BW216-219DH-4 Service Training PDF

Service Training
Single Drum Rollers

BW 216 DH / PDH - 4
BW 219 DH / PDH - 4
BW 226 DH / PDH - 4
Part-No. 008 097 20 08/2005

Service Training
Table of contents
Foreword A1
Documentation A2
General A3
New features A5
Technical data and adjustment values B1
Maintenance C1
Maintenance chart and table of fuels and lubricants C2
DEUTZ diesel engine 2012C with EMR D1

Service side D2
Starter side D3
Lubrication oil circuit D4
Coolant circuit D5
Fuel system D6
EMR D10
Trouble shooting D22
Diagnostics SERDIA D24
Checking and adjusting the valve clearance D26
Assembly of plug-type injection pump D28
Engine components D44
Travel system E1
Travel pump E3
Control E7
Charge pressure relief valve E8
High pressure relief valve E9
Pressure override valve E11
Axle drive motor E14
Drum drive motor E17
Test and adjustment points, travel system E19
Trouble shooting travel system E27
BW 216 / 219 / 226 DH / PDH -4

Service Training
Vibration F1
Vibration pump F3
High pressure relief valves F6
Control F7
Vibration motor F8
Drum F11
Test and adjustment points, vibration system F13
Trouble shooting vibration F15
Steering G1
Charge pump G2
Steering pump G3
Steering valve G5
Articulated joint G7
Measuring and adjustment points G9
Trouble shooting steering G10
Electrics H1
Wiring diagram
Hydraulic diagram
BW 216 / 219 / 226 DH / PDH -4

Service Training
Foreword and new features
Reliable construction equipment is of greatest advantage for all parties involved:
• for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
• in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
• for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
• the location of components in the machine eases maintenance work,
• the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
• the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.
BW 216 / 219 / 226 DH / PDH -4 -A1-

Service Training
Documentation
This Service Training is valid for the following BOMAG single drum rollers of series 4:
BW 216 DH / PDH -4
BW 219 DH / PDH-4
BW 226 DH / PDH-4
with Deutz diesel engine BF6M 2012C EMR
For the BOMAG machines described in this training manual the following documentation is additionally
available:
1. Operating and maintenance instructions

2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.
BW 216 / 219 / 226 DH / PDH -4 -A2-

Service Training
General
The new BOMAG single drum rollers of series 4 are mainly further developments of their predecessors
of series 3.
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 display with light emitting diodes and clear pictograms informs the operator about any
operating faults. The operator is therefore always informed about the present condition of the machine.
The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens,
as well as a heated rear windscreen, offers clear vision to all sides.
BW 216 / 219 / 226 DH / PDH -4 -A3-

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
• disc brakes in axle and drum drive motor serve as parking and emergency brakes
• high stability due to low centre of gravity and the use of an articulated joint
• operating safety due to the use of monitoring boards for all important system data
• automatic engine shut down after 15 seconds, if the engine temperature is too high
• automatic engine shut down after 10 seconds, if the coolant level is too low
and the engine oil pressure is too low.
The single drum rollers of series 4 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 216 / 219 / 226 DH / PDH -4 -A4-

Service Training
New features
The multi-function travel lever and the display
Back Front
up
down
BW 216 / 219 / 226 DH / PDH -4 -A5-

Service Training
Control, operation, data collector,
BW 216 / 219 226 DH / PDH -4 -A -

Service Training
Translation
Rückseite Back
Vorderseite Front
Rechts Right
Auf Up
Vibr. Taste Vibr. button
Links Left
Ab Down
INFO Teste 1 INFO button 1
INFO Taste 2 INFO button 2
Translation:
Fahrhebel Travel lever

Datensammler Data collector
Luftfilter Air filter
Blink. L Indic. l
Blink. R Indic. r
Licht an Lights on
D+ Signal D+ signal
Hyd. Ölfilt. Hyd. oil filter
Hyd. Temp. Hyd. temp.
Klimaanl. Aircon
Ampere Ampere
Wasserab. Water separ.
Kühl. Füll. Coolant level
Fahrhebel Travel lever

Stufenschalter Speed range switch
Sitzkontaktschalter Seat contact switch
Drucksensor Pressure sensor
Verstellung Control
Sensor Sensor
Vorderrahmen Front frame
Hinterrahmen Rear frame
Verstellung Control
Fahrmotor vorne Front travel motor
Neigungssensor Inclination sensor
Sensor Sensor
Verstellung Control
Fahrmotor hinten Rear vtravel motor
Fahrpumpe Travel pump
BW 216 / 219 226 DH / PDH -4 -A -

Service Training
Diesel engine with EMR
BW 216 / 219 / 226 DH / PDH -4 -A -

Service Training
Travel System
BW 216 / 219 / 226 DH / PDH -4 -A -

Service Training
Technical data and adjustment values
The following pages contain technical data valid at the date of printing (see front page of this manual).
Attention!
The currently valid technical data and adjustment values can be taken from the BOMAG Intranet
or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.
BW 216 / 219 / 226 DH / PDH -4 -B1-

BOMAG Central Service Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values
Status: 2005-08-05
Product type: BW 216 DH Serie 4

Type No.: 582 60
Serial numbers from: 101 582 60 1001
Engine:
Type: BF6M2012C
Combustion principle: 4-stroke-Diesel
Cooling: Water
Number of cylinders: 6
Power acc. to ISO 9249: 147 kW
Power data at nominal speed of: 2300 1/min
Low idle speed: 850+/-150 1/min
High idle speed: 2475+/-125 1/min
Spec. fuel consumption: 222 g/kWh
Valve clearance, inlet: 0,3 mm
Valve clearance, outlet: 0,5 mm
Opening pressure, injection valves: 250 bar
Starter voltage: 12 V
Starter power: 3,1 kW
Travel pump:
Type: 90R 075 (EP)
System: Axial piston-swash plate
Max. displacement: 75 cm3/U
Max. flow ratio: 75ccm x n l/min
High pressure limitation: 400 bar
Charge pressure, high idle: 25+/-1 bar
Reduction gear, drum:

Type: CR 51
Transmission ratio: 73,5
Travel motor, rear:

Type: 51D110 (EP)
System: Axial piston-bent axle
Max. displacement (stage 1): 110 cm3/U
Min. displacement (stage 2): 55,3 cm3/U
Perm. leak oil quantity: 2 + 10 l/min
Rinsing oil quantity: 10 l/min
Rinsing oil pressure limitation: 16 bar
Drum drive:
Type: 51C 110 (EP)
Displacement stage 1:
http://bsa.bomag.spx.com/bsa/tk_components/english/search_components_result.asp?... 05.08.2005
110 cm3/U
Displacement stage 2: 31,4 cm3/U
Vibration pump:
Type: 90R 075 (EP)
Starting pressure: 365+/-65 bar
Operating pressure, soil dependent: ca.100 bar
Vibration motor:
Type: A2FM 56 HDD
Displacement: 56 cm3/U
Frequency: 31 / 36 Hz
Amplitude: 2,0/0,9 mm
Steering and charge pump:

Type: HY/ZFS11/16
System: Gear pump
Max. steering pressure: 175+26 bar
Rear axle:
Type: CHC 193/66LD
Differential: No-Spin
Degree of locking: 100 %
Reduction ratio: 65,08
Filling capacities:
Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on
Ethane-diol-basis)
Engine oil: 12,5 l (SAE 15W-40, API CG-4 (for details see
maintenance manual))
Hydraulic oil: 60 l (HVLP 46 VI 150)
Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF)
Rear axle: 11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs: 2 l (SAE 90 EP, API GL 5)
Rear axle, transmission: 1,9 l (SAE 90 EP, API GL 5)
Reduction gear, drum: 3,2 l (SAE 90 EP, API GL 5)
AC refrigerant: 1400 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG Öl)
Status: 2005-08-05

Type No.: 582 70
Engine:
Type: BF6M2012C
Cooling: Water
Travel pump:
Type: 90R 100 EP
High pressure limitation: 435 +/-15 bar

Type: CR 51
Travel motor, rear:

Type: 51D110 (EP)
Drum drive:
Type: 51C 110 (EP)
110 cm3/U
Vibration pump:
Type: 90R 075 (EP)
Vibration motor:
Type: A2FM 63 HDD

Type: HY/ZFS11/16
System: Gear pump
Rear axle:
Type: CHC 193/55
Filling capacities:
Ethane-diol-basis)
Reduction gear, drum: 3,2 l (SAE 90 EP, API GL 5)
AC refrigerant: 1400 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG Öl)
Status: 2005-08-05

Type No.: 582 80
Engine:
Type: BF6M2012C
Cooling: Water
Travel pump:
Type: 90R 100 EP
High pressure limitation: 435 +/-15 bar

Type: 715 C 3B
Travel motor, rear:

Type: 51D110 (EP)
Drum drive:
Type: 51C 110 (EP)
110 cm3/U
Vibration pump:
Type: 90R 075 (EP)
Vibration motor:
Type: A2FM 80 HDD

Type: HY/ZFS11/16
System: Gear pump
Steering valve:
Type: OSPC 500 ON
System: Rotary valve
Rear axle:
Type: CHC 193/55
Filling capacities:
Ethane-diol-basis)
Service Training
Maintenance
Single drum rollers are heavy-duty construction machines for extremely difficult tasks in earth
construction. To be able to meet these demands the machines must always be ready to be loaded up
to their limits. Furthermore, all safety installations, protections and guards must always be in place and
fully functional.
Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably
higher functional safety, but also prolongs the lifetime of the machine and of important components.
The time required for thorough maintenance is only minor when being compared with the malfunctions
and faults that may occur if these instructions are not observed.
The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance
interval all the work for shorter preceding intervals must also be performed. During the 2000 hours
interval you must also perform the work described for the service intervals after 50, 250 and 500 hours.
During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and
lubricants (oils, fuels, grease etc.).
The designation specified under No: in the first column of the maintenance chart refers to the
corresponding number of the service work to be performed, as specified in the operating and
maintenance instructions. This also helps to find detailed information on the individual
maintenance tasks.
BW 216 / 219 / 226 DH / PDH - 4 -C1-

Maintenance
5.3 Table of fuels and lubri-

cants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention

Observe the level marks
Engine Engine oil ACEA: E3-96/E5-02 or approx. 12,5 litres without

oil filter
API: CG-4/CH-4
SAE 10W/40
(-20 °C to +40 °C)
SAE 15W/40
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 300 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm2/s at 40 °C
Vibration bearings Engine oil SAE 15W/40 approx. 2x0.8 litres
Drive axle Gear oil SAE 90, API GL5 approx. 11 litres
Wheel hubs Gear oil SAE 90, API GL5 approx. 2.9 per side
Axle reduction gear Gear oil SAE 90, API GL5 approx. 1,9 litres
Drum drive gear Gear oil SAE 90, API GL5 approx. 2,8 litres
Air conditioning system Refrigerant R134A 1400 g
Engine cooling system Cooling system protection agent approx. 16 litres
Tires Water approx. 195 litres
Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg

(MgCl2)
82 BOMAG BW 216 DH-4

Maintenance
5.4 Running-in instructions
The following maintenance work must be per-

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

l Retighten the V-belt
After 250 operating hours

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

l 2. Oil change vibration bearings
l 2. Oil change, drum drive reduction gear
BW 216 DH-4 BOMAG 83

Maintenance
5.5 Maintenance chart
every 10 operating hours, daily
every 1000 operating hours


after 250 operating hours
Running-in instructions
No. Maintenance work Remark
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Check the dust separator X
5.12 Check the tire pressure X
5.13 Clean the cooling fins on engine and X
hydraulic oil cooler
5.14 Check the oil level in the drive axle X
5.15 Check the oil level in the wheel hubs X
5.16 Check the oil level in the axle reduc- X
tion gear
5.17 Check the oil level in the drum reduc- X
tion gear
5.18 Check the oil level in the vibration X
bearings
5.19 Change engine oil and oil filter car- min. 1x per year X
tridge*
5.20 Change the fuel filter cartridge X
5.21 Drain the sludge from the fuel tank X
5.22 Service the battery Pole grease X
5.23 Change the fuel pre-filter cartridge X

Maintenance


as required
5.24 Check, replace the refrigerant com- X
pressor V-belt
5.25 Service the air conditioning X
5.26 Check, adjust the valve clearance Intake = 0,3 mm X
Exhaust = 0,5 mm
5.27 Check, replace the ribbed V-belt X
5.28 Check the engine mounts X X
5.29 Oil change in drive axle min. 1x per year X X
5.30 Oil change in wheel hubs min. 1x per year X X
5.31 Oil change, axle reduction gear min. 1x per year X X
5.32 Oil change in drum drive reduction min. 1x per year X X
gear**
5.33 Oil change vibration bearings** see foot note, min. 1 X X
x per year
5.34 Retighten the fastening of the axle on X
the frame
5.35 Tighten the wheel nuts X X
5.36 Check the ROPS X
5.37 Clean the oil bath air filter min. 1x per year X
5.38 Change hydraulic oil and breather fil- at least every 2 X
ter*** years
5.39 Change the hydraulic oil filter**** at least every 2 X
years
5.40 Change the coolant at least every 2 X
years
5.41 Check the injection valves X
BW 216 DH-4 BOMAG 85

Maintenance


as required
5.42 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2 years
5.43 Adjusting the scrapers X
5.44 Adjust the parking brake X
5.45 Change the tires X
5.46 Change the fresh air filter in the cabin X
5.47 Tightening torques X
5.48 Engine conservation X
* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h.
*** Also in case of repair in the hydraulic system.
**** Also in case of repair in the hydraulic system.

Maintenance
5.3 Table of fuels and lubri-

cants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention

Observe the level marks
Engine Engine oil ACEA: E3-96/E5-02 or approx. 12,5 litres without

oil filter
API: CG-4/CH-4
SAE 10W/40
(-20 °C to +40 °C)
SAE 15W/40
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 150 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm2/s at 40 °C
Vibration bearings Engine oil SAE 15W/40 approx. 2 x 1,8 litres
Drive axle Gear oil SAE 90, API GL5 approx. 12,5 litres
Wheel hubs Gear oil SAE 90, API GL5 approx3.5 l per side
Axle reduction gear Gear oil SAE 90, API GL5 approx. 1,9 litres
Drum drive gear Gear oil SAE 90, API GL5 approx. 7,5 litres
Air conditioning system Refrigerant R134A
Engine cooling system Cooling system protection agent approx. 16 litres
Tires Water approx. 390 litres
Calcium chloride (CaCl2) or magnesium chloride approx. 130 kg

(MgCl2)
62 BOMAG BW 226 DH-4/PDH-4

Maintenance
5.4 Running-in instructions
The following maintenance work must be per-

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

l Retighten the V-belt

l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.
l Retighten all wheel fastening screws with the
specified tightening torque.
l Oil change vibration bearings
l Oil change in drive axle
l Oil change in wheel hubs
l Oil change, axle reduction gear
l Oil change, drum drive reduction gear

l Oil change vibration bearings
BW 226 DH-4/PDH-4 BOMAG 63

Maintenance
5.5 Maintenance chart


as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Check the dust separator X
5.12 Check the tire pressure X
5.13 Clean the cooling fins on engine and X
hydraulic oil cooler
5.14 Check the oil level in the drive axle X
5.15 Check the oil level in the wheel hubs X
5.16 Check the oil level in the axle reduc- X
tion gear
5.17 Check the oil level in the drum reduc- X
tion gear
5.18 Check the oil level in the vibration X
bearings
5.19 Change engine oil and oil filter car- min. 1x per year X
tridge*
5.20 Change the fuel filter cartridge X
5.21 Drain the sludge from the fuel tank X
5.22 Service the battery Pole grease X
5.23 Change the fuel pre-filter cartridge X

Maintenance


as required
5.24 Check, replace the refrigerant com- X
pressor V-belt
5.25 Service the air conditioning X
5.26 Check, adjust the valve clearance Intake = 0,3 mm X
Exhaust = 0,5 mm
5.27 Check, replace the ribbed V-belt X
5.28 Check the engine mounts X X
5.29 Oil change in drive axle min. 1x per year X X
5.30 Oil change in wheel hubs min. 1x per year X X
5.31 Oil change, axle reduction gear min. 1x per year X X
5.32 Oil change in drum drive reduction min. 1x per year X X
gear
5.33 Oil change vibration bearings** see foot note, min. 1 X X
x per year
5.34 Retighten the fastening of the axle on X
the frame
5.35 Tighten the wheel nuts X X
5.36 Check the ROPS X
5.37 Clean the oil bath air filter min. 1x per year X
5.38 Change hydraulic oil and breather fil- at least every 2 X
ter*** years
5.39 Change the hydraulic oil filter**** at least every 2 X
years
5.40 Change the coolant at least every 2 X
years
5.41 Check the injection valves X
BW 226 DH-4/PDH-4 BOMAG 65

Maintenance


as required
5.42 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2 years
5.43 Adjust the scrapers X
5.44 Adjust the parking brake X
5.45 Change the tires X
5.46 Change the fresh air filter in the cabin X
5.47 Tightening torques X
5.48 Engine conservation X
* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h.
*** Also in case of repair in the hydraulic system.
**** Also in case of repair in the hydraulic system.

