 7 Vibration
BW 156/177 D-3/PD-3 - G 18 -
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Service Training
Switching the vibration on
Current flows from potential K11 via fuse (F03:05) to toggle relay (K04:05).
When pressing the push button (S13:05) the toggle relay will switch and the contact of toggle relay
(K04:05) will close.
Current flows to the selector switch for high / low amplitude (S35:29).
Depending on the switch position current flows to the solenoid valve (Y07:29) for high amplitude or
(Y08:34) for low amplitude. The selected vibration will start.
BW 156/177 D-3/PD-3 - G 19 -
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Inhaltsverzeichnis: BW 156...178−3 mit X−COM Klemmen
table of contents: BW 156...178−3 with X−COM terminals
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 582 700 71 Stromlaufplan Circuit Diagram
002 582 700 71 Versorgung, Heizung, Steckdosen supply, heating unit, sockets
003 582 700 71 Starten (je nach Motorausstattung) starting unnit (acc. to engine versions)
004 582 700 71 Signalhorn, Überwachungen, Anzeigen warning horn, monitoring, indicators
005 582 700 71 Frequenzanzeige, Tachograph, Geschwindigkeitsanzeige frequency meter, tachograph, speedometer
006 582 700 71 Fahren, Bremse, Fahrstufen, Lenkung driving, brake, speed ranges, steering
007 582 700 71 Vibrationseinschaltung activation of vibration
008 582 700 71 Anti − Schlupfregelung (nur bei DH / PDH Maschinen) anti spin control (only acc. to DH / PDH versions)
009 582 700 71 Variocontrol variocontrol
010 582 700 71 Omegameter, Terrameter omega meter, terrameter
011 582 700 71 Detailansicht Drucker− und Bedieneinheit detail view printer− and operation−unit
012 582 700 71 ZA Berieselung option sprinkler systhem
013 582 700 71 ZA Beleuchtung, Arbeitsscheinwerfer, StvZO Beleuchtung option illumination, working head lights, StvZO illumination
014 582 700 71 Kabine, Klimatisierung cabin, air conditioning
101 582 700 71 Bauteilliste component listing
201 582 700 71 Übersicht Schaltkasten overwiw e−box
15.06.2000
Werner Stromlaufplan 001 001 582 700 71
15.06.2000 circuit diagram
Seis 001
K32:30 K32:30 3:1
K11:30 K11:30 3:6
30 30 3:1
B+ 3:7
X1:19E X1:21E
15/54
1x6qmm
2x4qmm
2x4qmm
3:2
X1:61/2 2 1 X1:61/1
V03 F40 F05
25A 30A
X1:19A X1:21A
86
1
R10 K61 30
2 K61 Zusatzausrüstung innerhalb der Kabine X1:43
option inside of cabin F05 9:19
85 2:6
X1:9
X1:1
X1:2
X1:3
X1:4
87 87a Steuergerät
control unit
E30
Heizgerät A13
rt max.20A
heating unit
nenn.2A
X1:60 D+
4x4qmm 4:12 br
1x6qmm n
Sicherung Batterie
n
X1:106
fuse, battery
1 X18−1:2 4 n
F00
125A
2 n
X17−1:3
gn
1
Y14
B+ D+ S28
X1:146 2
gn
Schalter Kabinenheizung
G02
switch, cab heating
P00 D+
B− W 86
30 +
+
V24 G01 K09 Kraftstoffpumpe XS
X17−1:4 12V
− fuel pump heating unit −
31 85
X18−1:1 −
Außerhalb der Kabine montiert
assembled outside of cabin
X1:110
W
4:5 X1:144 X1:12
31 3:1
Load Dump Modul 2:10 14:3 Betriebsstundenzähler Steckdose

load dump module engine hour meter socket
Batterie Generator
battery generator
Nur bei Klimaanlage
only acc. to air conditioning
09.06.2000
1 1 582 700 71
Werner Versorgung, Heizung, Steckdosen
09.06.2000
Seis supply, heating unit, sockets 002
30 30 12:1
2:20
K32:30 2:20 K11:30 K11:30 9:12
2:20 X1:22E 3x1,5
X1:9 30
F13 K11
30A
K32 30 3:6 87
3:3 X1:112 X1:108 K11:87
X1:22A 4:1
87 87a
X18−2:7 X18−2:8 X18−2:5 X1:28E
X1:10 X1:8 F14

X1:10 X17−2:6 X17−2:5 X17−2:8
14:2 15A
X1:28A
X1:47
S00 P 0 1 2 3 30
X1:168
17
9:13
6:7
8:5
15/54 19 S01 X1:176
S03
58 50a 11 21 31 42 51 62 13 24
Startschalter Not−Aus Schalter Taster Signalhorn
ignition switch
emergancy shut off push button horn
X1:7 12 22 32 41 52 61 14 23
X1:177 Nur bei VARIOCONTROL
X1:41
15/54 only acc. to VARIOCONTROL
2:10 30 30
CE konformen Typen
K05 K22 X1:166 X1:167
Zweite Hupe nur bei

only acc. to ASC
6:6 4:12 Nur bei ASC
87 87a 87 87a
only acc. to cabin
50A
4:12
nur bei Kabine
X1:5 X1:6 X1:111
X18−2:1 X18−2:2 X18−1:7
X17−2:4 X17−2:3 X17−1:6
X1:126 X1:130
EW + HW max. 69A
max. 5A
HW max. 1,1A
max. 5A
AW max. 55A
2:10 B+ 1 1
AW HW B11 B11
86 86 B+ 50
K32 K11 ws rt 2 2
2 2
M01 V08 Y13
M 1 1 V07
sw
85 85
− X1:127 X1:131
2:20 31 31 4:1
3:3 3:12 Starter Hubmagnet 4BT3.9C Signalhörner

starter shut off solenoid 4BT3.9C warning horns
09.06.2000
1 1 582 700 71
Werner Starten (je nach Motorausstattung)
09.06.2000
Seis starting unnit (acc. to engine versions) 003
K11:87 K11:87 6:1
3:20
X1:29E
F24
15A
X1:29A
X1:45 X1:46 F24
5:1
ASC ERROR
8:6
hydraulic oil temperature BREMSE 6:5
X1:145 X1:97 X1:85 WARNBLINK 13:11

Hydrauliköltemperatur
Kühlmitteltemperatur
X1:82 X1:92
collant temperature
engine oil pressure
Sammelstöranzeige
br/ge
Drehzahlmesser
monitoring module
ws/rt
gn
Motoröldruck
Tankanzeige
rt
level gauge
RPM meter
50A X1:81 ws/ge
volt meter
Voltmeter
3:9 A15
2:6 D+ X1:84 ws/bl

or
P01 + P02 + P03 + P13 + P14 + P12 +
ws
sw
ge
vi
bl
gr
ws/gn
Q n P V
X1:105 ws/gr
br/gn
X1:101
X1:100
X1:102
G − G − G − G − G − − X1:90 X1:91
X1:103
X1:80 X1:96 X1:83
X1:104
X1:148
Blinker links / indicator LH

Blinker rechts / indicator RH
X1:113 X1:109
X18−1:5
X18−1:4
X18−2:3
X1:87
X1:86
X18−1:6 X18−1:3
BL 13:18
X17−1:8
X17−1:1
X17−2:2
W BR 13:18
X17−1:7 X17−1:2
SUMMER
2:6
14:3
X1:99
X1:88 X1:128
X1:188 X1:184
0,18A
0,12A
Geber Geber
sender sender
86 WK G B53 1 2 B21 2 B03 3 B55 3
1 1 rt
K22 H07 P P P Q
R03 R04
2 2 sw B06 3 4 4
85
X17−2:1
X1:191 X1:144 X18−2:4 X1:189 X1:187
X1:98
31 X1:107 31
3:20 5:1
3:12 Warnsummer Hydraulikölfilter
warning buzzer oil filter
ZA
Motoröldruck Luftfilter
option engine oil pressure air cleaner
Kühlmitteltemperatur Kühlmittelvorrat
collant temperature coolant stock level
09.06.2000
1 1 582 700 71
Werner Signalhorn, Überwachungen, Anzeigen
09.06.2000
Seis warning horn, monitoring, indicators 004
4:20 F24 F24
F07
13:11
Aufnehmer Vibration
transducer vibration
X1:72 X1:278 X1:282
X1:292
1 Tachographenmodul
2 X1:293 module, tachograph
A2+A3
B16 3 5 6 X1:283 A1 Klemmen X1:282−285 alternativ
P09 für Tachograph oder
4 X1:294 1 X1:284 B3 Geschwindigkeitsanzeige!
A16
7,8,9 2 X1:279 B4 terminals X1:282−285 for
X1:295 assembling tachograph or
4 3 X1:280 C4 speedometer
A5+A6
X1:296 Anzeige
X1:297 1 4 indicator X1:283
Frequenzanzeige
OUT+
OUT−
frequency meter
P05 − X1:284
OUT+
OUT−
15/54
Geschwindigkeitsanzeige
in
A51
P04
−
in
A06 Elektronik
transducer
3 2 5 A05 Elektronik
+ transducer
− 1 3 4
speedometer
+
−
Lern
Test
KA2
7:9
KA1
7:3
BW 156−179−3: −−−− GA2 7:9
BW 213,214,216−3: PIN 4: + GA1 7:3

BW 219−3: PIN 3: +
BW 225−3: PIN 4,3: + B60:3
10:4
BW 212−3: PIN 1: −
BW 212D/PD−3 Variom.: PIN 4: + / PIN 1: −
X1:281 X1:285
4:20 31 31 6:1
Platine Frequenzanzeige
circuit board, fequency indicator
ZA Frequenzanzeige ZA Tachograph ZA Geschwindigkeitsanzeige

option frequency meter option tachograph option speedometer
09.06.2000
1 1 582 700 71
Werner Frequenzanzeige, Tachograph, Geschwindigkeitsanzeige
09.06.2000
Seis frequency meter, tachograph, speedometer 005
4:20 K11:87 K11:87 7:1
X1:30E
F25
15A
X1:30A
X1:48 X1:49
X1:116 X1:119 X1:171 X1:171 Lenkhebel

steering lever
switch, speed range

Schalter Fahrstufen
L NR
BR/BN BR/BN 30 K26 30 23 1234 2 N PVREL
B13 B14 S42 Schalter Fahrstufen
K48 6:3 6:5 S42 switch, speed range N
BL/BU SW/BK 87a 87 87 87a 24 1 5 7 3 S71

BL/BU SW/BK
+ N S N −
X1:114 X1:115 X1:117 X1:118 BREMSE BREMSE 8:6 X1:330
4:20 X1:170 X1:172 X1:173 X1:170
X1:51 NEUT"0" 10:4
X1:52
Signalspannung Regelbereich: 3V−9V

proximity switch forward / zero position
signal voltage, control range: 3V−9V
X1:331
X1:178
21
proximity switch, tavel lever "0"
Signalspannung neutral: 6V
X1:332
signal voltage, neutral: 6V
S01 3:12
Leistungsaufnahme: 8W
signal current: 0,25mA
22 V04 V05
Initiator Vorwärts u. Null
Signalstrom: 0,25mA
Initiator Fahrhebel "0"
X1:179 2 1 1 2
input: 8W
X1:124 X1:134 X1:124
X1:132
max. 1,67A (Poclain)

X1:89
max. 1,23A (Sauer)

max 1,23A
max 1,23A
max. 1,8A
0,18A
0,18A
0,18A
X9:1 X1:336 X1:335

2 1
86 86 86
1 rt 1 1 V11 1
K48 K26 K05 Y04 V09 H14 Y31 V10 Y30 Y31
2 sw 2 2 V12 2 3
85 85 85
X9:2 Y64 −
X1:133 X1:190 X1:125 X1:135 X1:125 X1:337 X1:333
5:20 31 31 7:1
6:7 6:8 3:8 Magnetventil Bremse Stufenumschaltung hinten Stufenumschaltung vorn Magnetventil Lenkung
solenoid valve brake speed range selection, rear speed range selection, front solenoid valve steering
Rückfahrwarnsummer Stufenumschaltung hinten

back up alarm speed range selection, rear
für BW 156/177 D/AD für BW 178/179 D ZA

acc. to BW 156/177 D/AD acc. to BW 178/179 D option
09.06.2000
11 1 582 700 71
Werner Fahren, Bremse, Fahrstufen, Lenkung
09.06.2000
Seis driving, brake, speed ranges, steering 006
6:20 K11:87 K11:87 8:1
X1:31E X1:31E X1:31E X1:31E
F03 F03 F03 F03

15A 15A 15A 15A
X1:31A X1:31A X1:31A X1:31A
X1:50 X1:50 X1:50 X1:50

VERS1 9:1 VERS2 9:1
Modul Vibration Modul Vibration Modul Vibration Modul Vibration
30 56a module vibration 30 56a module vibration 30 56a module vibration 30 56a module vibration
K04 K04 K04 K04

56b 56b 56b 56b
S 56 S 56 S 56 S 56
emergency service
emergency service
emergency service
emergency service
X1:173 X1:173
switch speed ranges
switch speed ranges

Fahrstufenschalter
Fahrstufenschalter
123 61 123 61
Notbetrieb
Notbetrieb
Notbetrieb
Notbetrieb
S42 62 S42 62
X1:174
X1:174
X1:120 X1:164 X1:120 X1:164 X1:120 X1:164 X1:120
X1:164
push button, travel lever

Vibration klein/groß
Vibration klein/groß
vibration high / low
vibration high / low

X8:2 X8:2 X8:2 X8:2
Taster Fahrhebel
Taster Fahrhebel
Taster Fahrhebel
Taster Fahrhebel
S35 G 0 K 24 13 S35 G 0 K 24 13 S09 24 S09 24
S13 3 S13 3 S13 3 S13 3
4 23 14 4 23 14 4 23 4 23
X8:1 X1:162 X1:163 X8:1 X1:162 X1:163 X8:1 X8:1

X1:162 X1:162
X1:121 X1:121 X1:121 X1:121
GA1 GA2
5:10 5:10
KA1 KA2
5:10 5:10
max. 2,5A max. 2,5A max. 2,5A max. 2,5A
X2:49(A)
9:6 X2:49(B)
X1:159 X1:161 X1:159 X1:161 9:6
Y07 1 Y08 1 Y07 1 Y08 1
V13 2 V14 2 V13 2 V14 2