Service Training
Deutz diesel engine
The single drum rollers of product range BW 216 / 219 / 226 DH/PDH-4 are powered by a Deutz diesel
engine of series BF6M 2012 COM2 with electronic engine management (EMR). The engine cooling
system uses an external radiator. The cooling fan is mounted to the engine fan block and is directly
driven by the engine.
These engines are characterized by the following positive features:
• short and compact design,
• low noise level,
• almost vibration-free running,
• low fuel consumption,
• low exhaust emissions (EPA II),
• high power reserves and
• good access to all service points.
Crankcase and cylinders of this engine are made of alloyed cast iron. This provides strength and
ensures high wear resistance.
The forged steel conrods are fitted with compensation weights near the conrod bearing seats. These
weights compensate manufacturing tolerances with respect to weight and centre of gravity.
The pistons are made of an aluminium alloy. The combustion chamber recess is slightly offset from the
middle at its side walls are inclined for 10° towards the inside. All pistons are fitted with three piston rings
and a cast iron ring carrier for the first ring. The pistons are lubricated by an oil mist.
The forged crankshaft is equipped with integrated counterweights.
The block-type cylinder head is made of cast steel. Each cylinder is fitted with one intake and one
exhaust valve. The valve guides are shrunk into the cylinder head. The valve seat rings are made of
high-grade steel and are also shrink fitted.
BW 216 / 219 / 226 DH / PDH -4 -D1-

Service Training
Service side
3 4
2
5
6
14
9 8
13 12 11 10
Fig. 1: Service side BFM 2012
1 Oil filler neck 8 Fuel pump

2 Valve, boost fuel supply 9 Engine mounting
3 Engine solenoid 10 Fuel filter
4 Oil pressure switch 11 Lubrication oil filter
5 Cooling air blower 12 Oil sump
6 Coolant pump 13 Dipstick
7 V-belt pulley 14 Steering/charge pump
BW 216 / 219 / 226 DH / PDH -4 -D2-

Service Training
Starter side
3
1
Fig. 2: Starter side
1 Flywheel
2 Ground cable
3 Starter
4 Turbo charger
5 Generator
6 Coolant temperature switch
BW 216 / 219 / 226 DH / PDH -4 -D3-

Service Training
Lubrication oil circuit
3 4 5 6 7 8 9 10 11 12 13 14 15
2 1 22 21 20 19 18 17 16
Fig. 3: Lubrication oil circuit
1 Oil sump 12 Piston cooling nozzle

2 Return flow turbo charger to crankcase 13 Camshaft bearing
3 Turbo charger 14 Main oil channel
4 Oil line to turbo charger 15 Lubrication oil cooler
5 Line to mass balance wheel (2 x) 16 Lubrication oil pump
6 Oil pressure sensor 17 Pressure relief valve
7 Valve with pulse lubrication 18 Leak oil return line
8 Push rod, oil supply to rocker arms 19 Lubrication oil filter
9 Line to spray nozzles 20 Suction line
10 Rocker arm 21 Crankshaft bearing
11 Return flow to oil sump 22 Conrod bearing
BW 216 / 219 / 226 DH / PDH -4 -D4-

Service Training
Lubrication oil circuit
3 1
5 4
Fig. 4: Lubrication oil circuit
1 Cooler
2 To cooler
3 From cooler
4 Coolant pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder head cooling
8 Ventilation connection between cylinder head and heat exchanger
BW 216 / 219 / 226 DH / PDH -4 -D5-

Service Training
FuelFuel system
7
1a
1b
1c
Fuel tank
1d
Fig. 5: Fuel system
BW 216 / 219 / 226 DH / PDH -4 -D6-

Service Training
Legend Fig. 6:
1a Fuel lift pump
1b Fuel pre-filter
1c Water separator
1d) Water proportion sensor
2 Feed to fuel lift pump
3 Fuel lift pump
4 Connecting line lift pump – main filter (fuel pre-pressure up to 10 bar)
5 Main fuel filter (pressure resistant)
6 Connecting line main filter – supply for injection pump
7 Single injection pump
8 High pressure line
9 Injection nozzle
10 Leakage line
11 Pressure retaining valve - 5 bar
12 Return flow to tank
BW 216 / 219 / 226 DH / PDH -4 -D7-

Service Training
Fuel pre-filter with water separator
1
2
Fig. 6: Fuel pre-filter with water separator
1) Lift pump
2) Vent valve
3 Filter element
4) Water and dirt collecting bowl
5 Drain valve
6 Electric connection for water level sensor
The fuel pre-filter / water separator consists mainly of:
• the dirt / water sediment bowl with water level warning sensor
• and the filter element
BW 216 / 219 / 226 DH / PDH -4 -D8-

Service Training
Function:
The fuel lift pump draws the fuel through both filters.
The water resistant filter element retains remaining smaller dirt and water particles.
Once the water level reaches the height of the warning connections, the warning light in the dashboard
lights up.
Draining off water or fuel :
If the filter element is clogged before a service is due (indicated by e.g. a power drop), the filter may be
regenerated as follows to keep up operation of the engine:
• Open the bleeding screw (this applies atmospheric pressure to the filter element and releases bigger
dirt particles from the bottom side of the filter, which will then sink down.
• Open the drain valve and let approx. 0.5 l of fuel run out. The fuel above the filter element presses
through the filter element and cleans the underside of the filter element from dirt.
• Close the drain valve.
Draining off larger dirt particles or sludge:
• Unscrew the water separator housing
Bleed the system by operating the fuel lift pump and then tighten the bleeding screw.
Main fuel filter
Attention!
The main fuel filter is subjected to approx. 10 bar fuel pre-pressure from the fuel lift pump. This
pressure is considerably higher than on other engines. For this reason only original filter
elements must be used. Filter elements of similar design or with adequate dimensions are not
necessarily pressure resistant!
A filter element of insufficient pressure resistance will be damaged by the high pressure and will
disintegrate. This causes severe damage to the injection system!
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Service Training
Electronic engine control EMR II
The Deutz engines in single drum rollers DH-4 are equipped with an electronic engine speed control
(Deutz EMR II).
The most important benefits of this system are:
• shorter response times compared with mechanically controlled engines, i.e. the response times are
significantly better. This improvement is achieved without increasing the acceleration fumes or the
fuel consumption.
• electronic idle speed control enabling a higher starting torque
• no mechanical throttle control (light moving, maintenance free, less susceptible for faults)
• in comparison to the first version of the Deutz-EMR the essential advantage is

that an EMR-fault is directly displayed in form of a fault code.
The EMR-injection system is based on the approved Deutz-injection system of series 2012 with
individual injection pumps for each cylinder. However, the fuel quantity per stroke is not regulated
mechanically via a throttle cable, but is controlled by the EMR II-system by means of an electromagnetic
actuator acting on the governor rod.
The essential components of the EMR II-system for engine speed control are:
• EMR II control unit [A48] at the left under the operator's stand.
• The control unit processes the input signals from:
• displacement measuring system in the EMR actuator [Y 137] (current position of the injection pump
control rod)
• the coolant temperature sensor [B 113] on the cylinder head
• the rotary speed sensor [B 114] on the camshaft
• the engine oil pressure sensor [B 88] on the oil filter housing
• the charge air pressure and charge air temperature sensor [B 115] connected to the intake manifold
• The cold start device (heating flange) is additionally triggered by the EMR II in dependence on the
coolant temperature
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Service Training
These input signals are processed, sent as output signals to the EMR actuator Y 137 and there they are
converted to the required fuel quantity per stroke.
In ECO-mode the travel lever determines the engine speed setpoint. The control unit compares this
nominal value with the actual speed value detected by the engine speed sensor. If the nominal value
corresponds with the actual value, the signal to the EMR actuator will remain unchanged.
However, if the nominal speed deviates from the actual speed (e.g. when changing the travel lever
position or under higher load), the control unit uses the current turbo charger pressure and the coolant
temperature to determine the necessary change in fuel quantity to achieve the nominal speed value.
The control unit then sends a signal to the EMR actuator to change the control rod position and thereby
the engine speed.
This automatic speed adaptation only takes place in ECO-mode (in

the first DH-4 machines this was called "AUTO")
Throttle control lever
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Service Training
Individual EMR II components
Control unit EMR II
The EMR control unit is located above the central electrics under the operator's stand in the access
area. This is the computer unit of the EMR and it processes the input signals from the sensors to output
signals for the EMR actuator (governor rod).
1
2
3
Pos. Designation Pos. in wiring Deutz Measuring

diagram designation values
1 Control unit EMR II A 48 EMR II
2 Plug, engine side X 31
3 Plug, vehicle side X 30
BW 216 / 219 / 226 DH / PDH -4 - D 12 -

Plug, engine side [X31] Plug on vehicle [X30]
Control unit
EMR II
15
Pin assignment X 31 19 16 8 12 21 25 23 10 3 4 6
14 17 18 9 13 22 20 21 11 2 1 5 7
BW 216 / 219 / 226 DH / PDH -4

Connecting cable
Engine wiring harness
Control unit EMR II
EMR central plug engine [X57] Pin assignment complies with X 31
EMR engine wiring harness

Connection overview EMR sensors/actuators on engine
EMR-actuator Temperature Speed Pressure Pressure and temp. Speed

Y 137 Coolant Flywheel Engine oil Charge air Crankshaft
B 113 B 114 B 88 B 115 B 130
Service Training
- D 13 -
Service Training
Plug assignment X 31 (engine plug on EMR control unit)
Pos. Deutz designation Description

1 Spare Spare
2 not used
3 Output: Digital 4 Switching output heating flange (ground!)
4 empty
5 Input temp. (option) Charge air temperature
6 empty
7 empty
8 GND Reference potential for signal pin 9 coolant
temperature sensor B 113
9 Input: Analogue 7 Analogue input coolant temperature
sensor B 113
10 GND Reference potential Pin 11 crankshaft
speed sensor B 130
11 Input: Speed 2 Digital input rotary speed sensor
crankshaft B 130
12 GND Reference potential Pin 13 camshaft
speed sensor B 114
13 Input: Speed 1 Digital input rotary speed sensor camshaft
B 114
14 STG - PWM-output, signal for EMR-actuator coil
Y 137
15 STG + PWM-output, signal for EMR-actuator coil
Y 137
16 Screen not used
17 RF - common connection for reference and
measuring coil EMR-actuator Y 137
18 RF REF analogue input, measuring signal of
reference coil of EMR-actuator Y 137
19 RF MESS analogue input, measuring signal of
measuring coil of EMR-actuator Y 137
20 GND Reference potential for signal on pin 21, oil
pressure sensor B 88
21 Input: Analogue 4 Analogue input, sensor signal oil pressure
sensor B 88
22 +5V REF + 5 V reference voltage for signal on Pin
21, oil pressure sensor S 88
23 GND Reference potential for signal on pin 24,
boost pressure sensor B 115
24 Input: Analogue 2 Analogue input, sensor signal boost
pressure B 115
25 + 5V LDA + 5 V reference voltage for signal on pin 24
(max. 15mA), boost pressure sensor B 115
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Service Training
Plug assignment X 30 (vehicle plug on EMR control unit)
Pos. Designation Description

1 U Batt - Vehicle ground through X1:182
2
3
4
5 Output: Digital/ empty
PWM 1
6 Spare Spare
7 NC empty
8 NC empty
9 NC empty
10 L-line to diagnostics plug EMR, X32:L
11 K-line to diagnostics plug EMR, X32:K
12 CAN high X1:180, CAN2-
13 CAN low X1:181, CAN2+
14 U Batt + Power supply, vehicle voltage (ignition
on) from relay K11, X1:179
15
16 Output: Digital/ empty
PWM/Frequency
17 Ground empty
18 Input: digital/PWM empty
1
19 Input: digital / empty
analogue
20 Input: digital / empty
analogue
21 Input: digital/PWM empty
2
22
23
24
25
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Service Training
EMR actuator Y 137
The EMR actuator is directly connected with the governor rod of the injection pump and moves this rod
by being excited by the signal currents from the EMR control unit. At the same time the actual position
of the actuator is fed back to the EMR control unit. This component is generally a proportional magnet
with integrated path measuring system.
In case of a fault in the path measuring system the engine is shut down and a fault code displayed.
Pin assignment EMR-actua

view on actuator
8 (plug pins
mirror inverted)
2 Stg+
7
3 RF -
1 Stg+
9 4 RFMeß 6
5 RF Ref
Pin assignment of EMR-actuator looking towards actuator (plug pins mirror inverted)
EMR-actuator

Pin 1 Signal input actuator coil STG -
Pin 2 Signal input actuator coil STG +
Pin 3 common connection for measuring RF -
and reference coil
Pin 4 Measuring signals measuring coil RF MESS
Pin 5 Measuring signals reference coil RF REF
Pin 6 not used
Pin 7 not used
8 EMR-plug X 57
9 EMR-actuator Y 137
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Service Training
Temperature sensor B 113
The EMR coolant temperature sensor is mounted to the flywheel end of the engine. The EMR sensor
is the bottom sensor.
The coolant temperature influences the calculated injection quantity of the EMR.
The EMR sensor value is not only used for the EMR itself, but also for the high coolant temperature
control light in the display and for the heating flange control.
In case of a too high temperature the EMR shuts down the engine and a fault code is displayed.
In case of a sensor failure the display shows a fault code.