X1:158 X1:160 X1:158 X1:160
6:20 31 31 8:1
Vibration vorne groß Vibration vorne groß

vibration front, high vibration front, high
Vibration vorne klein Vibration vorne klein

vibration front, low vibration front, low
Standardvibration mit 2 Amplituden ohne ASC Standardvibration mit 2 Amplituden und ASC Variocontrol ohne ASC Variocontrol mit ASC
standard vibration / 2 amplitudes without ASC standard vibration / 2 amplitudes with ASC Variocontrol without ASC Variocontrol with ASC
09.06.2000
1 1 582 700 71
Werner Vibrationseinschaltung
09.06.2000
Seis activation of vibration 007
7:20 K11:87 K11:87 10:1
X1:34E
F51
15A
X1:34A
X1:62
X1:171 +45_G=4,5V 18: Analogsignal Neigungssensor
emergency service
X1:180 −45_G=0,5V 27: 1− Signal bei Fahrhebel in 0− Raste
1 09: 0− Signal = 1.Gang + Vibration
31 4 1V 09: 1−Signal und 08: 1−Signal = 2.Gang + Vibration
Not−Betrieb
S42 B57
123 21 12 43 61 09: 1−Signal und 08: 0−Signal = Transportgeschw. ohne Vibration
S01 Fahrstufen Neigungssensor 3 2,5V
3:12 speed ranges slope sensor
32 22 11 44 62 2 4V
0,5V−4,5V 5 6
X1:170
X1:181
X1:172
siehe Blatt 7
see page 7
4:19 ASC ERROR
BW 177PDH−3 (COR) mit CR31 Getriebe
BREMSE
X1:66/1
X1:66/2
6:8
max. 3,6A
BW 177 PDH−3 with CR31 gear
V01 Anschluß Diagnosegerät

connection diagnosis tool
1 2 X1:216 X1:219 X1:217 X1:218
BW 219 DH−3
BW 219 DH−3
X1:192 X1:202 X1:193 X1:194 X1:195 X1:196 X1:197 X1:212 X1:213 X1:214 X1:208
01 10 27 20 08 09 18 16 26 17 24
15 Elektronik
A36 electronic
X1:199 28 22 25
02 03 04 06 07 12 13 19 05 14 11
X1:209
X1:205
X1:206
X1:210
X1:207
X1:201 X1:211 X1:203 X1:222 X1:223 X1:226 X1:227 X1:198 X1:204
X1:63 X1:64
X1:220 X1:221 X1:224 X1:225 X1:55 X1:56 X1:57 X1:58 X1:59
X1:230
max. 1,67A (Poclian)
andere Typen
max. 1,23A (Sauer)
X1:229
X1:141
X1:136
X1:137
X1:138
other typs
X1:140
X1:142
speed
speed
X4:1 2 3
X1:228
B59 3 bl
B60 3 bl
1 1 R07
ws ws
Y30 Y31 2 2
br br
2 2 1 4 sw
1 4 sw
X1:143 X1:139
X1:65
7:20 31 31 9:1
Bandagenmotor Achsmotor Poti Fahrhebel Achsgeschwindigkeit

motor, drum motor, axle potentiometer travel lever sensor axle speed
Bandagengeschwindigkeit
sensor drum speed
09.06.2000
1 1 582 700 71
Werner Anti − Schlupfregelung (nur bei DH / PDH Maschinen)
09.06.2000
Seis anti spin control (only acc. to DH / PDH versions) 008
X2:47
7:15 VERS1
VERS2 X2:6 Aufnehmer Verstellmotor Beschleunigungssensoren K11:30 F05 F05 10:3
X1:236
7:19 3:20 2:20

sensor, adjustable notor acceleration sensors Automatik/Manuell/Prüfen Hand/Prüfen Automatik X1:43
X2:7
8,5V 1x1,5 1x1,5 automatic/manuell/test manuell/test automatic X1:237
AGND
X1:182 X2:48
X12:2 X2:31
X3:2 41 S13:2
X12:4 X2:32
X2:31
X2:72 X2:71 X2:72 S01 10:14
S13:8 X2:37 X2:55
X3:6 X3:11 +15V X3:1 X3:5 3:12 10:14
X2:10
42 X2:56
X2:8
X12:6
X2:31
X2:31
X2:36
−15V
X1:183 S104
X2:38
X2:49(A) X3:3 AMP

emergency service hor./vert.
for BW 177 with Pleiger

7:15
Für BW 177 m. Pleiger

X1:234 X1:235
monitoring modul
7:19 X2:49(B)
+/sw
X3:4 X12:5
Anzeigemodul
− B62 − B62 X2:45 X2:46 1 2 3 1 2 3
X2:32
X2:32
R23
13 X2:1E X2:2E 1kOhm
S65 G− P26
B61 −15V +15V
vertikal = 12V
AGND
−/rt F67 F84
Notbetrieb V/H
X1:238
+15V −15V R24
X20:2
X20:1
BH BV 30A 10A
S/ws S S
Amplitudenanzeige
amplitude indicator
X21:2 X21:1
+
1kOhm
14
G+ X2:49 X3:9 X3:7 X3:8 X2:1A X2:2A + +
S107 S106
R25
X11:19
X11:10
X11:9
X11:8
AGND AGND
X2:66
X2:67
X2:20
X2:68
1kOhm S S
1x0,75 / Elektronik
5x0,75 / Leistung
X2:11
P16
X2:39
X2:70
X2:69
X2:42
Zündung 15/54
X2:9
TERRA2 X20:3 1−6 X21:3 1−6

R26
X12:3
Sign. Vibr. ein
TERRA1 10:9 X2:58 1kOhm

F1 F2
10:9 X2:57
CAN+
CAN−
8,5V Notbetrieb
X2:35
X2:33
X2:34
X2:12
AGND
X2:13
+15V
−15V
12V
alive
X2:21
2 12 9 30 29 1 23 28 56 57 58 59 60 54 6 7 8 27 26 15
14 19 1 17 3 2 5 13 16 15 S13:1 10:14 X2:16 X11:1
A44:2,3 ESX Steuerung (Typ 7265)
X11:11
X11:13
X11:12
X11:3
X11:5
X11:7
X11:6
A46 Modul Variocontrol 10:6 A37
X11:2
X11:4
module variocontrol A44:1 ESX control unit (typ 7265)
10:5
X2:53
X2:52
X2:54
34 35 46 61 62 63 64 49 55 24 25 38 39 40 41 4 5 3 16
Gehäuse
Fahrtrichtungserkennung
18 4 10 9 7 8 12 11 6
X2:17
X2:18
X2:15
X2:14
X2:40
X2:78
X2:22
X2:63
X2:73
X2:5
X2:74
AGND X2:81
X2:79
X2:80
X2:82
X2:23 X2:77
X2:24 X2:76
1 X2:75
RxD
TxD
X2:25
X2:59 X2:60 X2:61 X2:62
X3:16
H04 2 X3:12 X3:13 X3:14 X3:15 S131 23 S132 23 S133 23 S134 23
H56
H57
1 1 1 1
1 1 1 1 P11
X11:15
X11:16
X11:17
X11:18
X11:14
V09 Y22 V09 Y119

X2:41
24 24 24 24
2 2 2 2 2 2 2 2 12V + −
Y125 Y128 Y126 Y127 Ventil Vibration
X3:17 X3:18 solenoid valve, vibration X3:19
X2:83
X2:64
X2:4 X2:5
8:20 31 X2:3 X1:239 31 10:1
Auslaßventil (4)
solenoid valve outlet (4) X2:29 A37:19 X2:19 A37:13
Einlaßventil (1) Einlaßventil (3) X2:30 A37:31 X2:26 A37:14 Ventil Arretierung Fertig Stop Löschen
solenoid valve inlet (1) solenoid valve inlet (3) X2:91 A37:32 X2:27 A37:17 solenoid valve, adjustment ready stop erase
X2:92 A37:47 X2:28 A37:18
Anzeige Störung Auslaßventil (2) X2:93 A37:48 Reserveklemmen Weiter Start Drucken Drucker
indicator failure solenoid valve outlet (2) terminals for resist continue start print printer
09.06.2000
1 1 582 700 71
Werner Variocontrol
09.06.2000
Seis variocontrol 009
8:20 K11:87 K11:87 12:1
X1:35E
NEUT"0"
6:8
F38 F05 F05 14:1 Stecker für in Planung
9:20
20A befindliche Zusatzanwendungen
5:19 B60:3 X1:43 connectors for additional
equipment, not jet available
X1:35A
11:12
11:12
11:12
11:13
11:13
11:13
11:14
11:15
11:15
11:15
11:16
Spannungsversorgung GPS
BCM V24 Mate−N−Lok

X1:71
max. 1A
+
Handeingabegerät
Datenleitung GPS
Datenleitung GPS
1
BCM V24 Sub−D

max. 10A
S6:1
S5:1
S6:3
S6:5
S6:6
S6:9
S5:3
S6:2
S5:2
S6:4
S5:4
E07 P07
2 −
X1:286
S21:6 X1:291
X1:287
X2:50 X2:9
S11:1−25
S8:1−10
S7:1−15
S19:1−6
S20:1−9
S9:1−5
connector board, omega meter

S4:1
S4:2
S6:1
S6:2
S6:3
S6:4
S6:5
S6:6
S6:9
S5:1
S5:2
S5:3
S5:4
Koppelplatine Omegameter
+5V
AGND
A44:2,3
Nur bei Anbau VARIOCONTROL

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

S13:1 S2:1 A08
S16:1
X1:289 S21:1
S18:1
S12:1−5
S17:1−8
X1:242
S14:1−5
S16:3
S16:7
S15:3
S15:5
S15:6
S15:7
X1:290 S21:5
S16:2
S18:5
S18:6
S15:8
S18:2
S15:4
S4:3
Winkelsignal
modul, terra meter
S2:2
S2:3
S2:4
S2:5
Modul Terrameter
also assembled
0−5V
+5V
X1:136
15/54 6 2,3 X1:67 S13:1
9:8
11:16 S16:1
r−out
11:11 S18:1
11:17 S16:3
11:17 S16:7
11:6 S15:3
11:6 S15:5
11:7 S15:6
11:7 S15:7
11:16 S16:2
11:12 S18:5
11:12 S18:6
11:7 S15:8
11:11 S18:2
11:6 S15:4
br 1 speed
X1:58 4 9:15 S13:2
bl
3 w−in S13:8
8 X1:68 9:15 5
B60 X1:138 A44
Versorgung von "B60" bei
1/4 w−out
supply of "B60" if ASC is
X1:59
und BW 216/219/225
BW 213/214 H−Version
r−in 5
2
sw
4 ws
X1:137 1 5 5 8
7
direction
gnd w−out
B62
X1:139
Beschleunigungsaufnehmer
X1:69 acceleration sensor
P15 Dip−Schalter 1: Geschlossen, für Bandagenart "D"
Dip−Schalter 1: Offen, für Bandagenart "PD"
A44:1 X1:241 15 8 Bildschirm Dip−Schalter 2: Geschlossen, für BW 213/214/217/219
9:8 B62 diplay
Dip−Schalter 2: Offen, für BW 142/172/212
9:8 A44:1 X10:1−19 Alle anderen Dip−Schalter : keine Verwendung
X1:241
Dip−switch 1: closed, for "D" − drum
B62
7 Dip−switch 1: open, for "PD" − drum
−5V
Dip−switch 2: closed, for BW 213/214/217/219

TERRA1 ST1:1 Dip−Schalter 2: open, for BW 142/172/212
9:8 Signalübertragung bei
all other Dip−switches : no use
TERRA2 angebauter Variocontrol ST2:1−8 Schnittstelle
9:9 A35
jeweils an PIN 1
ST1:2 interface
X1:288
9:20 31 31 12:1
Sensor Achsgeschwindigkeit Beschleunigungsaufnehmer (BH)

sensor, axle speed acceleration sensor (BH)
Beschleunigungsaufnehmer (BV)
acceleration sensor (BV) Terrameter, Ausrüstungsumfang VM2−VM5 Omegameter, Ausrüstungsumfang VM1
terra meter, applications VM2−VM5 omega meter, application VM1
09.06.2000
1 1 582 700 71
Werner Omegameter, Terrameter
09.06.2000
Seis omega meter, terrameter 010
Druckereinheit
S12 S4 P11 printer−unit
ST21 S14 S5 20
Koppelplatine BTM05
S6
S15
link−unit BTM05
S16 S7
Druckercontroller
printer−controller
paper formfeed
Papiervorschub
3
S17 S153
S8 X15 X16
S18 1 3 4 2 6 5 4 3 2 1
4
S9
S19
X13 X14
S10 1 2 3 4 5 6 7 1 2 3 4
S13
S6:1
S6:2
S6:3
S6:4
S6:5
S6:6
S6:9
S5:1
S5:2
S5:3
S5:4
S20 S11
10:11
10:11
10:11
10:11
10:10
10:10
10:13
10:13
10:12
10:12
10:12
10:11
10:12
10:12
10:12
10:13
10:13
10:10
10:11
10:11
10:11
10:10
10:10
10:9
10:9
S16:1
S18:1
S15:3
S15:5
S15:6
S15:7
S16:3
S16:7
S15:8
S18:5
S18:6
S16:2
S18:2
S15:4
Bedieneinheit
operation−unit
+ + +
23 23 23 13 13 23 X2 X2 X2 X2 X2
S131 S132 S133 S152 S140 S134 H56 H57 E07 E05 E04 P07 P05 P04
f v
X1 X1 X1 X1 X1 − − −
24 24 24 14 14 24
START DRUCKEN TEST−NORMAL WEITER Bel. Omegameter Omegameter Geschwindigkeitsanzeige

start print test−normal continue illum. omegameter omegameter speedometer
STOP PD−D LÖSCHEN FERTIG Bel. Frequenzanzeige Frequenzanzeige
stop PD−D clear comp. achieved illum. frequency meter frequency meter
Bel. Geschwindigkeitsanzeige
illum. speedometer
18.05.19100
1 1 582 700 71
T. Seis Detailansicht Drucker− und Bedieneinheit
18.05.2000
Werner detail view printer− and operation−unit 011
10:20 K11:87 K11:87 13:1
3:20 30 30 13:1
X1:33E
X1:20E
F37 F06
40A 15A
X1:20A
X1:33A
X1:70
X1:258 X1:259 4s abschaltverzögert
11 23
30
K23 S05 012 15 in V 4s − −
01
12:12 Schalter Berieselung
87 87a switch, sprinkler system K37 1s 2s
12 24
Zeitrelais
timing relay
X1:262
X1:261
87a St+
15 out 30 87 St− −
0,18A
86 K46 30
K46 12:6
87 87a
85
X1:254 X1:256 X1:264 X1:264

X1:260
max. 7,2A
1,83A
max 8A
0,18A
+ 1 2 +
86
M02 A01 1 M03 1
M V15 Y06 K23 M V16 Y06
2 2
− 85 −
3/4 1,83A
X1:263
X1:255 X1:257 X1:265 X1:265
10:20 31 31 13:1
Berieselungspumpe 12:9 12:4 Emulsionspumpe Berieselungsventil