1 EMR temperature sensor for B 113 Switching point
coolant 110°C
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Service Training
Speed sensors: Camshaft B114 and crankshaft B 130
The sensors for camshaft and crankshaft speeds are installed in the side of the engine block.
These sensors deliver the actual engine speed value for the EMR control unit.
If the engine speed is too high (pushing operation) the governor rod is returned to zero position, until the
speed has dropped to the permissible range.
In case of a sensor failure the engine is shut down and the fault code appears in the display.
With a missing rotary speed signal from standstill the engine will not start, however, no fault message
will be displayed, because the EMR assumes that the engine is at standstill and does therefore not
release any fuel.
The EMR speed sensor has a fixed stop and does not need to be adjusted after installation.
1
1
22

1 EMR speed sensor camshaft SAE B 114
housing
2 EMR speed sensor crankshaft SAE B 130
housing
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Service Training
Engine oil pressure sensor B88
The engine oil pressure sensor is mounted on the engine oil filter housing. The oil pressure is
permanently monitored by the EMR.
With a too low engine oil pressure the display shows a fault code.
• In case of a too low pressure the EMR shuts down the engine and a fault code is displayed.
• In case of a sensor cable defect or a broken sensor cable the engine keeps on running and the
display shows a fault code.
Pin 3 (+ 5 V from EMR)
Pin 2 (Signal)
Pin 1 (AGND)
Ventilation
Ventilation
Fig. 7Oil pressure sensor

1 EMR oil pressure sensor B 88
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Service Training
Charge air pressure and temperature sensor B 115
The Deutz engine BF4M 2012C (EMR) is fitted with a combination sensor for charge air pressure and
charge air temperature. This sensor measures the pressure and temperature in the intake manifold. The
sensor itself is located on the intake manifold. Charge air pressure and charge air temperature inform
the EMR about the actual load state of the engine.
1
1

1 EMR charge air pressure and B 115
temperature sensor
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Service Training
Heating flange R 19
Instead of glow plugs this engine is fitted with a heating flange before the intake air manifold, which
heats up the passing air with resistance heated wires when the engine is cold. This system is electrically
supplied via high current relay K14, located to the left next to the engine. This high current relay is
triggered by the EMR-control unit (ground triggering) in dependence on the coolant temperature.
1
2
2
1
1
2

1 Heating flange R 19
2 High current relay K14
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Service Training
Trouble shooting
The display shows the fault codes
For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)
All electric faults are mainly shown by the display
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Service Training WZ-4 DH Version and higher
2 Selected Fault Reactions of the ESX Control

Reaktion Symbol in fault Warning Warning Engine stop
message display
Signal Code output Code output Code output
without buzzer with buzzer with buzzer
Engine oil pressure

(from EMR) 5100 5101
5112 5112
1) 2)
after 10s
Coolant temperature
(from EMR)
5100 5101
5116 5116
1) 2)
after 15s
Coolant level
5024 5025
after 5s after 10s
Engine air filter
5026 5027
after 5s after 2min. 3)
Charge control
Preheating of engine
Brake
ASC
Various error causes and reaction times.
See error codes
Hydraulic oil filter
5502 5503
after 5s after 2min.
Water separator in fuel filter
5028 5029
Ant-theft warning display
(Option)
Seat contact
(Option)
Air conditioning fault

(Option)
1) 3)
After reaching the warning limit! Shut-down currently deactivated via parameter
Version/Status: V2.07 / 24.06.05 Page 6 of 67

Author: Seis / TE
Dateiname: p:\schulung\wz-4\elektrik\esx\englisch\schulung elektrik wz4 v2_07_gb.doc
Service Training
Possible diagnostics with SERDIA
with fault code 5140: a fault diagnose is only possible via SERDIA
SERDIA is a software program from Deutz which can be used in connection with a laptop computer to
perform more detailed fault analyses, especially reading out of the error log.
This displays information on
• Fault location (e.g. ’sensor’, ’coolant temperature sensor’)
• Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)
• Environmental data / operating data (speed and operating hours at the time of the last fault
occurrence)
• Number of fault locations
• Frequency of fault
• Fault status (active – fault present / passive- fault no longer present)
Fault messages for non-present / rectified faults can be deleted with SERDIA.
Further display possibilities:
• Function test: With the engine shut down the control outputs and the travel of the governor rod can
be activated.
• Assignment of inputs/outputs Display of the current input/output assignment of the EMR-control
• Representation of measuring values: There are a lot of measuring values available which can be
used if no EMR II fault is present (starting performance, engine sawing, lack of power).
Operation of SERDIA is described in a separate operation manual.
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Service Training
Connection of SERDIA (in electric installation box)
For this purpose the PC or Laptop is connected to the diagnostic interface with a special interface cable.
The EMR diagnostics plug is located in the electric installation box of the machine.
EMR
Replacement of system components
• Replacement of the EMR II-control unit:

Each control unit is clearly designated to the engine, in accordance with the respective application.
In case of a replacement the control unit therefore needs to be completed with the engine specific
data set. When ordering a new control unit you must not only specify the part-number, but also the
engine serial number (see sticker on EMR-control unit).
Note: The Deutz part-number specified on the EMR-control unit is the part number without software
specific for the engine. The correct part number can be found in the spare parts catalogue.
• Replacement of the EMR actuator (Y137)

On engines of types 1013 and 2012 the actuators can be replaced without any additional
programming of the control unit.
• Replacement of other EMR-components

All other EMR-components (sensors etc.) must not be repaired, but should only be replaced if they
are faulty. Programming of the control unit is not required
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Service Training
Checking and adjusting the valve clearance
Excessive or insufficient valve clearance can cause failure of the engine as a result of mechanical and
thermal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the
intervals specified in the operating and maintenance instructions.
Note: The valve clearance must be checked and adjusted when the engine is cold.
Intake valve: = 0.3 mm
Exhaust valve= 0.5 mm
• Turn the crankshaft until both valves on cylinder 1 are overlapping (the exhaust valve is not yet
closed, the intake valve starts to open).
Flywheel
side
1 2 3 4
Fig. 9: Crankshaft position 1
• Check and adjust the valve clearance by following the black marking in the adjustment schematics.
For control purposes mark the respective rocker arm with chalk.
Flywheel
side
1 2 3 4
Fig. 10: Crankshaft position 2
• Turn the crankshaft one full turn (360°) further. Check

and adjust the valve clearance by following the black marking in the adjustment schematics.
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Service Training
plug-in injection pump
Deutz diesel engines of product range 2012 are equipped with plug-in injection pumps of series PF 33
from Bosch.
The concept of the plug-in fuel injection pumps enables the realization of high injection pressures in
connection with extremely short injection lines, which contributes to a high hydraulic stiffness of the
injection system. This in turn provides the prerequisite for low exhaust emission values (soot) in
combination with a low fuel consumption.
Plug-in fuel injection pumps have the following plunger dimensions:
• Stroke 12 mm
• Diameter 9 mm
Cavitation in the injection lines and injection overrun, which is normally associated with high pressures,
is prevented by a return flow nozzle arranged after the pressure valve
The constant volume relief is 50 mm³.
Assembling the plug-type injection pumps
The adjustment of the injection pump timing (FB) affects:
• the fuel consumption,
• the power
• the exhaust emission
of the engine.
On engines of series 2012 the start of delivery is adjusted without tolerance. The start of delivery is
entered in degree of crank angle measured from the top dead centre of the piston and depends on
application, power and speed setting of the engine.
The plug-in injection pump is in position of start of delivery when the plunger just closes the fuel supply
bore in the plunger sleeve.
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Service Training
On engines with inline injection pumps the engine drive is turned to start of delivery position and closing
of the fuel supply bore is determined by means of a high pressure pump. Occurring tolerances are
compensated in the coupling of the injection pump drive, whereby the injection pump camshaft is turned
to start of delivery position against the fixed engine drive.
The injection pump cams on engines of series 2012 are arranged on the camshaft of the engine. For
this reason the conventional adjustment method for the start of delivery cannot be used.
The start of delivery of the injection pump must be adjusted using the new method.
For this the conventional adjustment method is subdivided into length measurements of individual
engine parts and calculations.
The permissible manufacturing tolerances for the components
• cylinder crankcase,
• camshaft,
• plunger
• plug-in injection pump
are measured and eliminated by the adjustment of the start of delivery.
However, in cases of interest for BOMAG engineers the engine will not be overhauled completely, but
individual injection pumps will be replaced.
Crankcase, camshaft and plunger remain unchanged.
This results in a certain installation measurement for the engine drive, which is stamped on the engine
type plate.
In column „EP“ it is stamped as „CODE“ for each cylinder.
Note:
If an injection pump and/or nozzle is replaced, the respective high pressure line between pump and
nozzle must also be replaced..
1. Remove crankcase ventilation and cylinder

head cover.
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Service Training
Fig. 11:
2. EMR engines are not fitted with a lift

solenoid !
Fig. 12:
3. Insert the pressing device, WILBÄR No. 100

830 carefully into the groove in the governor
rod and tighten.
Fig. 13:
4. Turn the knurled fastening screw to press the

governor rod to stop position.
Note:
Tighten the knurled fastening screw by hand.
Fig. 14:
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Service Training
5. Set the cylinder of the injection pump to be
replaced to ignition top dead centre (valves
overlapping). Then turn the crankshaft
approx. 120° against the sense of rotation.
Note:
View on flywheel
Fig. 15:
6. Remove injection line and injection pump.
Fig. 16:
7. Take the compensation shim carefully out with

the rod magnet.
Fig. 17:
Determine the thickness of the new compensation shim:
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Service Training
Determination of the compensation shim thickness when replacing plug-in fuel injection
pumps
On the engine type plate column - EP – contains a code for the plug-in fuel injection pump for each
cylinder.
295
Each line represents 1 cylinder

e.g. 1st line = cylinder 1
2. line = cylinder 2 etc.
Fig. 18: Injection pump code BFM 2012
The EP-code is used to determine the installation measurement to be corrected „Ek“ from table 1.
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Service Training
EK EP EK EP EK EP EK EP
(mm) code (mm) code (mm) code (mm) code
119,250 230 119,850 254 120,450 278 121,050 302
119,275 231 119,875 255 120,475 279 121,075 303
119,300 232 119,900 256 120,500 280 121,100 304
119,325 233 119,925 257 120,525 281 121,125 305
119,350 234 119,950 258 120,550 282 121,150 306

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

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

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

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

119,775 251 120,375 275 120,975 299
119,800 252 120,400 276 121,000 300
119,825 253 120,425 277 121,025 301
Fig. 19: Injection pump code table BFM 2012
Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from
table 1.
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Service Training
During the manufacture of the plug-in fuel injection pump the high pressure method is used to determine
the wear in the fuel supply bore. In this position – injection pump plunger in start of fuel delivery position
- the distance between pump contact face and plunger foot contact face is measured.
Measurement "A" in 1/100 mm has been written on the pump with an electric marker.
64
Fig. 20: Plunger code inscription
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Service Training
A=XXX
Fig. 21: Individual injection pump
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Service Training
Measurement "A" specifies by how many 1/100 mm the gap between contact area on cylinder
crankcase and plunger foot is longer than the hydraulic base measurement Lo.
Lo
A = XX
A/100
Fig. 22: Presentation of measurement „A“
• Lo = 117,5 mm - BFM 2012
BW 216 / 219 / 226 DH / PDH -4 - D 36 -

Service Training
Ek Lo+A/100
Z
Ts
Fig. 23: Drive in start of delivery position after determination of „Ts“
The plug-in fuel injection pump is now positively connected with the drive, which has been set to start
of delivery by inserting a compensation shim "Z" of calibrated thickness..
The illustration explains that according to calculation:
(Ek) - (Lo + A/100)
there is a gap „Ts“ between injection pump plunger foot and roller plunger. This gap has to be
compensated with a compensation shim "Z" of appropriate (calculated) thickness.
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Service Training
Theoretical Compensation Theoretical Compensation

thickness shim thickness shim
„Ts“ thickness „Ss“ „Ts“ thickness „Ss“
(mm) (mm)
(mm) (mm)
0.95 - 1.049 1.0 2.45 - 2.549 2.5
1.05 - 1.149 1.1 2.55 - 2.649 2.6
1.15 - 1.249 1.2 2.65 - 2.749 2.7
1.25 - 1.349 1.3 2.75 - 2.849 2.8
1.35 - 1.449 1.4 2.85 - 2.949 2.9
1.45 - 1.549 1.5 2.95 - 3.049 3.0
1.55 - 1.649 1.6 3.05 - 3.149 3.1
1.65 - 1.749 1.7 3.15 - 3.249 3.2
1.75 - 1.849 1.8 3.25 - 3.349 3.3
1.85 - 1.949 1.9 3.35 - 3.449 3.4
1.95 - 2.049 2.0 3.45 - 3.549 3.5
2.05 - 2.149 2.1 3.55 - 3.649 3.6
2.15 - 2.249 2.2 3.65 - 3.749 3.7
2.25 - 2.349 2.3 3.75 - 3.850 3.8
2.35 - 2.449 2.4
Table 1: Shims 2012
For the determination of the theoretical shim thickness „Ts“ it is also necessary to determine
measurement Lo + A/100 of the new fuel injection pump, which must then be subtracted from the
corrected injection pump measurement Ek.
Ts = Ek - (Lo + A/100) [mm]
The real compensation shim thickness „Ss“ is determined with the help of table 2.
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Service Training
Exemplary calculation for BFM 2012
EP-code read off engine type plate: 295
• see table 1
corrected injection pump measurement „Ek“: 120,875 mm
Lo = 117,5 mm (fixed measurement)
Value for A/100 read off new injection pump A/100 = 42
• Ts = Ek - (Lo + A/100)
Ts = 120,875 mm - (117,5 + 42/100 mm)
Ts = 2.955 mm
see also table 1
Ts = 3,0 mm
8. P?lace the new calculated compensation shim

on the roller plunger.
Fig. 24:
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Service Training
9. Turn the injection pump control lever to
approx. middle position.
Fig. 25:
10. Apply some oil to the locating bore in the

crankcase and the O-rings on the injection
pump. Carefully insert the injection pump
control lever into the governor rod.
Fig. 26:
11. Attach the flange.
Note:
The chamfer must face towards the injection

pump body
Fig. 27:
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Service Training
12. Slightly oil the screws and tighten them
evenly with 5Nm.
Fig. 28:
13. Loosen the screws again for 60°.
Fig. 29:
14. Carefully turn the injection pump with and

open end spanner in anti-clockwise direction
against the noticeable stop
Fig. 30:
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Service Training
15. Tighten the screws again for 60° and
continue in stages with tightening torques of
7 Nm, 10 Nm and 30 Nm.
Note:
Start with the outer screw, viewed from the

flywheel. (see arrow).
Fig. 31:
16. Back out the knurled screw of the pressing

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

ring.
18. Reinstall the cylinder head cover. Tightening

torque: 9 +/-1 Nm.
Note:
If necessary replace the gasket.
Fig. 32:
19. Slightly oil the O-ring of the crankcase ventilation. Reassemble the crankcase ventilation. Tightening
torque 9 +/- 1Nm
Note: If necessary replace the gasket.
Tools
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Service Training
The following tools can be ordered from the respective supplier (in brackets) under the stated part-
number.
For tools from Hazet and Bosch you should consult your nearest representative, orders to Wilbär should
be addressed to:
Co. Wilbär
P.O. box 140580
D - 42826 Remscheid
Fig. 33
• Pressing device for governor rod 100 830 (Wilbär)
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Service Training
Electrical components and measuring points on the engine
2
1
1
Fig. 34: Auxiliary power take-off side
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

diagram
1 EMR - central plug X 57
2 Hand pump - fuel pre-cleaner
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Service Training
Fig. 35: Diesel engine starter side

diagram
1 Air filter vacuum switch B 03 50 mbar
BW 216 / 219 / 226 DH / PDH -4 - D 45 -

Service Training

diagram
1 Coolant level sensor B 55
BW 216 / 219 / 226 DH / PDH -4 - D 46 -

Service Training
Travel system
25
Charge pressure filter

Charging
from
BW 216 / 219 / 226 DH / PDH-4

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Service Training

diagram
10 BW 216 travel pump 90R075 EP 10
10 BW 219 and 226 travel pump 10
90R100 EP
12 Drum drive motor electr.-prop. 12
51C110
13 Axle drive motor, electr.-prop. 13
51D110
14 Axle 14
25 BW 216 and 219 reduction gear CR 25
51
25 BW 226 reduction gear 715 C 3B 25
The travel system of the single drum rollers is a closed hydraulic circuit and consists
mainly of:
• travel pump with control and safety elements,
• Drum drive motor with reduction gear;
• axle drive motor,
• two charge pumps,
• hydraulic oil filter (in charge circuit),
• hydraulic oil cooler with thermostat
• hydraulic lines.
Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump. The travel pump is the first pump section, flanged directly to the flywheel side
of the diesel engine.
The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to ∆p = 400 bar between low and high pressure
sides.
The flushing valves in axle drive and drum drive motors flush a certain oil quantity out of the closed
circuit when the machine is driving (∆p between the two sides of the closed circuit). Leakage in the
individual components of the circuit are replaced by the charge circuit through the boost check valves
in the travel pump.
The charge pump inside the vibration pump draws hydraulic oil out of the tank and delivers it through
the hydraulic oil filter to the boost check valves in travel and vibration pump. The return flow from the
steering system also flows through the hydraulic oil filter and is then available for the closed circuit
charging system. The charge circuit also provides the oil for the control functions in the closed circuits
for travel and vibration drive and to release the parking brakes.
Both travel motors and the travel and vibration pumps are electrically proportionately
controlled.
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.
4
1 2
Charging

diagram
1 BW 216 travel pump 90R075 EP 10 75ccm
1 BW 219 and 226 travel pump 10 100cm
90R100 EP
2 Charge pressure relief valve 10 26 bar
3 Control, electr.-prop. 10
4 Multi-function valve 10 400 bar
BW 216 / 219 / 226 DH / PDH-4