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

Intervallschalter Berieselungsventil Emulsionsberieselung Emulsionsberieselung
interval switch solenoid valve sprinkler alternative assembling for not assembled acc. to
emulsions sprinkler application emulsions sprinkler application
09.06.2000
1 1 582 700 71
Werner ZA Berieselung
09.06.2000
Seis option sprinkler systhem 012
12:20
13:9
X22:2
15A
31
X1:318
87
4,6A X1:314
12:5 30
Scheinwerfer links
F11
2
X1:17A
X1:17E
head light LH
X22:1
12:20 K11:87
K16 30
4,6A X23:1
S15
87a
Scheinwerfer rechts
2
E16 1 E17 1
head light RH
X1:315
13:10
012
X23:2
X1:319
Schalter Arbeitsbeleuchtung
K06
X1:307
X1:165
switch, working head lights
switch, StvZO
Schalter StvZO
85
86
24
S53 23
32
31
0,18A
X1:40
X1:169
12
11
15A
0,42A X1:305
F18
Umrißleuchte vorne links
Seis
2
X1:301
contour indicator front, LH
Werner
24
23
0,42A
09.06.2000
09.06.2000
Umrißleuchte hinten links
2
X1:300
contour indicator rear, LH

X1:32A
X1:32E
15A
X1:306
F09
X24:3
X1:320
X1:16A
X1:16E
Schlußleuchte links X24:1
2
tail light, LH 0,42A
X1:326
Parkleuchte links X25:2
X1:316
parking light, LH 0,42A
X1:310
X1:311
Parkleuchte rechts X26:2
werfer ohne StvZO
2
lights without StvZO
X1:317
parking light, RH 0,42A
15A
F10
X25:1 X26:1 X27:3

Anschluß Arbeitsschein−
connection working head
X1:15A
X1:15E
Schlußleuchte rechts X27:2
X1:327
tail light, RH 0,42A
X1:321
0,42A Anschluß Instru−
Umrißleuchte vorne rechts
2
mentenbeleuchtung
contour indicator front, RH ohne StvZO
switch, rotary beacon
0,42A connection illumina−

Umrißleuchte hinten rechts
2
tion instruments
contour indicator rear, RH
13:2
without StvZO
Schalter Rundumkennleuchte
E41 1 E42 1 E13 1 E12 1 E14 1 E15 1 E43 1 E44 1 K16

0,18A
S38
85
86
24
23
X1:149
0.166A
X1:53
Bel. Tankanzeige
2
13:3
illumination level gauge

87
X1:40
0.166A
Bel. Öldruckanzeige
2
K06 30
illumin. oil pressure indicator

5:9
4:19
87a
0.166A
Bel. Hydrauliköltemperatur
2
illumin. hydraulic oil temperature
F07
X1:54
0.166A
Bel. Temperaturanzeige
2
rotary beacon
illumin. temperature indicator

WARNBLINK
S14
0.166A
Bel. Drehzahlmesser
2
Rundumkennleuchte
E32
illumination RPM meter

01
Warnblinkschalter
switch, hazard light
0.166A
Bel. Voltmeter
2
15A
01
F07
illumin. voltmeter
X1:72
X1:303
X1:18A
−
+
5A
X1:18E
24
23
0.166A X1:298
Bel. Frequenzanzeige
2
option illumination, working head lights, StvZO illumination

X1:299
308
illumin. frequency meter
ZA Beleuchtung, Arbeitsscheinwerfer, StvZO Beleuchtung

11
12
0.166A X2:43 X1:240

15A
Bel. Vektoranzeige
F08
2
E01 1 E45 1 E22 1 E02 1 E03 1 E46 1 E05 1 E54 1
illumin. vector indicator

X2:5
X2:51
X1:36A
X1:36E
63
64
X2:44
X1:95
X1:304
15A
34
33
4,6A
F22
X1:23A
X1:23E
X1:152
Arbeitsscheinwerfer hinten links
2
working head lights, rear lh.

43
44
X1:150
4,6A
X1:156
Arbeitsscheinwerfer hinten rechts
2
bei ROPS−Aufbau
working head lights, rear rh. X1:154

S37
4,6A
X1:153 X1:151
Anschluß Arbeitsschein−
werfer u. Rundumleuchte
Arbeitsscheinwerfer vorne links

2
Connection head lights and
working head lights, front lh.

rotary beacon acc. to ROPS
15A
4,6A
L0R
F19
X1:24A
X1:24E
X1:157
switch indicator
Schalter Blinker
Arbeitsscheinwerfer vorne rechts

2
E27 1 E28 1 E23 1 E25 1
working head lights, front rh.

L0R
X1:155
14
13
A02
49
31
23
24
1
Blinkgeber
49a
indicator relay
1,75A X1:312
BL
BR
4:19
4:19
X1:309
Blinkleuchte VL X25:3
2
indicator front, LH
X1:94
1
1,75A
Blinkleuchte HL X24:2
2
indicator rear, LH
X1:322
X1:93
1,75A X1:313
Blinkleuchte VR X26:3
2
E08 1 E09 1 E10 1
indicator front, RH
1,75A
Blinkleuchte HR X27:1 Anschluß Arbeitsscheinwerfer
STV2
2
E11 1
STV1
30
K11:87
indicator rear, RH X1:323 bei Kabine

Connection head lights
with cabin
582 700 71
31 14:1
14:15
14:15
013
3:3 X1:10 X29/1:5 X29/2:8
STV2
13:19
10:7 F05 STV1
Reserve
13:19
reserve
X1:44 F42 B F43 C F44 D F31 E F17 F F02 A
30 30 10A
2 10A
3 10A
4 15A
5 10A
6 10A
1
K33 K09
14:5 2:8 X32:1
87 87a 87 87a
X1:270
X34:1 S45 3 7 2 7 2
01W 01W 012 3
0123 B Schalter Klimaanlage 01 01
S102
switch, air conditioning
4
S21 5 4 S20 5 4 S44
L MH C 5 1
A12 S38 5
B51 15 B51
+ + + +
X28/2:6
X28/2:8
X28/2:5
X28/2:7
X29/2:5
X29/2:7
X28/2:2
X29/2:6
X29/2:2
X29/2:1
− − − −
ge/rt
rt/ge
31 7 1
rt
1
Thermostat
M
M09 B29 _t thermostat
X29/1:6
X29/1:7
X29/1:3
X28/1:7
X28/1:5
X28/1:6
X29/1:8
X28/1:3
X28/1:8
X29/1:4
Lüfter 2
blower
X34:2 X34:3
X1:268 X1:269
X31:1
X30:1
X31:3
X33:1
X31:4
X30:3
X30:3
X33:3
X1:340
K49 30
Überwachung Kühlmitteldruck
monitoring coolant pressure
14:4 B75 4 1 1 1 1 1
5A
E32
87 87a M09 +
P E29 M05 M M04 M M E27 E28 E23 E25
LP HP
X1:73/1 2 2 2 2 2
4,6A
4,6A
4,6A
4,6A
14,2A
1,3A
2,9A
4,7A
1 3 −
X1:338 V02 X1:341

2
X32:2 X30:2 X31:2 X33:2
X1:73/2
SUMMER
4:14
max. 3,5A
X1:277 X1:276
X1:275 X1:274
0,18A
ZA
Y15 1 2 86 86 + + option
V17 K49 K33 M07 M M06 M
2 1
85 85 − −
max. 3,8A
max. 3,8A
X1:339
X1:11 X1:186 X1:185

31 31
13:20
14:3 14:2 Innenleuchte Wascher hinten Wascher vorn Arbeitsscheinwerfer hinten Radio
inside light, cabin washer rear washer front working head lights, rear radio
Magnetkupplung Klimagerät
Wischer hinten Wischer vorne Kabinenlüfter Arbeitsscheinwerfer vorn Rundumkennleuchte
magnetic clutch, air conditioning windscreen wiper, rear windscreen wiper, rear cab ventilator working head lights, front rotary beacon
ZA
option
09.06.2000
1 1 582 700 71
Werner Kabine, Klimatisierung
09.06.2000
Seis cabin, air conditioning 014
Name Bl. Pf. Benennung title TYP
A01 012 6 Intervallschalter Berieselungssystem Interval switch, sprinkler system
A02 013 17 Blinkrelais Indicator relay
A05 005 15 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer MODUL
A06 005 3 Elektronik Frequenzanzeige vorne Electronic system, frequency meter, fr.
A08 010 18 Elektronik Omegameter Electronic system, Omegameter
A12 014 17 Radio Radio
A15 004 13 Platine Ueberwachungsmodul Printed circuit board, monitoring module
A16 005 8 Elektronik Tachograph Electronic system, tachograph
A33 010 7 Zentralplatine Kopplung Verdichtungskomponenten Connection dircuit board, compac. components
A35 010 14 Versorgungsplatine Suppling circuit board
A36 008 5 Elektronik Antischlupfregelung Elektronic antispin control
A37 009 11 Elektronik Variomatic Elektronic variomatic
A44 010 5 Zusatzelektronik Additional control unit
A46 009 2 Modul Variomatik Modul, variomatik
Seis
09.06.2000
Werner
09.06.2000
A51 005 10 Platine Frequenzanzeige Circuit board,frequenzy meter
B03 004 19 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B06 004 15 Druckschalter Motoroel Pressure switch, engine oil
B11 003 16 Signalhorn Warning horn MAX. 5A
B11 003 19 Signalhorn Warning horn MAX. 5A
B13 006 3 Naeherungsinitiator Fahrhebel links Proximity switch, travel lever, lh.
B14 006 5 Naeherungsinitiator Fahrhebel rechts Proximity switch, travel lever, rh.
B16 005 2 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 004 18 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B29 014 4 Raumthermostat Room thermostat
B51 014 17 Lautsprecher Radio Speaker radio
B51 014 18 Lautsprecher Radio Speaker radio
B53 004 16 Temperaturgeber Kuehlmittel Temperature switch, collant
B55 004 19 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B57 008 12 Neigungssensor Stufenumschaltung Slope sensor, speed range selection
B59 008 13 Aufnehmer Bandagengeschwindigkeit Sensor, drum speed
B60 008 15 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B60 010 2 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 009 7 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 009 9 Beschleunigungsaufnehmer Acceleration sensor
B75 014 5 Kuehlmitteldruck coolant pressure
E01 013 9 Beleuchtung Tankanzeige Illumination, level gauge

E02 013 11 Beleuchtung Temperaturanzeige Illumination, temperature gauge
component listing
E03 013 12 Beleuchtung Drehzahlmesser Illumination, rpm meter

E04 011 13 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
Bauteilliste
E05 011 12 Beleuchtung Frequenzanzeige vorne Illumination, frequency gauge, front

E05 013 13 Beleuchtung Frequenzanzeige vorne Illumination, frequency gauge, front
E07 010 17 Beleuchtung Omegameter Illumination, Omegameter
E07 011 12 Beleuchtung Omegameter Illumination, Omegameter
E08 013 18 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 013 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 013 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 013 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 013 6 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 013 5 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 013 6 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 013 7 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 013 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 013 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E22 013 10 Beleuchtung Temperaturanzeige Hydr.−oel Illumination, temp. gauge, hydraulic oil
E23 013 16 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 014 16 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E25 013 16 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 014 17 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E27 013 14 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 014 15 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E28 013 15 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 014 16 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E29 014 7 Innenleuchte Kabine Inside light, cabin 1,3A
E30 002 12 Heizgeraet Heating unit MAX.20A/NENN2A
E32 013 12 Kennleuchte Warning light 5A
E32 014 20 Kennleuchte Warning light 5A
E41 013 4 Umrissleuchte vorne links Contour illumination front, lh. MAX. 0,42A
E42 013 4 Umrissleuchte hinten links Contour illumination rear, lh. MAX. 0,42A
E43 013 7 Umrissleuchte vorne rechts Contour illumination front, rh. MAX. 0,42A
E44 013 8 Umrissleuchte hinten rechts Contour illumination rear, rh. MAX. 0,42A
E45 013 10 Beleuchtung Oeldruckanzeige Illumination oil pressure indicator
E46 013 12 Beleuchtung Voltmeter Illumination volt meter
E54 013 13 Beleuchtung Vektoranzeige Illumination vector indicator
F00 002 2 Hauptsicherung Batterie Fuse, main, battery 125A

F02 014 19 Ersatzsicherung Fuse, spare 10A
1
F03 007 2 Sicherung Vibration Fuse, vibration 15A

F05 002 19 Sicherung Steckdose Fuse, socket 30A
10
F06 012 6 Sicherung Berieselung Fuse, sprinkler system 15A

F07 013 12 Sicherung Warnblinker Fuse, hazard light 15A
F08 013 13 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 013 5 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 15A
582 700 71
F10 013 7 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 15A
F11 013 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 003 5 Sicherung Startschalter Fuse, starter switch 30A
F14 003 12 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 15A
F17 014 17 Sicherung Radio Fuse, radio 10A
101
F18 013 4 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 15A
F19 013 16 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 15A
F22 013 14 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 15A
F24 004 2 Sicherung Ueberwachungsmodul Fuse, monitoring module 15A
F25 006 3 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 15A
F31 014 13 Sicherung Kabinenluefter Fuse, cabin ventilator 15A
F37 012 4 Sicherung Berieselungspumpe Fuse, sprinkler pump 40A
F38 010 2 Sicherung Terrameter Fuse, terrameter 20A
F40 002 12 Sicherung Kabinenheizung Fuse, heating unit cab 25A
F42 014 7 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
F43 014 8 Sicherung Wischermotor hinten Fuse, wipermotor rear 10A
F44 014 11 Sicherung Wischermotor vorn Fuse, wipermotor front 10A
F51 008 5 Sicherung Antischlupfregelung Fuse, antispin control 15A
F67 009 12 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 30A
F84 009 13 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
G01 002 2 Batterie Battery

Seis
09.06.2000
Werner
09.06.2000.
G02 002 5 Generator Generator
H04 009 2 Meldeleuchte Betriebsstoerung Indicator light, breakdown

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

K05 006 6 Relais Startstrom Relay, starting current BOSCHW
K06 013 3 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 003 6 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K16 013 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K22 004 12 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K23 012 12 Relais Berieselungssystem Relay, sprinkler system BOSCHW
K26 006 5 Relais Rueckfahrwarneinrichtung Relay, back up alarm BOSCHW
K32 003 3 Relais Kabine Relay, cabin BOSCHW
K33 014 5 Relais Warnsummer Betriebsstoerung Relay, warning buzzer, failure indication BOSCHW
K37 012 16 Zeitrelais Timing relay
K46 012 6 Umschaltrelais Switching relay BOSCHW
K48 006 3 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K49 014 4 Relais Warnsummer Relay, warning buzzer BOSCHW
K61 002 6 Relais Ladekontrolle Relay, charge control BOSCHW
component listing
M01 003 7 Starter Starter