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

2 Drive shaft 6 Valve plate
3 Swash plate bearing 7 Control piston
4 Pistons with slipper pads
With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.
When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.
All valves as well as the safety and control elements needed for operation in a closed circuit, are
integrated in the pump.
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Cross-sectional view of travel pump
2
4
5
1 3
9
10
8
11
Fig. 2: Cross-sectional view of travel pump
1 Retainer for swash plate 7 Swash plate bearing

2 Sliding block 8 Swash plate guide
3 Control piston 9 Swash plate
4 Servo arm 10 Swashing lever
5 Servo valve
6 Feedback device
BW 216 / 219 / 226 DH / PDH-4

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Service Training
View of the rotating group
4 3
5
Fig. 3: Travel pump, view of the rotating group
1 Working pistons
2 Slipper pad
3 Pre-tensioning spring
4 Cylinder block
5 Drive shaft
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Description of function
2 3 4 5 6
1
8 6 7
Fig. 4: Function of travel pump
1 Drive shaft 5 Cylinder block

2 Drive shaft bearing 6 Multi-function valves
3 Swash plate 7 Charge pump (only in vibration pump)
4 Pistons with slipper pads 8 Valve plate
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).
With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).
BW 216 / 219 / 226 DH / PDH-4

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Service Training
When moving the swash plate out of neutral position, the working pistons will perform a stroke
movement with every rotation of the cylinder block.
The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.
During a full rotation of the cylinder block each working piston will move through the bottom and top dead
centre back to the initial position. During this movement each piston performs a complete stroke.
During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Travel and vibration pump as tandem pump
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Sauer-Danfoss tandem pump general, connections and adjustment points
38
Thermostat
housing
Fig. 5: Connections and adjustment points
BW 216 / 219 / 226 DH / PDH-4

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Service Training
1 Rear vibration pump connecting plate, turned by 90° !!!
2 Proportional solenoid (vibration pump)
3 Multi-function valve 400 bar (charging and pressure limitation), travel system
4 Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
5 Multi-function valve 400 bar (charging and pressure limitation), travel system
6 Pump flange
7 Port L, leak oil to vibration pump
8 Electr.-prop. control (travel pump)
9 Pressure test port, pilot pressure
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 bar
12 not on EP-pumps
13 Port L2, leak oil to tank
14 Pressure test port MB, high frequency
15 Pressure test port MA, low frequency
16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 Charge pump (only in vibration pump)
19 Port L2, (connection to vibration pump)
20 not on EP-pumps
21 Filter block for charge circuit
22 Multi-function valve 400 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between hydraulic oil tank and charge pump
24 Multi-function valve 400 bar (charging and pressure limitation), vibration low frequency
25 Charge pressure relief valve, vibration pump (fixed setting 40 bar)
26 Filter block for charge circuit
27 Port L1, leak oil port to travel pump
28 Pressure test port MB, high pressure reverse
29 Charge oil from filter
30 Pressure test port MA, high pressure forward
31 High pressure port A, high pressure forward
Thermostat housing:
32 Port C, from solenoid valve for brake/speed range selection
33 Leak oil port D, leak oil from axle drive motor
34 Leak oil port A, leak oil from travel pump
35 Leak oil port G, leak oil from drum drive motor
36 Leak oil port F, leak oil from vibration motor
37 Leak oil port B, leak oil to oil cooler
BW 216 / 219 / 226 DH / PDH-4

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Service Training
servo control
The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal
from the proportional valve into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (the displacement of the pump), as well as the
swashing direction (flow direction of the pressure fluid).
The flow quantity delivered by the variable displacement pump is proportional to the value of the input
signal from the proportional valve. A mechanical feedback device ensures the fixed correlation between
the proportional valve input signal and the swashing angle of the swash plate (displacement of pump).
Servo cylinder
Control piston
Sliding block
Servo arm
Control piston in pump
Since the control is spring centred, the swash plate will automatically return to neutral position under the
following conditions, thereby interrupting the oil flow and braking the machine:
• when shutting the engine down,
• if the pressure in the charge circuit drops below a certain value.
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Multi-function valves
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.
1 2
3
A
6 5
B
4
Fig. 6: Multi-function valves
1 to the control 6 Drive shaft

2 Multi-function valve 7 to the control piston
3 Charge pump 8 to the control piston
4 Charge pressure relief valve A Port A
5 Pilot pressure relief valve B Port B
If the adjusted pressure is reached, the pressure override will move the swash plate quickly back
towards neutral position, thereby limiting the system pressure. The average response time is less than
90 ms.
BW 216 / 219 / 226 DH / PDH-4

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

2 Hydraulic by-pass piston 8 Pressure limitation
3 Spring plate 9 Spring
4 Spring 10 By-pass housing
5 High pressure relief valve 10 By-pass sleeve
6 Valve seat
Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.
With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.
Note:
The multi function valves must be tightened with a torque of 89 Nm!
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Charge pressure relief valve
The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety
elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted
value (26 bar).
The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits
and provides the necessary pressure to control the travel and vibration pumps, the speed range
selection and to operate the multi-disc brakes in the travel drives.
Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.
When parking the machine on level ground with the engine running, the pressures in both
sides of the closed circuit are identical (charge pressure).
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Axle drive motor
The axle drive motor is a swash plate controlled Sauer-Danfoss axial piston motor of series 51 D 110
with an electrical proportional control for variable displacement.
HD-Pump Brake valve
Charge pressure
5
4
2
Leak
oil
HD-Pump
Fig. 1Hydraulic diagram, axle drive motor
1 Motor drive
2 Control piston
3 Proportional control with proportional solenoid
4 Flushing valve with flushing pressure limitation valve
5 Axle with brake
6) Rotary speed sensor (flange sensor)
BW 216 / 219 / 226 DH / PDH-4

- E 16 -
Service Training
.
5 7 8
6
9
11
10
4
2
Fig. 2: Axle drive motor,
1 Control piston 7 Cylinder block

2 Flushing valve with flushing limitation valve8 Universal joint
3 Proportional control 9 Output shaft
4 Spindle with ball 10 Output shaft bearing
5 Qmin-screw 11 Working piston
6 Valve plate
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Function
The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.
Control
The motor is electric-proportionally controlled.
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle
between cylinder block and output shaft.
With a large angle position the motor works with maximum displacement, slow speed and high torque.
When changing the swash plate position to minimal angle the motor works with minimum displacement,
high speed and low torque.
The displacement is changed by a control piston, which is tightly connected with the valve segment.
The front travel motor (drum drive) also is an axial travel motor 51C110
from Sauer-Danfoss.
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Speed sensor in form of a flange sensor
The Sauer-Danfoss travel motors of series 51 with electrical proportional control have a flange sensor
for speed and travel direction.
Due to the simple fastening of the flange sensor time-consuming adjustment work is no longer
necessary.
The sensor is plugged in against the stop and fastened with a socket head cap screw.
BW 216 / 219 / 226 DH / PDH-4

- E 19 -
Service Training
Excerpt from the electric wiring diagram: Page 004, rear travel motor B60 and front travel motor B59
BW 216 / 219 / 226 DH / PDH-4

- E 20 -
Service Training
Flushing valve
Fig. 8Cross-section of flushing valve
1 Flushing spool with flushing quantities from 10 to 16 l/min

2 Flushing quantity limitation valve (16 bar )
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.
BW 216 / 219 / 226 DH / PDH-4

- E 21 -
Service Training
Manual releasing of brake on axle drive
For manual releasing of the brakes on the rear axle you should proceed as follows:
Fig. 9: Manual releasing of rear axle brakes
• Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.
• Turn the brake releasing screw (2) in against the stop.
• To release the brake tighten the screw for max. 1 complete turn.
Attention!
Turn the screws on both sides in uniformly (alternately by 1/4 of a turn)
• Repeat this procedure on the opposite side of the axle.
BW 216 / 219 / 226 DH / PDH-4

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Service Training
BW 216 and 219 DH-4
Drum drive motor 51C110 with reduction gear CR 51
The drums on the DH-4 and PDH-4 versions are driven by a Sauer axial piston motor 51C110. This
motor is almost identical with the rear axle motor. Another detailed description at this point is therefore
not necessary.
The motor is a plug-type motor plugged into a reduction gear CR51.
This motor is a fast rotating hydraulic motor. Since the output speed of this motor is much too high to
drive the drum, a reduction gear reduces the output speed to the actually required drum drive speed.
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Reduction gear CR 51
6
3 4 5
7 8 9 10
2
11
1
7
12
13
16
15 14
1 Travel motor 9 Planet gear 2nd stage

2 Brake releasing device 10 Planet gear 3rd stage
3 Fastening on frame 11 End cover
4 Mechanical seal 12 Planet shaft
5 Oil filler screw 13 Sun gear
6 Housing and fastening on drum 14 Brake discs
7 Tapered roller bearing 15 Brake piston
8 Planet gear 1st stage 16 Brake spring
BW 216 / 219 / 226 DH / PDH-4

- E 24 -
Service Training
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.
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.
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Manual drum drive brake release (in the reduction gear)
Brake releasing device
in operation position
Brake releasing device in

position “brake manually
released”
For manual brake release both screws on the drum drive reduction gear (marked with arrow) must be
turned in uniformly, until the drum is able to rotate freely.
BW 216 / 219 / 226 DH / PDH-4

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Service Training
BW 226 DH-4
Drum drive motor 51C110 with reduction gear 715 C 3B
2 5 4 7
6 8
9
11
10 13 12
1 Travel motor 8 Planet gear 2nd stage

2 Brake releasing device 9 Planet gear 3rd stage
3 Oil drain plug 10 Brake spring
4 Mechanical seal 11 Sun gear
5 Oil filler screw 12 Brake discs
6 Planet gear 1st stage 13 Brake piston
7 Roller bearing
This gear has no manual brake releasing device
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Travel circuit with drum drive motor 51C110 and gear
2
9
Travel lever
forward
3
8
4
7 5
n
6 ti o
ec 1 Travel pump
l dir 2 Vibration pump
a ve
Tr 3 Hydraulic oil filter
4 Rear axle
High pressure 5 Axle drive motor
6 Reduction gear
Low pressure
7 Drum drive motor
Charge pressure 8 Hydraulic oil tank
Leak oil 9 Travel lever
Travel circuit 51 C 110 and CR 51 or 715 C 3B
BW 216 / 219 / 226 DH / PDH-4

- E 28 -
Service Training
Brake control BW 226 (with Sauer motor 51C110 and 715 C 3B)
Brake valve
Charge pressure
Brake releasing pressure
Leak oil
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Test and adjustment points, travel system
Charge pressure filter and travel pump
2
2
3
3
1
5
4
4

diagram
1 charge oil filter 16
2 Charge oil filter pressure differential B21 Page 005 ∆p 3,5 bar
switch
3 Pressure test port, charge pressure MA 26 bar
4 Travel pump - pressure test port 10 / A / MD max. 426 bar
Travel pressure forward
5 Test port travel pump forward A 10 / A
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Travel pump
2
2
3
1
1

diagram
1 Travel pump - pressure test port 10 / B / MC max.426 bar
Travel pressure reverse
2 Prop. solenoid travel forward Y17 / X16 Page 12V / 0,4-1,2 A
004
3 Prop. solenoid travel reverse Y16 / X15 Page 12V / 0,4-1,2 A
004
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Travel and vibration pump BW 219 and 226 DH-4
2
1

diagram
1 Test port travel pump reverse B 10 / B
2 Pressure test port, charge pressure MA 26+/-3 bar
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Travel and vibration pump BW 216 DH-4
2
2

diagram
1 Test port travel pump reverse B 10 / B
2 Pressure test port, charge pressure MA 26 bar
BW 216 / 219 / 226 DH / PDH-4

- E 33 -
Service Training
Travel motor (drum drive)
4
3
1
5
2

diagram
1 Pressure travel forward 12 - A
2 Pressure travel reverse 12 - B
3 Port X X1 approx. 26bar
4 Prop. solenoid Y30 Page 004 12V / 0,4-1,2 A
5 Speed flange sensor PPU B59 Page 004
6 Brake port in travel gear Brake closed
without pressure
BW 216 / 219 / 226 DH / PDH-4

- E 34 -
Service Training
Travel motor (axle drive)
5 4
2
1

diagram
1 Prop. solenoid Y 31 Page 004 12V / 0,4-1,2 A
2 Port X X1 approx. 26bar
3 Travel pressure sensor B 112 Page 004 0 - 426 bar
4 High pressure travel pump forward 13 - B
and further to drum drive motor
5 High pressure travel pump reverse 13 - A
and further to drum drive motor
6 Speed sensor (flange sensor) B 60 Page 004
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Speed sensor and travel pressure sensor
NEW : Speed flange sensors in both travel motors and a travel

pressure sensor at the front left hand side under the operator's platform!

diagram
1 Speed flange sensor PPU axle B60 Page 004
motor
1 Speed flange sensor PPU drum B59 Page 004
drive motor
2 Travel pressure sensor in frame, B112 Page 004 0 - 426 bar
front left under operator's platform
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Brake valve BW 216 DH-4
3 4
1
1

diagram
1 Brake valve Y 04 Page 006 08 0V closed 12V
open
BW 216 / 219 / 226 DH / PDH-4

- E 37 -
Service Training
Brake valve BW 219 DH-4
4
11 3
1

diagram
open
BW 216 / 219 / 226 DH / PDH-4

- E 38 -
Service Training
Brake valve with manual pump for emergency brake release BW 226 DH-4
5
2
3 4
1
1
1
5
4 3
diagram
open
2 Hand pump 17
3 Emergency release button 17
4 Pressure test port, brake pressure 17 26 bar
5 PRV 17 38 bar
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Travel lever
Multi-function travel lever
For a detailed description of the travel lever buttons

BW 216 / 219 / 226 DH / PDH-4

- E 40 -
Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
BW 216 / 219 / 226 DH / PDH-4

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Service Training
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
Maschine fährt mit Fahrhebel in Stellung 'Neutral'

Max.Fahrgeschwindigkeit wird nicht erreicht
Maschine fährt nur in eine Fahrtrichtung
Maschine fährt nicht (vor und zurück)
FEHLERSUCHE FAHRANTRIEB
Hydrauliköl wird zu heiss

BW 216/219/226 DH/PDH-4
SYMPTOME
MÖGLICHE URSACHEN
Bremsventil (elektrisch/mechanisch/hydraulisch) 1
Bremse Achse/Bandagenmotor (mechanisch/hydraulisch) 2 2 3
Fahrpropverstellung /defekt/Verkabelung 1
Speisepumpe / Speisedruckbegrenzungsventil(e)
2 3
verschmutzt/defekt
Pumpenansteuerung (Servoverstellung) 2 1 2 3
Druckabschneidung/ Hochdruckbegrenzung Fahrpumpe
3 2 3 3
verschmutzt/verstellt/defekt
Fahrhebel 1 2
Nullage Fahrpumpe 3 3
Fahrpumpe(n) defekt 3 3 2
Stellventil Fahrmotoren (elektrisch / mechanisch / hydraulisch) 1 2
Spülventil Fahrmotoren hängt 3
Fahrmotor(en) defekt 3 3
Hydraulikölkühler verschmutzt (intern/extern) 1
Thermostat (Hydraulik) verschmutzt/verklemmt/defekt 2
Kupplung Dieselmotor-Pumpe 2
Dieselmotor 1
Drehzahl-Flanschsensoren im Fahrmotor (Verkabelung) 1 1 2
BW 216 / 219 / 226 DH / PDH-4

- E 42 -
Machine does not move (forward and reverse)
Machine travels with travel lever in 'Neutral'