Bauteilliste
M02 012 4 Berieselungspumpe Sprinkler pump 8A

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

P01 004 2 Tankanzeige Level gauge
P02 004 4 Temperaturanzeige Hydraulikoel Temperature gauge, hydraulic oil
P03 004 6 Drehzahlmesser Rpm meter
P04 005 17 Geschwindigkeitsanzeige Speedometer
P04 011 17 Geschwindigkeitsanzeige Speedometer
P05 005 5 Frequenzanzeige vorne Frequency meter, front
P05 011 16 Frequenzanzeige vorne Frequency meter, front
P07 010 19 Omegameter Omegameter
P07 011 15 Omegameter Omegameter
P09 005 12 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 009 19 Drucker Printer
P11 011 12 Drucker Printer
P12 004 11 Voltmeter Volt meter
P13 004 8 Anzeige Motoroeldruck Pressure gauge, engine oil
P14 004 9 Anzeige Kuehlmitteltemperatur Temperature gauge, coolant
P15 010 13 BCM 03 Bildschirm BCM 03 terminal
P16 009 19 Fehleranzeige Variomatic Fault indication, varimatic
P26 009 5 Anzeige Amplitude amplitude indicator
R03 004 2 Geber Tankanzeige Sender, level gauge

R04 004 4 Geber Hydraulikoeltemperatur Sender, hydraulic oil temp.
R07 008 11 Potentiometer Geschwindigkeitsk. Potentiometer speed control
R10 002 5 Parallelwiderstand Parallel resistor 82 OHM
R23 009 14 Widerstand Resistor 1KOHM
2
S00 003 5 Startschalter Starter switch

S01 003 12 Schalter NOT AUS Switch, emergency off NOTAUSH
S03 003 17 Taster Signalhorn Push button, warning horn
S05 012 6 Berieselungsschalter Switch, sprinkler system
10
S09 007 14 Vibrationsschalter vorne Switch, vibration, front

S09 007 19 Vibrationsschalter vorne Switch, vibration, front
S13 007 2 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
582 700 71
S14 013 12 Warnblinkschalter Switch, hazard light
S15 013 3 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 014 11 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
102
S21 014 8 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear

S35 007 4 Vibrationsschalter klein/gross Switch, vibration low/high
S35 007 10 Vibrationsschalter klein/gross Switch, vibration low/high
S37 013 16 Schalter Blinker Switch, indicator
S38 013 9 Schalter Kennleuchte Switch, warning light
S38 014 20 Schalter Kennleuchte Switch, warning light
S42 006 10 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S44 014 13 Schalter Kabinenluefter Switch, cabin ventilator
S45 014 7 Kabineninnenleuchte Switch, cabin inside light
S53 013 3 Schalter Arbeitsbeleuchtung Switch, working lights
S65 009 2 Schalter Vibration horizontal/vertikal Switch, vibration horizontal/vertical
S71 006 18 Schalter Lenkung Switch, steering
S102 014 3 Schalter Klimaanlage Switch air conditioning
Seis
09.06.2000
Werner
09.06.2000
S104 009 15 Schalter man./autom. Switch man./autom.

S106 009 17 Schalter Verdichtungsenergie Switch, compaction energy
S107 009 16 Schalter Amplitutenverstellung Switch,amplit. adjustment
S131 009 16 Schalter Start Switch, start
S131 011 4 Schalter Start Switch, start
S132 009 16 Schalter Stop Switch, stop
S132 011 5 Schalter Stop Switch, stop
S133 009 17 Schalter Drucken Switch, print
S133 011 6 Schalter Drucken Switch, print
S134 009 18 Schalter Loeschen Switch, erase
S134 011 8 Schalter Loeschen Switch, erase
S140 011 8 Schalter Test / Normal Switch, test mode / standard mode
S152 011 7 Schalter PD−D Switch, PD−D
S153 011 18 Papiervorschub paper formfeed
V01 008 8 Diode Diode WAGO

V04 006 14 Diode Diode FE5B/KABEL
V09 006 8 Diode Diode LÜTZE
V09 009 9 Diode Diode VENTIL
component listing

Bauteilliste

V24 002 1 Load−Dump−Modul Load−dump−modul
X1:1 002 2 WAGO, E−KASTEN WAGO, E−BOX

3

10

582 700 71

103

Seis
09.06.2000
Werner
09.06.2000

component listing

Bauteilliste

4

10

582 700 71

X1:15A 013 7 SIKA − KLEMME fuse terminal
104
X1:15E 013 7 SIKA − KLEMME fuse terminal

Seis
09.06.2000
Werner
09.06.2000

component listing

Bauteilliste

5

10

582 700 71

105

Seis
09.06.2000
Werner
09.06.2000

component listing

Bauteilliste

6

10

582 700 71

106

Seis
09.06.2000
Werner
09.06.2000

X1:61/1 002 9 WAGO, E−KASTEN WAGO, E−BOX
X2:3 009 7 VARIOCONTROL variocontrol
component listing

X2:1A 009 12 VARIOCONTROL variocontrol
Bauteilliste
X2:1E 009 12 VARIOCONTROL variocontrol

X2:2A 009 13 VARIOCONTROL variocontrol
X2:2E 009 13 VARIOCONTROL variocontrol
7

10

582 700 71

107

Seis
09.06.2000
Werner
09.06.2000

X3:1 009 8 WAGO, BANDAGE Wago, drum
X4:1 008 11 AMP, POTI FAHRHEBEL AMP, poti travel lever
X8:1 007 2 AMP FAHRHEBEL AMP, travel lever
component listing

Bauteilliste

X9:1 006 9 AMP WARNSUMMER AMP, buzzer
X9:2 006 9 AMP WARNSUMMER AMP, buzzer
XS 002 19 Steckdose Socket
X10:1−19 010 13 SCHALTBAU FAHRERSTAND SCHALTBAU, operators platform
X11:1 009 19 SCHALTBAU DIAGNOSE Schaltbau diagnosis
X12:2 009 14 AMP, SCHALTER AMP, switch
X13:1 011 12 Druckerschnittstelle intreface printer
8

10

X15:1 011 12 Druckercontroller Printer−controller
582 700 71

108

X17−1:1 004 16 MOTORSTECKER MOTOR engine plug, engine side
Seis
09.06.2000
Werner
09.06.2000
X18−1:1 002 5 MOTORSTECKER MASCH. engine plug, machine side

X20:1 009 16 AMP POTI S107 AMP poti S107
X22:1 013 2 STECKER SCHEINW. STVZO connector head lights StvZO
X24:1 013 5 STECKER SCHLUßLEUCHTE connector tail lights
X25:1 013 6 STECKER PARKLEUCHTE connector parking lights
component listing

Bauteilliste

X30:1 014 9 WISCHER HINTEN connector wiper rear
X30:3 014 8 STECKER WISCHER HINTE connector wiper rear
X31:1 014 12 WISCHER VORN connector wiper front
X32:1 014 7 STECKER INNENLEUCHTE connector inside light, cabin
X32:2 014 7 STECKER INNENLEUCHTE connector inside light, cabin
X33:1 014 14 STECKER LÜFTER connector blower
X34:1 014 3 STECKER KLIMAANL. KAB connector air cond. cabin
X28/1:3 014 11 KABINE HAUPTSTECKER main connector cabin
9

10
Y04 006 7 Magnetventil Bremse Solenoid valve, brake MAX. 1,8A

Y06 012 9 Magnetventil Berieselung Solenoid valve, sprinkler system 1,83A
582 700 71
Y06 012 17 Magnetventil Berieselung Solenoid valve, sprinkler system 1,83A

Y07 007 4 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high MAX. 2,5A
Y07 007 10 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high MAX. 2,5A
Y08 007 6 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low MAX. 2,5A
Y08 007 11 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low MAX. 2,5A
109
Y13 003 12 Hubmagnet Motor Shut off solenoid, engine 1,1A/55A