Machine moves to one direction only
Max. travel speed is not reached

TROUBLE SHOOTING TRAVEL
SYSTEM
Hydraulic oil overheats

BW 216/219/226 DH/PDH-4
SYMPTOMS
POSSIBLE CAUSES
Brake valve (eletrical/mechanical/hydraulical) 1
Brake axle/drum drive motor (mechanical/hydraulical) 2 2 3
Proportional solenoid travel system /defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/high pressure limitation travel pump
3 2 3 3
dirty/deadjusted/defective
Travel lever 1 2
Travel pump neutral position 3 3
Travel pump(s) defective 3 3 2
Travel motor control valve (electrical / mechanical / hydraulical) 1 2
Flushing valve for travel motors stuck 3
Travel motor(s) defective 3 3
Hydraulic oil cooler soiled (internally/externally) 1
Thermostat (hydraulics) soiled/jammed/defective 2
Coupling engine - pump 2
Engine 1
Flange-type speed sensors in travel motor (wiring) 1 1 2
TROUBLE SHOOTING
Service Training
Vibration
3
4

diagram
1 Vibration pump 75 cm³ 11
2 Integrated charge pump 17 cm³ 11
3 Multi-function valves with high 11 400 bar
pressure limitation and boost check
valve function
4 Proportional control 11
BW 216 / 219 / 226 DH / PDH -4 -F1-

Service Training
diagram
5 Vibration motor with flushing valve 15
The vibration system on these single drum rollers works with different frequencies and tow amplitudes.
This enables perfect adaptation of the machine to various types of soil and different applications.
The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit.
The main components of this circuit are
vibration pump,
Vibration motor
and the pressure resistant hydraulic hoses.
Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the
diesel engine.
By operation of a proportional valve the pilot oil is guided to one of the control piston sides. This actuates
the pump from neutral position to one of the two possible maximum displacement positions.
When changing the swashing angle through the neutral position to the opposite side, the flow direction
of the oil and the sense of rotation of the vibration motors will change.
Since the engine speed is variable in "Position ECO", the pump displacement must always be
proportionately adapted in order to maintain the vibration frequency at a constant level.
The vibration motor output shaft is joined with the exciter shaft in the drum via a Bowex coupling. The
rotation of the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically
suspended drums.
The eccentric weights on the vibrator shaft are fitted with additional change-over weights.
BW 216 / 219 / 226 DH / PDH -4 -F2-

Service Training
Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract
from the basic weights.
Basic weight + change-over weight = high amplitude
Basic weight - change-over weight = low amplitude
The displacement of the pump may be different to both flow directions. This results in different exciter
shaft speeds for the different senses of rotation of the motor.
The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled
with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.
Sense of rotation of exciter shaft
BW 216 / 219 / 226 DH / PDH -4 -F3-

Service Training
Vibration pump
The vibration pump is a swash-plate controlled axial piston pump with variable displacement of type 90
R 075 EP from Sauer-Danfoss. The pump is fitted with all control and safety elements needed for
operation in a closed hydraulic circuit.
5 4
2 6 3

diagram
1 Vibration pump 75 cm³ 11
2 Integrated charge pump 17 cm³ 11
3 Multi-function valves with high 11 400 bar
pressure limitation and boost check
valve function
4 Prop. solenoids X 6 and X 7 11
5 servo control 11
6 Safety valve in charge circuit 11
BW 216 / 219 / 226 DH / PDH -4 -F4-

Service Training
Function
1 2
5 4 3
Cross-section of vibration pump
1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate
BW 216 / 219 / 226 DH / PDH -4 -F5-

Service Training
1
2
5
4 3
Cross-section of vibration pump
1 Control
2 Servo piston
3 Friction free swash plate bearing
4 Attachment plate
5 Spool valve
BW 216 / 219 / 226 DH / PDH -4 -F6-

Service Training
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.
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 converts the electric proportional input signal into a load
controlling output signal.
The vibration pump has an integrated charge pump, an internal gear pump with a displacement of 17
cm³ per revolution
The vibration pump is equipped with an integrated charge pressure relief valve, which is set to a
pressure of 40 bar. This valve only has a safety function in the charge circuit.
Multi-function valve
BW 216 / 219 / 226 DH / PDH -4 -F7-

Service Training
As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.
1 From the charge pump
2 Closed circuit
3 High pressure relief valve with integrated boost check valve
Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 426 bar
(pressure difference between high and low pressure side = 400 bar + charge pressure = 26 bar).
The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit.
Vibration motor
BW 216 / 219 / 226 DH / PDH -4 -F8-

Service Training
The vibration motor is a Bosch-Rexroth axial piston motor of series A2FM with fixed displacement in
bent axle design. Since the motor can be subjected to pressure from both sides, it is most suitable for
the use in closed hydraulic circuits.
Vibration motors of the machines: BW 216- A2FM56, BW 219- A2FM63, BW 226- A2FM80
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 426 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a
BW 216 / 219 / 226 DH / PDH -4 -F9-

Service Training
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).
Hard ground = High operating pressure
Loose ground = Low operating pressure
A MA
3 1
B MB
Circuit diagram of vibration motor
1 Vibration motor
2 Flushing valve
3 Flushing pressure relief valve
Flushing valve
All vibration motors are fitted with a flanged on flushing valve
BW 216 / 219 / 226 DH / PDH -4 - F 10 -

Service Training
The vibration motor is equipped with an integrated flushing valve. This flushing valve is located inside
the bolted on connecting block. When switching the vibration on a pressure difference will appear
between the two sides of the closed circuit. The higher pressure moves the valve spool of the flushing
valve against the neutral setting spring, so that oil can flow out of the low pressure side.
1
A
Flushing valve
1 Flushing spool
2 Flushing pressure relief valve
The flushing valve is fitted with a downstream 16 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 216 / 219 / 226 DH / PDH -4 - F 11 -

Service Training
Speed sensor
The vibration system fixed displacement motor A2FM is equipped with a Hall effect rotary speed sensor
from Bosch Rexroth HDD1L or HDD2L
Fixed displacement motor

A2FM
BW 216 / 219 / 226 DH / PDH -4 - F 12 -

Service Training
Connection in wiring diagram, vibration speed sensor B16 on page 006
BW 216 / 219 / 226 DH / PDH -4 - F 13 -

Service Training
Drum
4
14
5 9
7 13
6
10
3 8 11
12
Fig. 1Cross-section of drum
1 Drum shell 8 Change-over weight

2 Vibration bearing 9 Coupling vibr.-motor – vibrator shaft
3 Basic weight 10 Travel bearing
4 Vibrator housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Vibrator shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing
BW 216 / 219 / 226 DH / PDH -4 - F 14 -

Service Training
Test and adjustment points, vibration system
Vibration pump
7 8
6 6 72
1
8
6 5
7
5 1
5 4
3 4 1
2
3
4 2 3
diagram
1 Pressure test port, vibration 11 - B - ME Starting pressure
pressure low amplitude 330 -400 bar
2 Pressure test port, vibration 11 - A - MF Starting pressure
pressure high amplitude 330 -400 bar
3 High pressure port low amplitude 11 - B max. 400+26 bar
4 High pressure port high amplitude 11 - A max. 400+26 bar
5 Multi-function valve with high 11 - B
pressure limitation low amplitude
6 Multi-function valve with high 11 - A
pressure limitation high amplitude
7 Solenoid valve, low amplitude Y07 / X 8 11 - B 12V / 0,4 - 1,2A
8 Solenoid valve, high amplitude Y07 / X 7 11 - A 12V / 0,4 - 1,2A
BW 216 / 219 / 226 DH / PDH -4 - F 15 -

Service Training
Vibration motor BW 216 and 219 DH-4
5 3
1
1 2
2
4
3
2 31

diagram
1 High pressure port high amplitude 15 - A
2 High pressure port, low amplitude 15 - B
3 Flushing valve with pressure 15
retaining valve
4 Leakage and flushing 15 approx. 8-10 l incl.
flushing quantity
BW 216 / 219 / 226 DH / PDH -4 - F 16 -

Service Training
Vibration motor BW 216 and 219 DH-4

diagram
1 RPM-sensor B 16 15
BW 216 / 219 / 226 DH / PDH -4 - F 17 -

Service Training
Vibration motor BW 226 DH-4
2 3 1

diagram
1 High pressure port high amplitude 15 - A
2 High pressure port, low amplitude 15 - B
3 Flushing valve with pressure 15
retaining valve
4 Leakage and flushing 15 approx. 8-10 l/min
incl. flushing
quantity
5 RPM-sensor B 16 15
BW 216 / 219 / 226 DH / PDH -4 - F 18 -

Service Training
Trouble shooting
BW 216 / 219 / 226 DH / PDH -4 - F 19 -

Service Training
Procedure:
Erregerwellendrehzahl nicht korrekt

Keine Vibration (Speisedruck OK)
Vibration nur in einer Amplitude
FEHLERSUCHE VIBRATION
BW 216/219/226 DH/PDH-4
SYMPTOME
MÖGLICHE URSACHEN
Vibrationschalter (Amplitudenvorwahl) 1 1
Fahrhebel, Taster Vibration (an/aus), Verkabelung 1
Elektrik defekt / Verkabelung 2 2
Pumpenansteuerung (elektrisch / hydraulisch) 1 1
Druckabschneidung/ Hochdruckbegrenzung Vibrationspumpe
2
verschmutzt/verstellt/defekt
Speisepumpe / Speisedruckbegrenzungsventil
2
verschmutzt/defekt
Frequenzeinstellung Vibrationspumpe 2
Vibrationspumpe defekt 2 2
Kupplung zwischen Dieselmotor und Fahrpumpe defekt
Erregerwellenlager defekt 3
Vibrationsmotorkupplung defekt 2
Vibrationsmotor defekt 2 1
Dieselmotor 1 1 1
Drehzahlsensor (Verkabelung) 1 1 1
Spülventil Vibmotor hängt 2
FEHLERSUCHE
BW 216 / 219 / 226 DH / PDH -4 - F 20 -

No vibration (charge pressure OK)
Vibration only with one amplitude
Exceiter shaft speed not correct
TRROUBLE SHOOTING
VIBRATION
BW 216/219/226 DH/PDH-4
SYMPTOMS
POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1
Travel lever, vibration button (on/off), wiring 1
Electrics defective / wiring 2 2
Pump control (electric / hydraulic) 1 1
Pressure override/ high pressure limitation vibration pump
2
soiled/deadjusted/defective
Charge pump / charge pressure relief valve
2
soiled /defective
Vibration pump frequency setting 2
Vibration pump defective 2 2
Coupling between engine and travel pump defective
Exciter shaft bearing defective 3
Vibration motor coupling defective 2
Vibration motor defective 2 1
Engine 1 1 1
Rotary valve (wiring) 1 1 1
Flushing valve in vibration motor stuck 2
TROUBLE SHOOTING
Service Training
Steering
Single drum rollers BW 216 / 219 / 226 of series 4 are equipped with a hydrostatically operated
articulated steering system.
The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.
to charge
system
1
7
6
5
3
2
4
from steering pump
Fig. 1Steering hydraulics
1 Rating pump
2 Distributor valve
3 Steering pressure relief valve (∆p =175 bar)
4 Check valve (pre-loaded to 0.5 bar)
5 Anti-cavitation valve
6 Shock valves (240 bar)
7 Steering cylinders
The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.
When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.
The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.
BW 216 / 219 / DH / PDH -4 -G1-

Service Training
Charge pump
The charge pump for travel circuit and vibration works also as steering pump The pump is an external
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.
BW 216 / 219 / DH / PDH -4 -G2-

Service Training
Steering pump
The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.
9 9 6 1 7
8
2
4 5
Fig. 2Steering pump
1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals
BW 216 / 219 / DH / PDH -4 -G3-

Service Training
Working principle of the gear pumps
The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of
both gears mesh with minimum clearance when rotating.
The displacement chambers are created between the tooth flanks, the inside wall of the housing and
the faces of the bearing plates.
When the pump is running the chambers transport hydraulic oil from the suction side to the pressure
side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The
tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.
To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic
fluid can be transported from the suction side to the pressure side without any losses.
For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.
This pressure field is always under the actual system pressure.
BW 216 / 219 / DH / PDH -4 -G4-

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

2 Housing
3 Inner spool
4 Outer spool
5 Universal shaft
6 Ring gear
7 Gear
8 Check valve
9 Pressure relief valve
When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating
pump. The rating pump guides the oil flow through the distributor valve to the corresponding
sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the
rotation angle of the steering wheel.
This oil flow to the steering cylinders articulates the machine and causes a steering movement.
BW 216 / 219 / DH / PDH -4 -G5-

Service Training
240 bar
∆p = 175 bar
240 bar
0,5 bar
Fig. 4Steering valve, hydraulic diagram
The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.
The charge pressure value must be added to this pressure, because the oil leaving the steering system
is fed into the charge circuit for the closed travel circuits.
The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks
which may occur, e.g. when driving over obstructions, and protect the system against overloads.
Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.
A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case
of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would
act as pumps and press the oil back to the pump.
BW 216 / 219 / DH / PDH -4 -G6-

Service Training
Articulated joint
Front and rear frames of series 4 single drum rollers are connected by an oscillating articulated joint.
This ensures that drum and wheels are at all times in contact with the ground, even when driving
extreme curves.
Fig. 5Articulated joint
BW 216 / 219 / DH / PDH -4 -G7-

Service Training
The rear console is tightly bolted to the rear frame.
The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.
The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.
The steering cylinder anchor point is welded to the front console.
When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.
All bearings on the articulated joint are maintenance free and do not require any lubrication.
Notes on assembly:
When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.
Please follow the instructions in the repair manual for the articulated joint.
BW 216 / 219 / DH / PDH -4 -G8-

Service Training
Test and adjustment points steering points
3 4
1
1
2 2
2
Steering pump

diagram
1 Steering pump (and charge pump) 09
2 Steering pressure test port MB max.170+26 bar
BW 216 / 219 / DH / PDH -4 -G9-

Service Training
Vibration and noise damper
The damper is located in the steering/charge circuit directly after the steering and charge pump.
It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.
The damper is mounted to the front plate of the rear frame, between both steering cylinders.
BW 216 / 219 / DH / PDH -4 - G 10 -

Service Training
Trouble shooting
BW 216 / 219 / DH / PDH -4 - G 11 -

Service Training
Procedure:
FEHLERSUCHE LENKUNG
BW 213/214 DH/PDH-4
Endanschläge werden nicht erreicht
Lenkung schwergängig
Keine Lenkfunktion
SYMPTOME
MÖGLICHE URSACHEN
Lenkorbitrol 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2
BW 216 / 219 / DH / PDH -4 - G 12 -

TROUBLE SHOOTING STEERING
BW 213/214 DH/PDH-4
End stops are not reached

Steering hard to move
No steering function
SYMPTOMS
POSSIBLE CAUSES
Orbitrol steering valve 2 2 1
Steering/charge pump 1 1 2
Steering cylinder 3 3 3
Articulated joint 3 3 2
TROUBLE SHOOTING
Service Training
Electrics
Single Drum Rollers – 4
Version 2.07
Author: Seis / TE
Table of contents
1 CONFIRMATION OF CHANGES ..................................................................................5

1.1 Document ..................................................................................................................................................................... 5
1.2 Software ....................................................................................................................................................................... 5
2 SELECTED FAULT REACTIONS OF THE ESX CONTROL ..................................6
3 DESCRIPTION OF ERRORS IN THE LC DISPLAY .................................................9

3.1 Calling up service mode............................................................................................................................................ 9
3.2 Entering input codes.................................................................................................................................................. 9
3.3 Adjusting the machine type....................................................................................................................................11
3.4 Changing the steering unit on BVC-4 machines (from version 1.09)...........................................................12
3.5 Teaching the travel direction sensor...................................................................................................................13
3.6 Automatic detection of surge currents in travel system................................................................................13
3.7 Teaching the electronic end stops of the steering angle sensor (BVC) .....................................................15
3.8 Automatic detection of surge currents on steering valves (BVC)................................................................17
3.9 Driving against the closed brake..........................................................................................................................18
3.10 Showing stored faults .............................................................................................................................................18
3.11 Delete all stored faults ............................................................................................................................................18
4 HOW TO PROCEED WHEN REPLACING COMPONENTS?...............................19

4.1 Replacement of an ESX-control............................................................................................................................19
4.2 Replacement of a travel pump / axle drive motor / drum drive motor .........................................................19
4.3 Replacement of a steering valve (BVC)...............................................................................................................19
4.4 Replacement of a steering angle sensor ...........................................................................................................19
4.5 How to proceed when replacing a front / rear axle sensors?.......................................................................19
4.6 Which components can be replaced without a subsequent adjustment procedure?............................20
5 DESCRIPTION OF THE SIGNALS ON THE ESX-CONTROL ..............................21
6 DESCRIPTION OF SIGNALS ON THE DATA COLLECTOR................................27
7 DESCRIPTION OF SIGNALS ON THE TRAVEL LEVER......................................29
8 DESCRIPTIONS OF SIGNALS ON THE LC - DISPLAY ........................................31
9 DESCRIPTION OF SIGNALS ON DIOS-MODULE..................................................32
10 FAULT CODES OF THE ESX CONTROL .............................................................34

10.1 Overview.....................................................................................................................................................................34
10.2 Description of fault reactions ................................................................................................................................35
10.3 Detailed description of fault codes and their possible causes....................................................................36

Author: Seis / TE
10.3.1 General _________________________________________________________________ 36

10.3.2 Brake___________________________________________________________________ 37
10.3.3 Travel lever ______________________________________________________________ 37
10.3.4 Travel speed range selector switch ____________________________________________ 38
10.3.5 Travel system ____________________________________________________________ 39
10.3.6 Steering_________________________________________________________________ 42
10.3.7 Driver's seat arm rest sensor_________________________________________________ 43
10.3.8 Vibration ________________________________________________________________ 44
10.3.9 Attachment plates _________________________________________________________ 46
10.3.10 Diesel engine ____________________________________________________________ 47
10.3.11 Diesel engine EMR ________________________________________________________ 47
10.3.12 Miscellaneous ____________________________________________________________ 50
10.3.13 Machine type _____________________________________________________________ 50
11 INPUT CODES FOR ESX CONTROL ....................................................................51

11.1 Fault log.......................................................................................................................................................................51
11.2 Value displays ...........................................................................................................................................................51
11.2.1 General _________________________________________________________________ 51
11.2.2 Brake___________________________________________________________________ 51
11.2.3 Travel lever / driving ________________________________________________________ 52
11.2.4 Travel speed range selector switch ____________________________________________ 52
11.2.5 Travel pump: Travel direction forward___________________________________________ 53
11.2.6 Travel pump: Travel direction reverse___________________________________________ 53
11.2.7 Travel motor front (drum) ____________________________________________________ 54
11.2.8 Travel motor rear (wheel axle) ________________________________________________ 54
11.2.9 Adaption values for speed regulation ___________________________________________ 54
11.2.10 Travel pressure sensor _____________________________________________________ 55
11.2.11 55
11.2.12 Inclination sensor _________________________________________________________ 55
11.2.13 Travel condition values _____________________________________________________ 55
11.2.14 Speed limitation___________________________________________________________ 55
11.2.15 Arm rest contact___________________________________________________________ 55
11.2.16 Adaption values traction control _______________________________________________ 56
11.2.17 Steering: Steering valve _____________________________________________________ 56
11.2.18 Steering: Angle sensor in articulated joint _______________________________________ 56
11.2.19 Steering: Steering wheel ____________________________________________________ 57
11.2.20 Vibration ________________________________________________________________ 57
11.2.21 Attachment plates, option (only BW213 BVC) _____________________________________ 58
11.2.22 Engine __________________________________________________________________ 59
11.2.23 Hydraulics _______________________________________________________________ 59
11.3 Test settings ..............................................................................................................................................................60
11.3.1 Brake___________________________________________________________________ 60
11.3.2 Disable electric supply to wheel and drum drive motors (switch off)____________________ 60
11.4 Settings / Teach / Emergency functions .............................................................................................................60
11.4.1 Changing the machine code _________________________________________________ 60
11.4.2 Automatic detection of surge currents in travel system ______________________________ 60
11.4.3 Speed detection, trimming of measuring values __________________________________ 61
11.4.4 Speed detection, teaching of distance pulses ____________________________________ 61
11.4.5 Detection of wheel rotation___________________________________________________ 61
11.4.6 Steering: Automatic detection of surge currents on steering valve _____________________ 62
11.4.7 Steering: Determining the steering stops ________________________________________ 62
11.4.8 Steering: Emergency function ________________________________________________ 62
11.4.9 Steering: Other functions ____________________________________________________ 62
11.4.10 Vibration: Cancellation of the vibration permission in dependence on the travel speed _____ 62
11.4.11 Plates __________________________________________________________________ 63
12 TERMINOLOGY IN CONNECTION WITH ESX.....................................................64

Author: Seis / TE

Author: Seis / TE
1 Confirmation of changes
1.1 Document
No. Date Description of changes resp.

2.01 23.04.2004 Creation of version 1.00 Werner
2.02 06.05.2004 Revision, teach functions Fondel
2.03 11.05.2004 Revision, supplements version 1.01 Seis
2.04 24.06.2004 Revision, supplements to version 1.02
2.05 23.01.2005 Revision, supplement to software versions from 2.00 MASH
2.06 29.04.2005 Revision, supplement to software versions from 2.06 MASH
2.07 22.05.2005 Error code description 5121 changed Löw
1.2 Software
Ver. Date Description of changes resp.

1.03 02.09.2004 ⇒ Surge currents travel system teach function changed Schroeder,
⇒ Known faults Fondel
⇒ Revision of error codes
⇒ Deactivation of electric steering on BVC machines
⇒ How to proceed when replacing components?
2.00 16.12.2004 ⇒ List of error codes extended Schroeder
Fondel
MASH
2.02 08.03.2005 ⇒ Adaptive adaptation of gradability. Display codes for the factors MASH
"Front top" 1500 and "Tail top" 1501
⇒ Input code to shut down the speed dependent Vib-limitation
(3047..3049).
⇒ Error message (8440..8443) for invalid BabyBoard equipment of
the ESX-travel control.
⇒ Overspeed protection for wheel drives (axle and drum drives)
2.06 29.04.2005 ⇒ Input codes (1158/1159) for manual adaptation of axle speed MASH
recording.
⇒ Input codes to record the pulse frequency of the drives:
Recording of speeds (1160..1169)
⇒ Adapted tank characteristic.
⇒ Change of speed limitation for operation with plates.
2.07 22.05.2005 ⇒ Tank characteristic values changed. MASH

Author: Seis / TE
2 Selected Fault Reactions of the ESX Control

Reaktion Symbol in fault Warning Warning Engine stop
message display
Signal Code output Code output Code output
without buzzer with buzzer with buzzer
Engine oil pressure

(from EMR) 5100 5101
5112 5112
1) 2)
after 10s
Coolant temperature
(from EMR)
5100 5101
5116 5116
1) 2)
after 15s
Coolant level
5024 5025
after 5s after 10s
Engine air filter
5026 5027
after 5s after 2min. 3)
Charge control
Preheating of engine
Brake
ASC
Various error causes and reaction times.
See error codes
Hydraulic oil filter
5502 5503
Water separator in fuel filter
5028 5029
Ant-theft warning display
(Option)
Seat contact
(Option)
Air conditioning fault

(Option)
1) 3)
After reaching the warning limit! Shut-down currently deactivated via parameter

Author: Seis / TE
2)
After reaching the shut-down limit!

Author: Seis / TE
Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Effect: Cause:
Display remains dark, no voltage PIN in display plug X 28 bent
Error code 5100, 5140 and engine does not Switch the ignition off and on and restart the
respond to full speed switch or travel lever machine immediately.
After switching on the display shows "Error code Code 8224 is no error code, but a software fault in
8224“ the display software, which has been rectified in
display firmware version 1.36 and higher

Author: Seis / TE
3 Description of errors in the LC display

Apart from its normal display function the LC display is also able to shpw error codes, which had
previously been visualized by means of the 3-digit error code display.
Currently existing faults and warnings are displayed by flashing. If several faults are detected, the
displayed fault codes will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible. Negative
values are identified by a "Minus sign".
The following chapter describes the operation of the LC display via travel lever buttons.
3.1 Calling up service mode

For this purpose the display must be switched via input mode to service mode. This is accomplished via
the two yellow info buttons "INFO 1" and "INFO 2" on the back of the travel lever. Navigation in input and
service mode takes place via the green and blue buttons on the front of the travel lever.
Werte ändern Navigieren

INFO 1 Taste (grün) (blau)
(gelb)
INFO 2 Taste
(gelb) Werte ändern
(grün)
Navigieren
(blau)
The travel lever must be in locked braking position in order to activate input mode! Input mode
is switched on by simultaneously pressing both INFO – buttons over a period of approx. 3 seconds.
3.2 Entering input codes

Input mode starts with flashing of the left hand digit. Here service code 9 9 9 9 provides the possibility to
change to the service mode. The green buttons can be used to increase or reduce the values of the
corresponding digit. By operating one of the blue buttons one can jump to the next (left or right) digit.
Once the last right hand digit has been entered the code will be transferred to the control by pressing the
right hand blue button once again.
If the access code has been entered correctly, the "Spanner" symbol is displayed and the first input digit
flashes again. Individual operating states of the machine can now be interrogated by transferring the input
code to the control (as described above).
When operating both INFO buttons again for approx. 3 seconds, another input code can be entered. The
input of code "0 0 0 0 " or switching of the ignition quits the service mode.
If the travel lever is shifted out of the brake lock while in service mode, all machine functions will become
active, with the exception of the LC-display, which remains in service mode and continues to display the
operating values requested last.
Version/Status: V2.07 / 24.06.05 Functions of ESX control Page 9 of 67

Author: Seis / TE
Normal mode (travel lever in brake gate!)

Call up optional displays via
Info button 1 and Info button 2
„Input“ - Modus:
Changeover display function
Display setting
Press INFO 1 +
INFO 2 approx. 3s
Plate adjustment deactivated!
Press INFO 1 +
INFO 2 approx. 3s Input
or shift travel Access code
lever out of 9999
brake gate
„Service“- Modus:
CODE – input „0000" or Input diagnostic codes
Ignition off
Calling up / deleting the error log
Change machine type
Plate adjustment deactivated!
Travel lever out of brake gate:

Diagnostics mode active in foreground

Author: Seis / TE
3.3 Adjusting the machine type

Since the same control is used for all DH-4 single drum rollers with electronically controlled engine (EMR
II), it is necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This
adjustment of machine type is necessary, because the machines may be equipped with different drum
drive or axle drive motors or different tire sizes, thus resulting in different rolling circumferences, or they
may be equipped with attachment plates or other options.
For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module when switching the ignition on. It can also be checked by entering code 0720.
The following machine types can be adjusted:
0 1 2 3 4 5 6 7 8 9
72XX
0 Default BW 177 BW 177 BW 179 BW 179 BW 213/ BW 213 BW 213 BW 213 BW 216 DH
DH-4 PDH-4 DH-4 PDH-4 BW 214 BW 214 DH-4 PDH-4 DH-4
(dozer DH-4 PDH-4 USA USA
blade)
1 BW 216 BW 219 BW 219 BW 226 BW 226 BW 226 BW 226 DH
PDH-4 DH-4 PDH-4 DH-4 PDH-4 DH-4 PDH-4
147kW 147kW 174kW 174kW
2 DH
3 DH
4 DH
5 BW 177 BW 213 BW 213 BW 226 BW 226 BVC

DH-4 DH-4 DH-4 DH-4 DH-4
BVC BVC BVC w. BVC BVC
plates 147 kW 174 kW
6 BVC
7 BVC
8 BVC
9 BVC
EXAMPLE: Machine code for BW 219 PDH-4: 7212
Note: Parameter adjustments can only be performed when the engine is not running.

Author: Seis / TE
Note: This function can only be activated / deactivated when the travel lever is locked in the
brake gate. (à Input mode)
The following procedure must be used for initial start-up of a control:
• The control has been installed into the machine.

• Switch the ignition on. Approx. 4 seconds after switching on the letters C O D E are displayed for
a period of approx. 3 seconds. After this the display changes and shows code 7200.
• Use the Arrow Up or Arrow Down keys to select the correct machine code from the list of codes.
• Confirm the selection with the Arrow Right key.
• After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for approx.
3 seconds. The new parameters are loaded according to the machine type setting. Do not switch
the ignition off during this time!
• After this switch the ignition off and on again to accept the configuration.
• After this the normal display will appear again.
The following applies for a correction of the machine type code after it has been set.
• Enter code number 9 9 9 9 (activation of service mode)

• Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type“.
The display module now permanently shows the code 7 2 0 0 .
• Select the machine code from the table above and confirm it with the Arrow Right key. After operating
the Arrow Right key the control switches automatically off and on again.
• After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for approx.
3 seconds. The new parameters are loaded according to the machine type setting. Do not switch
the ignition off during this time!
• After this switch the ignition off and on again to accept the configuration.
• After this the normal display will appear again.
Attention: A machine must not be operated with a wrong type adjustment, because in such
a case the correct function of the control cannot be assured!
New controls are delivered with a default machine type setting 7 2 0 0 . This
does not enable to drive or steer the machine. It only serves the purpose of
commissioning.
3.4 Changing the steering unit on BVC-4 machines (from version 1.09)
By standard all BVC-4 machines (code 72xx) are equipped with electric steering. If the hydraulic steering
option is selected, the electric steering must be deactivated as follows.
• Enter code number 9999 (activation of service mode)

• Enter code number 2 0 6 0 . This code number activates the function "Adjusting the steering unit“.
• The following code numbers are available to activate the assembled steering unit.
Hydraulic steering 2062

Electric steering 2061
• The display shows O K
Attention: The steering unit can only be changed when the engine is not running!

Author: Seis / TE
3.5 Teaching the travel direction sensor

Teaching of the travel direction sensor is required for initial commissioning and after the replacement of a
travel motor. Perform the following sequence
• Turn the speed range selector switch to "MAX"
• Shift the travel lever slowly out of neutral, until a travel speed of approx. 1 km/h is indicated.
• If one or both travel direction sensors detected a counteracting direction the error codes 1106 and/or
1116 will appear after approx. one machine length. Otherwise no error code will be displayed. The
travel direction detection is now automatically set.
However, should one of the two error codes appear, this must be caused by a sebsor fault.
3.6 Automatic detection of surge currents in travel system

This function is only valid from software version 1.09!
For a sensitive and exact function of the travel system the surge currents in the travel system must be
determined for both travel directions. The surge currents are automatically determined after entering a
code number, so that no electric meter is required.
The surge currents must only be determined during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and after
the replacement of the ESX-control.
The measurement is identical for both travel directions: After entering the respective code number the
current is increased by the control solenoid on the travel pump in steps of 5 mA, starting from 250 mA..
After each current increase the system waits for 3 seconds. If a considerable drum movement is
measured during the waiting time, the surge current is reached. In order to enhance the measuring result
this measurement is performed three times. The final surge current is the mean value of these three
measurements. This surge current is automatically stored and is valid from the next start of the machine.
Before the measurement you should strictly make sure that the machine is parked on level ground and
has a sufficient distance for movement to front and back, because the machine will move to the
respective direction when performing the measurement.
Attention! First set the machine to input mode (code 9 9 9 9 ). It must be strictly assured that the speed
sensor (in front right hand hydraulic motor) is working correctly. For a function test enter code number
1 1 0 6 at the display module. This code can be used to display the number path pulses from the speed
sensor. The displayed value must change when the machine is driven.
If this value does not change even though the machine is moving, the measurement must not
be performed!
The state of the speed sensor must first be corrected, as otherwise the movement of the drum will not be
detected. (See also: „Resetting the surge currents in the travel system”)
Attention!
During the measurement the machine will move when the surge current is reached!
Do not leave the machine while the measurement is progressing!
During the measurement keep an eye on your environment!
To stop the machine reset the travel lever to neutral position!
The automatic measurement of the travel system surge currents is performed as follows:
• The speed selection switch must be in position ECO.
• If necessary enter code number 9 9 9 9 to access the service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents in
the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This code
number must be entered to be able to perform the following steps. From this point the machine
can no longer be operated with the travel lever! The travel lever will only be in function
again after the teach function has been completed or the machine has been restarted.