Y14 002 15 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 014 2 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y22 009 10 Magnetventil Vibration Solenoid valve, vibration
Y30 006 13 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 1,23A/1,67A
Y30 008 7 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 1,23A/1,67A
Y31 006 10 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y64 006 18 Magnetventil Lenkung Solenoid valve, steering 0,33A
Y119 009 13 Magnetventil Arretierung Solenoid valve, adjustment
Y125 009 3 Einlassventil 1 Intake valve 1
Y126 009 5 Einlassventil 3 Intake valve 3
Y127 009 5 Auslassventil 2 Exhaust valve 2
Y128 009 4 Auslassventil 4 Exhaust valve 4
Seis
09.06.2000
Werner
09.06.2000
component listing
Bauteilliste
10
10
582 700 71
110
X1:
X1:
83 80 1
84 81
2
057 564 17
85 82
88 86 3
89 87
93 90 4
057 564 23
94 91
5
95 92
K11
98
99
96
97
6 057 543 05
103 100
7
104 101 8
105 102
057 564 29
110 106 9
057 564 19
111 107
057 564 22
112 108
10
113 109
Seis
11
057 564 35
B57
117 114
Werner
118 115 12
Neigungssensor
119 116
057 664 01
14.06.2000
14.06.2000
122 120 F10 15
123 121
F09 16
128 124
options area
129 125 F11 17
Bereich für ZA
130 126
131 127 F07 18 057 268 42
K61
134 132 F40 19

057 664 33
135 133
140 136 F37 20
K22
141 137
F05 21
142 138
143 139 F13 22
147 144
F22 23
K48
148 145
149 146
F19 24
057 564 36
154 150
155 151 F14 28
156 152
K26
157 153 F24 29

160 158 F25 30
161 159
K05
166 162 F03 31

167 163
F18 32
168 164
169 165 F06 33
K06
173 170
174 171 F51 34
175 172
F38 35
options area
180 176
K46
Bereich für ZA
181 177 F08 36

182 178
183 179 40 30
188 184 41 15/54
K23
189 185 42 15/54

190 186 43 F05
191 187 057 564 25 44 F05
202 192 45 F24
46 F24
K32
203 193
204 194 47 F14
057 565 36
057 564 20
205 195 48 F25

206 196 49 F25
207 197 50 F03
K09
208 198 51 Bremse

209 199 52 Neutral 0
210 200 53 K16/E01
54 K16/E01
options area
211 201
K33
55 Bandage Richtung
Bereich für ZA
216 212
56 Bandage Speed
217 213
57 Achse Richtung
overwiw e−box
ASC Version
218 214
58 Achse Speed
219 215
K49
59 Achse Speed
Übersicht Schaltkasten
222 220 60 D+
057 564 21
223 221
61 V03
226 224 62 F51
227 225
K16
63 +5V
231 228 64 +5V
057 564 30
232 229 65 −5V

233 230 66 V01
A02
240 234 67 A44:2/3

241 235 68 A44:8
242 236 69 A44:1
options area
243 237 70 F06

244 238 71
Bereich für ZA
F38
245 239 72 F07
Variocontrol
250 246 73 V02

251 247
057 664 38
252 248
057 556 55
872 801 41
253 249
256 254
257 255 2 R10 1
K04
82_O
261 258
262 259
263 260
AD−Version
266 264
267 265
A44
271 268
A06
options area
272 269
Terrametermodul
Frequenzmodul
273 270
Bereich für ZA
580 034 24
057 664 80
Kabine
276 274
277 275
282 278
283 279
284
Tachogr.
280
285 281
289 268
A16
modul
Zeitmodul
K37
Berieselung
290 287
Terram.
Tachographen−
057 664 10
291 288
options area
296 292
Bereich für ZA
297 293
298 294
Frequenzanz.
299 295
1
305 300
306 301
307 302
057 664 44 (BW 216/225)
A51
308 303
Tachograph
Frequenzplatine
309 304
320 310
057 665 08 (außer BW 216/225)
321 311
322 312
1
323 313
057 665 89 (BW 225)
057 664 92 (BW 219)
StvZO Beleuchtung
324 314
325 315
326 316
327 317
328 318
329 319
are internaly connected!
334 330
335 331
Ebene sind intern gebrückt!
336 332
Joy−Stick
057 665 90 (BW 178/211/213/214/216)
337 333
340 338
blue terminal, upper and lower flat
341 339
Klimaanl.
blaue Klemme, d.h. obere u. untere
582 700 71
201
057 563 57 057 563 56
Anschlußstecker ESX 7265 057 563 58 057 563 55
connector ESX 7265
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
057 563 54
057 564 21
057 564 22
057 564 24 057 564 20 057 564 25
057 564 35
11
10
13
15
16
17
19
91
12
18
21
14
30
93
20
23
25
26
27
29
92
22
28
94
24
5
6
7
9
8
1
4
3
2
X2:
A37 A46
F67
F84
582 701 38 057 664 70

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

additional electrical equipment for variocontrol
14.06.2000
1 1 582 700 71
Werner Schaltkastenübersicht für Zusazelektrik Variocontrol
14.06.2000
Seis overview e−box for additional equipment variocontrol 202

Service Training Overview

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Service Training

Single Drum Rollers

008 098 14 Edition 04/2000

Cummins Diesel engine C1

Trouble shooting travel system DTr 1

Trouble shooting vibration system ETr 1

Trouble shooting steering system FTr 1

BW 156/177 D-3/DH-3/PDH-3 -A1-

1. Operating and maintenance instructions

2. Spare parts catalogue

3. Electric circuit diagram*

BW 156/177 D-3/DH-3/PDH-3 -A2-

* These documents are part of this training manual

BW 156/177 D-3/DH-3/PDH-3 -A3-

BW 156/177 D-3/DH-3/PDH-3 -A4-

• strong ROPS/FOPS according to SAE-standard

• wear free service brake by closed hydrostatic travel circuits

• multi-disc brakes in planetary gears as parking and emergency brakes

BW 156/177 D-3/DH-3/PDH-3 -A5-

BW 156/177 D-3/PD-3 -B1-

Travel motor (drum)

BW 156/177 D-3/PD-3 -B2-

Travel motor (axle)

BW 156/177 D-3/PD-3 -B3-

Coolant (50% water/50% anti-freeze) l 15

BW 156/177 D-3/PD-3 -B4-

Manufacturer Cummins Cummins

Manufacturer Sauer Sauer

Travel motor (drum)

Manufacturer Sauer Sauer

BW 156/177 D-3/PD-3 -B5-

Reduction gear (drum)

Manufacturer Lohmann + Stolterfoth Lohmann + Stolterfoth

Travel motor (axle)

Manufacturer Sauer Sauer

Manufacturer Clark-Hurth Clark-Hurth

Manufacturer Sauer Sauer

Manufacturer Sauer Sauer

BW 156/177 D-3/PD-3 -B6-

Manufacturer Bosch Bosch

Manufacturer Danfoss Danfoss

Coolant (50% water/50% anti-freeze) l 15 15

BW 156/177 D-3/PD-3 -B7-

Travel motor (drum)

BW 156/177 D-3/PD-3 -B8-

Travel motor (axle)

BW 156/177 D-3/PD-3 -B9-

Coolant (50% water/50% anti-freeze) l 15

Manufacturer Cummins Cummins

Manufacturer Sauer Sauer

Travel motor (drum)

Manufacturer Sauer Sauer

Reduction gear (drum)

Manufacturer Lohmann + Stolterfoth Lohmann + Stolterfoth

Travel motor (axle)

Manufacturer Sauer Sauer

Manufacturer Clark-Hurth Clark-Hurth

Manufacturer Sauer Sauer

Manufacturer Sauer Sauer

Manufacturer Bosch Bosch

Manufacturer Danfoss Danfoss

Coolant (50% water/50% anti-freeze) l 15 15