Author: Seis / TE
• The measurements (forward/reverse) must be started by entering a code number. The code number
required to teach the travel direction is as follows:
Determination of control surge currents 1 0 9 1
• After the input of the above code number the display shows " F O R E ". Shifting the travel lever
forward starts the first surge current measurement for forward travel.
• During the measurement the actual current is displayed (display value = current in mA).
• Once the surge current measurement is finished the display will show the reading O K for a period of
5 seconds.
• After this wait time the display reading changes to " B A C K ". Now shift the travel lever backward
to start the surge current measurement in reverse.
• After completion of the measuring process in reverse the display will show O K again.
• The travel lever must now be returned to braking position.
• Once both surge currents have been learned correctly and the travel lever is in "braking position", the
display shows the reading "D O N E", the values are saved and the function is completed. Now the
machine can be operated again with the travel lever. The new surge current values for the travel
system are valid from the next start.
• The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.
The following procedure applies for software versions 1.07 and 1.08:
The automatic measurement of the travel system surge currents is performed as follows:
• The seat must be adjusted for travel direction forward!
• The speed selection switch must be in position ECO.
• If necessary enter code number 9 9 9 9 to access the service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents in
the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This code
number must be entered to be able to perform the following steps. From this point the machine
can no longer be operated with the travel lever! The travel lever will only be in function
again after the teach function has been completed or the machine has been restarted.
• Both measurements (forward/reverse) must be started by entering a code number. The code numbers
for both travel directions are:
Determine surge current for control forward 1 0 9 1
Determine surge current for control reverse 1 0 9 2
• After entering one of the above code numbers the measurement will only start after moving the travel
lever to the respective travel direction.
ATTENTION: The ASC fault indicator light will come on during the teach process. In this case this is
of no relevance. The warning will disappear when restarting the machine.
• Teaching is required for both travel directions.
• When returning the travel lever to neutral position after the two measurements, the display will show O
K for 3 seconds and the averaged values will be saved.
• Once both surge currents have been measured the machine can be operated again with the travel
lever. The new surge current values for the travel system are valid from the next start.
• The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.

Author: Seis / TE
3.7 Teaching the electronic end stops of the steering angle sensor (BVC)
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: During the measurement the machine should be parked on level ground.
The drum should be standing on old rubber tires or a metal plate.
Specify the engine speed -> travel lever out of braking position = neutral position
(Not while entering a code).
To prevent the steering from moving all the way to the mechanical stops of the steering cylinder it is
necessary to determine a defined safety distance to these end stops.
• Enter code number 9 9 9 9 to access the service mode.

• Enter code number 2 0 1 0 to activate the mode "Teach steering stops".
• Return the travel lever to neutral position (no braking function, but to relieve the machine of strain).
The display shows the standardized steering position (0..1000 → right ... left).
• Now turn the electric steering wheel clockwise, until the mechanical stop is reached The displayed
value should be in the range of 100..300. Then shift the travel lever to braking position and enter code
number 2 0 1 2 (press both Info-buttons first to access the input mode). In case of acceptance the
value 2 2 2 2 will appear for a moment. In case of a fault the value 9 9 9 9 upon acceptance (see
below).
• Return the travel lever to neutral position (no braking function, but to relieve the machine of strain).
The display shows the standardized steering position (0..1000 → right ... left).
• Now turn the electric steering wheel anti-clockwise, until the mechanical stop is reached The
displayed value should be in the range of 700..900. Then shift the travel lever to braking position and
enter code number 2 0 1 3 (press both Info-buttons first to access the input mode). In case of
acceptance the value 3 3 3 3 will appear for a moment. In case of a fault the value 9 9 9 9 upon
acceptance (see below).
• To leave the mode the machine must be switched off or code 2 0 1 1 must be entered.
Possible error causes (code 9 9 9 9 ) :
- Incorrect connection of hoses -> have checked by engineer -> correct.

- Connecting fault on potentiometer -> have checked by an electrician -> correct.
- Potentiometer faulty -> replace the potentiometer.

Author: Seis / TE
START
Machine on level
ground
Tires or metal plate

under drum
Machine on level
ground
enter 9999
enter 2010
Travel lever in
neutral position
Turn steering wheel to the

RIGHT to the STOP
(PRV can be heard,
cylinder full extended or
retracted).
Travel lever in brake

position
Display shows Display shows

enter 2012 2222 9999
OK ERROR
Travel lever in
neutral position
Turn steering wheel to the

LEFT to the STOP
(PRV can be heard,
cylinder full extended or
retracted).
Travel lever in brake

position
Display shows Display shows

enter 2013
3333 9999
OK ERROR
Switch ignition off

and on again OR enter 2011
FINISHED

Author: Seis / TE
3.8 Automatic detection of surge currents on steering valves (BVC)
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: Execute this function only AFTER "Teaching electronic end stops of angle sensor".
During the measurement the machine should be parked on level ground.

Before the measurement both drums should be steered to straight ahead position.
The travel motor must be moved out of braking position -> raised idle speed!
To enable a sensitive and exact function of the steering the surge currents of the two control solenoids
and both steering valves must be measured. The surge currents are automatically adjusted after entering
a code number, so that no electric meter is required.
The surge currents must only be adjusted during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and after
the replacement of the ESX-control.
The measurement is identical for both solenoids:
Example BW 177 BVC:

After entering the respective code number the current is increased by the control solenoid in steps of 5
mA, starting from 650 mA.. After each increasing step the system waits for 2 seconds. If a change in
drum angle is measured after the waiting time, the surge current is reached. In order to enhance the
measuring result this measurement is performed three times. The final surge current is the mean value of
these three measurements. This surge current is automatically stored and is valid from the next start of
the machine.
For all other machine types the same procedure is used, however, currents and times will vary.
Before the measurement you must strictly make sure that the steering system is „bled“, because an air
cushion in the steering cylinders would have a negative effect on the measurement and therefore on the
steering performance of the machine. Sufficient bleeding is achieved by performing a few quick steering
movements at full engine speed.
The automatic measurement of the steering valve surge currents is performed as follows:
• The engine must be operated in ECO-mode!
• Enter code number 9 9 9 9 to access the service mode.
• Travel lever in neutral position (Brake must be relieved!)
• Enter code number 2 0 0 0 . This code number activates the function "Automatic detection of steering
valve surge currents"; the display now shows the reading 0 0 0 0 with the first digit flashing.
• Now code number 2 0 0 1 must be entered.
• After entering one of the above mentioned code numbers the measurement of the surge current will
start immediately.
• The drum is thereby first steered to the right and then to the left.
• During the measurement the actual valve current is displayed (display value in mA).
• Attention! During the measurement the drum cannot be steered ! The steering wheel has no
effect.
• During the measurement the machine should not be driven !
• Once the measurement is completed the display value OK will appear for 3 seconds, after this the
code number 0000 is displayed with the first digit flashing, the next measurement can be started.
• The new surge current values are valid from the next start.

Author: Seis / TE
3.9 Driving against the closed brake

After entering the code number 0 5 0 0 the brake will not be released. If the travel lever is in this
condition shifted out of the brake gate and moved to any travel direction, the travel pumps will be
triggered according to the chosen travel direction. At the same time a warning (fault code 0 5 0 0 )
appears on the display and the warning buzzer is triggered, in order to keep the operator informed about
the condition. The brake control light in the LC-display remains activated.
In order to terminate this function and release the brake you must either enter code number 0 5 0 1 or
switch the ignition off. After entering code number 0 5 0 1 the function is aborted and OK is displayed as
confirmation for 5 seconds. After this the code needs to be entered again.
3.10 Showing stored faults

Switch on function „Show stored faults“:

• Enter code number 0 7 0 0 . This code number enables the function „Show stored faults“.
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will
appear again. If no faults are stored in the ESX, the display will show "- - - - - "
Switch off function „Show stored faults“:

• Enter code number 0 7 0 1 . This code number disables the function „Show stored faults“.
Note: Apart from the stored faults the current faults are also displayed.
3.11 Delete all stored faults

Execute the function „Delete all stored faults“:

• The engine must not be running!
• Enter code number 0 7 1 0 .
• Switch the ignition off and on again.
All stored faults are now deleted.
Note: The stored faults can only be deleted when the engine is not running.

Author: Seis / TE
4 How to proceed when replacing components?

Each machine is adjusted individually during initial commissioning. This adjustment or teaching process
is necessary to make sure that the travel and steering functions are almost identical on all machines.
Background of these adjustment procedures are the tolerances of the components used, e.g. hydraulic
pump for travel system, proportional valves for steering, steering angle sensors and ESX control. These
tolerances apply for both mechanical as well as electrical functions and are unavoidable for
manufacturing reasons.
To enable simple and quick adjustment procedures we have decided to do without expensive tools. All
that is needed is this manual and a bit of time. By following the described procedure it is possible to take
a machine back into operation after the replacement of one of the components specified above and to re-
establish the usual functional quality, with almost any previous knowledge. Even an incorrectly or
incompletely conducted teaching procedure can be repeated without problems as often as necessary. At
the first glance it seems to be at bit awkward to perform this adjustment work on every machine, but this
procedure enables the operation of all machines with the same operating software. At the end of the day
this considerably increases the spare parts availability.
4.1 Replacement of an ESX-control

Since the control stores all teach values of the machine, each teaching procedure must be performed
with the new control after a replacement.
Attention: Before performing one of the following steps you must first set the corresponding
machine type (see chapt. 3.3)!
When changing the machine type all previously made adjustments will be lost!
Now the teach functions must be executed.
• From DH
• Automatic detection of travel system surge currents (see chapt. 3.6)
• On BVC
• Automatic detection of steering valve surge currents (see chapt. 3.7)
• Teaching the electronic end stops of the steering angle sensor (see chapt. 3.8)
4.2 Replacement of a travel pump / axle drive motor / drum drive motor
• Automatic detection of travel system surge currents (see chapt. 3.6)
•
4.3 Replacement of a steering valve (BVC)

• Automatic detection of steering valve surge currents (BVC) (see chapt. 3.7)
•
4.4 Replacement of a steering angle sensor

• Teaching the electric end stops of the steering angle sensor (see chapt. 3.8)
4.5 How to proceed when replacing a front / rear axle sensors?

• Teaching the travel direction sensor

Author: Seis / TE
4.6 Which components can be replaced without a subsequent adjustment

procedure?
• Display
• Data collector
• Joystick
• Electric steering wheel
• Diesel engine
• All switches in the dashboard
• Vibration motor
• Vibration pump
Note: A final function test of the complete machine is highly recommended.

Author: Seis / TE
Service Training WZ – 4 Description of Signals on the ESX Control
5 Description of the Signals on the ESX-Control

Notes:
Wherever the value of 24 V is mentioned in the following text, it refers to the current battery voltage
under due consideration of voltage drops in the lines.
ESX terminal Signal description Nominal values (voltage / current)

X35:1 AGND = Analogue ground: Ground potential for sensors (steering angle approx. 0 V measured against ground (terminal 31)
sensor, steering unit etc.)
X35:2 Output amplitude changeover active, i.e. high amplitude Fapprox. 12 V
Digital output (max. 2.5 A) inactive, i.e. low amplitude F 0V
X35:3 Output warning buzzer Warning buzzer active Fapprox. 12 V
Digital output (max. 2.5 A) Warning buzzer inactive F 0V
X35:4 RS 232 RxD interface, not used for normal operation. Measurement not possible!
X35:5 RS 232 TxD interface, not used for normal operation. Measurement not possible!
X35:6 Not used ---
X35:7 Not used ---
X35:8 Not used ---
X35:9 Not used ---
X35:10 Not used ---
X35:11 Not used ---
X35:12 Input axle speed Signal changes between approx. 0V and 12V, when machine is driving.
Frequency input (0....7,5kHz) Frequency with travel speed m/min
Machine type:
XX m/min Fapprox.XX Hz
Machine type:
Machine type:
X35:13 Not used ---
Version/Status: V2.07 / 24.06.05 Description of Signals on the ESX Control Page 21 of 67

Author: Seis / TE

X35:14 Not used ---
X35:15 Input seat contact switch Seat operated F 0V
Digital input active high Seat not operated F ?V
X35:16 Not used ---
X35:17 Input BTS brake (from travel lever) Brake released Fapprox. 12 V
Digital input active high Brake applied F 0V
X35:18 Input steering sensor (S1/A) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned.
Frequency depends on speed of turning
X35:19 Input steering sensor (S1/B) Signal changes between approx. 0V and 12V, when steering wheel is
X35:20 Output steering left Steering left active F 0,4..1,6 A
PWM digital output (max. 4 A) Steering left inactive F 0A
X35:21 Output steering right Steering right active F 0,4..1,6 A
PWM digital output (max. 4 A) Steering right inactive F 0A
X35:22 Output vibration pump attachment plate permissible current range: approx. 0..1,2 A
PWM digital output (max. 4 A) Vibration pump active F 0,6..1,2 A
Vibration pump not active F 0A
X35:23 Voltage supply for sensors Nominal voltage = 8,5 V
This output supplies steering angle sensor and steering unit. Permissible range: approx. 7,65..9,35 V
Without this voltage the control cannot work correctly and will switch toThis voltage must be measured against AGND.
override mode (emergency function).
X35:24 Output backup alarm Backup alarm inactive F 0V
Digital output (max. 2.5 A) Backup alarm active Fapprox. 12 V
X35:25 Not used ---
X35:26 Interface CAN-Bus 1 Wire -, is used for communication with MESX, data
collector, LCD-display and BOP. MEASUREMENT NOT POSSIBLE!
X35:27 Interface CAN-Bus 1 Wire +, is used for communication with MESX, data
collector, LCD-display and BOP. MEASUREMENT NOT POSSIBLE!
X35:28 Input potential terminal 15 Control switched on Fapprox. 12 V
Digital input active high Control switched off Fapprox.2 V
This signal must be present, so that the control can work.

Author: Seis / TE

X35:29 Input steering angle sensor Position steering angle sensor (measured against AGND)
Analogue input / voltage input 0..8.5 V right hand stop F 0,50..1,00 V
straight ahead / neutral / middle F ..V
left hand stop F 6,80..8,70 V
X35:30 Input longitudinal inclination of machine Inclination of machine (measured against AGND)
Analogue input / voltage input 0..8.5 V -45° axle high F 0,50..2,49 V
Neutral position F 2,50 V
maximum down F 2,51..4,50 V
X35:31 Input hydraulic pressure travel pump circuit 0 bar F approx.4 mA
Analogue input (current input 4mA..20mA) from pressure sensor on travel 600 bar F approx.20 mA
pump
X35:32 Not used ---
X35:33 Interface CAN-Bus 2 Wire -, is used for communication with travel lever
and engine EMR. MEASUREMENT NOT POSSIBLE!
X35:34 Input drum speed Signal changes between approx. 0V and 12V, when machine is driving.
Frequency input (0....7,5kHz) Frequency with travel speed m/min
Machine type:
Machine type:
Machine type:
X35:35 Input vibration motor Frequency with vibration frequency in Hz
Frequency input (0....2,0kHz) Machine type:
Vib. frequency XX Hz Fapprox.XX Hz
Machine type:
Machine type:

Author: Seis / TE

X35:36 Input sense of rotation of vibration motor Sense of rotation forward Fapprox. 12 V
(currently not used) Sense of rotation backward Fapprox.2 V
Digital input active high
X35:37 Input sense of rotation of drum Sense of rotation forward Fapprox. 12 V
Digital input active high Sense of rotation backward Fapprox.2 V
X35:38 Input sense of rotation of axle Sense of rotation forward Fapprox. 12 V
Digitaleingang aktiv high Sense of rotation backward Fapprox.2 V
X35:39 Not used ---
X35:40 Input steering sensor (S2/A) Signal changes between approx. 0V and 12V, when steering wheel is
X35:41 Input steering sensor (S2/B) Signal changes between approx. 0V and 12V, when steering wheel is
X35:42 Output emergency steering Emergency steering active Fapprox. 12 V
Emergency steering inactive F 0V
X35:43 Not used ---
X35:44 Not used ---
X35:45 Not used ---
X35:46 Output drum drive motor permissible current range: approx. 0..0,6 A
PWM power output (max. 4 A) Drum drive motor active F 0,0..2,0 A
Drum drive motor not active F 0A
X35:47 Output axle motor permissible current range: approx. 0..0,6 A
PWM power output (max. 4 A) Axle motor active F 0,0..2,0 A
Axle motor not active F 0A
X35:48 Output vibration pumpe permissible current range: approx. 0..0,6 A
PWM digital output (max. 4 A) Axle motor active F 0,0..2,0 A
Axle motor not active F 0A
X35:49 Output travel pump forward Travel forward active F 0,0..2,0 A
PWM power output (max. 4 A) Travel forward inactive F 0A
Sauer components with EDC

Travel forward active F 18..80 mA

Author: Seis / TE

Travel forward inactive F 0 mA
X35:50 Not used ---
X35:51 Not used ---
X35:52 Not used ---
X35:53 Interface CAN-Bus 2 Wire +, is used to communicate with the travel lever
and engine EMR. MEASUREMENT NOT POSSIBLE!
X35:54 Voltage supply for electronics (permanent voltage) Control running Fapprox. 12 V
Control not running F 0V
X35:55 Ground connection electronics 0 V (measured against ground)
X35:56 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:61 Output brake Open brake Fapprox. 12 V
Digital output (max. 4 A) Close brake F 0V
X35:62 Output blower coupling stage 2 (currently not used) Active Fapprox. 12 V
Digital output (max. 4 A) Inactive F 0V
X35:63 Output blower coupling stage 3 (currently not used) Active Fapprox. 12 V
Digital output (max. 4 A) Inactive F 0V
X35:64 Output travel pumps reverse Travel forward active F 0,0..2,0 A
PWM power output (max. 4 A) Travel forward inactive F 0A
Sauer components with EDC

Travel forward active F 18..80 mA
Travel forward inactive F 0 mA
X35:65 Test connection Baby Boards approx. 0 V

Author: Seis / TE

Author: Seis / TE
Service Training WZ – 4 Description of Signals on the Data Collector
6 Description of signals on the data collector

Notes:
Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage
PIN data Signal description Nominal values (voltage / current)

collector
X26:1 Input indicator right Indicator right active Fapprox. 12 V
Digital input active high Indicator right inactive F 0V
X26:2 Input indicator left Indicator left active Fapprox. 12 V
Digital input active high Indicator left inactive F 0V
X26:3 Input engine running (D+) Engine running Fapprox. 12 V
Digital input active high Engine not running F 0V
X26:4 Not used ---
X26:5 Input hydraulic oil filter differential pressure Filter clogged F 0V
Digital input active low Filter OK F ?V
X26:6 Not used ---
X26:7 Input air conditioning Air conditioning on Fapprox. 12 V
Digital input active high Air conditioning off F 0V
X26:8 Input engine air filter Filter clogged F 0V
Digital input active low Filter OK F ?V
X26:9 Input background illumination Illumination on Fapprox. 12 V
Digital input active high Illumination off F 0V
X26:10 Input coolant supply Coolant supply too low F 0V
Digital input active low Sufficient coolant supply F ?V
X26:11 Not used ---
X26:12 Ground connection 0V (measured against ground)
X27:1 Not used
X27:2 Input fuel level The voltage signal changes with the filling level in the fuel tank
Analog input Fuel tank empty F ?? V
Fuel tank full F ?? V
X27:3 Not used ---
Version/Status: V2.07 / 24.06.05 Description of Signals on the Data Collector Page 27 of 67

Author: Seis / TE
Service Training WZ – 4 Description of Signals on the Data Collector
PIN data Signal description Nominal values (voltage / current)

collector
X27:4 Voltage supply for monitoring of water separation (PIN X27:9) Voltage supply O.K. Fapprox.12 V
No voltage supply F 0V
X27:6 Interface CAN-Bus 1 Wire +, is used for communication with MESX, Measurement not possible!
ESX, LCD-display and BOP.
X27:7 Interface CAN-Bus 1 Wire -, is used for communication with MESX, ESX, Measurement not possible!
LCD-display and BOP.
X27:8 Voltage supply (permanent voltage) Control running Fapprox. 12 V
Control not running F 0V
X27:9 Input water separation If a sufficient amount of water has been separated, a low current flows over
Current input the over the contacts and the water in the separator bowl. This input
analyses this current.
No water separated F I= 0A
Water separated F I∗ 0,03mA
X27:10 Not used ---
X27:11 Not used ---
X27:12 Not used ---
Version/Status: V2.07 / 24.06.05 Description of Signals on the Data Collector Page 28 of 67

Author: Seis / TE
Service Training WZ – 4 Description of Signals on the Travel Lever
7 Description of signals on the travel lever

Notes:
PIN Signal description Nominal values (voltage / current)

travel lever
X23:1 Voltage supply (permanent voltage) Electronics functioning Fapprox. 12 V
Electronics not working F 0V
X23:3 Output BTS brake Brake opens Fapprox. 12 V
Digital output (max. 4 A) Brake closes F 0V
X23:4 Output BTS (not used)
Digital output (max. 4 A)
X23:5 Output voltage supply for additional analog evaluations Nominal voltage = approx. 5,0 V
This output supplies the 24-stage travel range selector switch. This Permissible range: approx. 4,8..5,2 V
voltage is required to connect and evaluate further analog switches to the This voltage must be measured against AGND.
travel lever.
X23:6 Interface CAN-Bus 2 Wire +, is used to communicate with ESX and Measurement not possible!
engine EMR.
X23:7 Interface CAN-Bus 2 Wire -, is used to communicate with ESX and Measurement not possible!
engine EMR.
X23:8 AGND = Analogue ground: Ground potential for additional analog approx. 0 V measured against ground (terminal 31)
evaluations
Reference to PIN X23:5
X23:9 Node address addressing 1 Connection to machine ground (0V)
X23:10 Node address addressing 2 Connection to machine ground (0V)
Version/Status: V2.07 / 24.06.05 Description of Signals on the Travel Lever Page 29 of 67

Author: Seis / TE
Service Training WZ – 4 Description of Signals on the Travel Lever
PIN Signal description Nominal values (voltage / current)

travel lever
X23:11 Input travel stage selector switch The voltage signal changes with the adjusted travel speed range
Analog input Travel stage min. F ?? V
Travel stage max. F ?? V
X23:12 Not used ---
X24:1 Not used ---
X24:2 Input high amplitude High amplitude active Fapprox. 12 V
Digital input active high High amplitude inactive F 0V
X24:3 Input low amplitude Low amplitude active Fapprox. 12 V
Digital input active high Low amplitude inactive F 0V
X24:4 Not used ---
X24:5 Not used ---
X24:6 Input arm rest left (not yet realized) ---
Digital input active high
X24:7 Output voltage supply for additional digital evaluations Voltage supply active Fapprox. 12 V
This output supplies the amplitude selector switch. This voltage is Voltage supply inactive F 0V
required to connect and evaluate further digital switches to the travel
lever.
X24:8 Output voltage supply ground potential 0V (measured against ground)
In connection with PIN X24:7 this output enables the control of additional
components (relays, displays etc.)
Version/Status: V2.07 / 24.06.05 Description of Signals on the Travel Lever Page 30 of 67

Author: Seis / TE
Service Training WZ – 4 Description of Signals on the LC-Display
8 Descriptions of signals on the LC - Display

Notes:
PIN Display Signal description Nominal values (voltage / current)

X28:1 Voltage supply (permanent voltage "ignition on") Electronics functioning Fapprox. 12 V
X28:3 Interface CAN-Bus 1 Wire +, is used for communication with MESX, Measurement not possible!
ESX, data collector and BOP.
X28:4 Interface CAN-Bus 1 Wire -, is used for communication with MESX, ESX, Measurement not possible!
data collector and BOP.
X28:5 Voltage supply (permanent voltage "Battery +“ for RTC) Electronics functioning Fapprox. 12 V
X28:6 Not used ---
X29:1 Input lower frequency Adjustment active Fapprox. 12 V
Digital input active high Adjustment inactive F 0V
X29:2 Input higher frequency Adjustment active Fapprox. 12 V
Digital input active high Adjustment inactive F 0V
X29:3 Input engine speed high idle High idle active Fapprox. 12 V
Digital input active high High idle inactive F 0V
X29:4 Input engine speed low idle Low idle active Fapprox. 12 V
Digital input active high Low idle inactive F 0V
X29:5 Not used ---
X29:6 Not used ---
X29:7 Output voltage supply for additional digital evaluations Voltage supply active Fapprox. 12 V
This output supplies the engine speed switch and the switch for Voltage supply inactive F 0V
frequency adjustment. This voltage is required to connect and evaluate
further digital switches to the LCD.
X29:8 Not used ---
Status: 24.06.05 Description of Signals on the LC-Display Page 31 of 67

Author: Seis / TE
Service Training WZ - 4 Description of Signals on the DIOS-Module
9 Description of Signals on DIOS-Module

(only for option with attachment plates)
DIOS terminal Signal description Nominal values (voltage / current)

X62:1 Interface CAN-Bus 1 Wire +, is used to communicate with the ESX- Measurement not possible!
control.
X62:2 Interface CAN-Bus 1 Wire -, is used to communicate with the ESX- Measurement not possible!
control.
X62:3 Voltage supply for electronics Ignition ON: Fapprox. 12 V
Ignition OFF: F 0V
X62:4 Input proximity switch, plates middle Plates in middle position Fapprox. 12 V
Digital input active high Plates outside middle position F 0V
X62:5 Output plates up Up active Fapprox. 12 V
Digital output (max. 4 A) Up inactive F 0V
X62:6 Output plates down Down active Fapprox. 12 V
Digital output (max. 4 A) Down inactive F 0V
X62:7 Output plates left Sliding to left active Fapprox. 12 V
Digital output (max. 4 A) Sliding to left inactive F 0V
X62:8 Output plates right Sliding to right active Fapprox. 12 V
Digital output (max. 4 A) Sliding to right inactive F 0V
X62:9 Voltage supply for outputs Ignition ON: Fapprox. 12 V
Ignition OFF: F 0V
X62:10 Voltage supply for outputs Ignition ON: Fapprox. 12 V
Ignition OFF: F 0V
X62:11 Ground connection 0 V measured against ground
X62:12 Input proximity switch, plates top Plates lifted above sensor F 0V
Digital input active high Plates lowered below sensor Fapprox. 12 V
X62:13 Output plates float position 1 Float position active Fapprox. 12 V
Digital output (max. 4 A) Float position inactive F 0V
X62:14 Output plates priority Priority active Fapprox. 12 V
Digital output (max. 4 A) Priority inactive F 0V
X62:15 Output plates float position 2 Float position active Fapprox. 12 V
Digital output (max. 4 A) Float position inactive F 0V
X62:16 Not used ---
Version/Status: V2.07 / 24.06.05 Description of Signals on the DIOS-Module Page 32 of 67

Author: Seis / TE
Service Training WZ - 4 Description of Signals on the DIOS-Module
Version/Status: V2.07 / 24.06.05 Description of Signals on the DIOS-Module Page 33 of 67

Author: Seis / TE
Service Training Fault Codes on ESX Control
10 Fault codes of the ESX control
10.1 Overview
Fault code Fault description
0000 - General faults / warnings / machine tests
0999
1000 - Fault in travel system
1999
2000 - Fault in steering system
2499
2500 - Fault in remote control
2999
3000 - Faults in work functions (vibration, attachment plates, rotor, chip
4499 spreader)
4500 - Fault in measuring systems
4999
5000 - Fault diesel engine
5499
5500 - Fault hydraulic system
5999
6000 - Fault anti-theft warning system, localization system, access
6999 system, time account, etc.
7000 - Input of machine codes
7499
7500 - Input of codes for measuring technology
7899
7900 - Operating hours, load spectrum, etc.
7999
1
8000 - Severe software error
8999
9000 - Errors of external IO-nodes (joystick, data collector, Dios module,
9999 LC-display, etc.) 1
1
These faults are not broken down hereunder!
Version/Status: V2.07 / 24.06.05 Fault Codes on ESX Control Page 34 of 67

Author: Seis / TE
Service Training WZ – 4 Description of Fault Codes on Control
10.2 Description of fault reactions

Fault reaction Description of fault reaction
1 Warning.
Fault code is displayed.
2 Warning.
Audible signal
3 Function affected, the faulty function is replaced by an emergency function.

Audible signal
4 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is stopped if this fault occurs.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Audible signal
5 Partial function faulty, the partial function cannot be overridden by an emergency function.
F the diesel engine is shut down.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
Audible signal
6 Fatal fault. The function of the control can no longer be guaranteed.

F Control is switched off.
F the diesel engine is shut down, if possible.
The fault code is displayed, the signal light in the monitoring board is permanently on.
No audible signal!
Note: Errors with error reaction 1 and 2 are only warning messages and are NOT stored in the error log.
Version/Status: V2.07 / 24.06.05 Description of Fault Codes on Control Page 35 of 67

Author: Seis / TE
10.3 Detailed description of fault codes and their possible causes
10.3.1 General
Fault Fault description Possible causes Equip. Assignment Input Fault
Code conn.- DH-4 BVC-4 code for reaction
Terminal diagnose
500 Driving against brake – warning A corresponding input code has been entered X X
The function "Driving against brake" is activated
502 Simulated engine run - warning A corresponding input code has been entered X X
The function "Simulated engine run" is activated
504 Ant- Slip Control (ASC) deactivated - warning A corresponding input code has been entered X X
The function "Anti Slip Control (ASC)" is deactivated
507 Drum drive deactivated - warning A corresponding input code has been entered X X
Test mode "Drum drive deactivated" was activated.
508 Axle drive deactivated - warning A corresponding input code has been entered X X
Test mode "Axle drive deactivated" was activated.
560 Overvoltage 8,5V Connection of voltage level to operating voltage, another X35:23 X X
The voltage level of the 8,5V range is impermissibly voltage potential or control defective
exceeded
(see signal description)
561 Undervoltage 8,5V Connection of voltage level to ground, another voltage potential X35:23 X X
The voltage level of the 8,5V range is impermissibly fallen or control defective
short of
562 Error "Voltage Override Relay" X X
The voltage level of the 8,5V range is...

Author: Seis / TE
10.3.2 Brake
Terminal diagnose
1001 Brake valve line breakage The connecting line between control output and control X35:61 X X
The required control power cannot be transmitted to the solenoid is interrupted, or
control solenoid. The proportional solenoid is defective
1002 Brake valve Cable breakage in ground line, or X35:61 X X
Signal outside the valid range (see signal description) Connecting cable between valve and ground connection has
come loose
1003 Brake valve Cable breakage in connecting line, or X35:61 X X
Signal outside the valid range (see signal description) Connecting cable between valve and supply has come loose
1004 BTS brake / travel lever (BTS=output driver) Hardware defect on travel lever X35:17 X X
Overheating of the BTS has the effect, that the braking
position of the travel lever is not correctly recognized
1005 BTS brake / plausibility (BTS=output driver) Hardware defect on travel lever, input X35:17 has not the same X35:17 X X
Plausibility conflict in evaluation of travel lever X- and y- voltage as the BTS
axes to the brake contact signal
10.3.3 Travel lever

Terminal diagnose
1025 Travel lever sum error X-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of axis
1026 Travel lever cable breakage X-axis Cable breakage in travel lever -> Replace travel lever. X X
Signal outside the valid range (see signal description)
1027 Travel lever parameterization X-axis Internal fault in travel lever -> Replace travel lever. X X
1028 Travel lever direction evaluation X-axis Internal fault in travel lever -> Replace travel lever. X X
The direction of travel lever movement could not be
determined
1029 Travel lever difference error X-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of travel lever signal
1030 Travel lever software error X-axis Internal fault in travel lever -> Replace travel lever. X X
Software does not work fault free

Author: Seis / TE

Terminal diagnose
1031 Travel lever sum error Y-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of axis
1032 Travel lever cable breakage Y-axis Cable breakage in travel lever -> Replace travel lever. X X
Signal outside the valid range (see signal description)
1033 Travel lever parameterization Y-axis Internal fault in travel lever -> Replace travel lever. X X
1034 Travel lever direction evaluation Y-axis Internal fault in travel lever -> Replace travel lever. X X
The direction of travel lever movement could not be
determined
1035 Travel lever difference error Y-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of travel lever signal
1036 Travel lever software error Y-axis Internal fault in travel lever -> Replace travel lever. X X
Software does not work fault free
10.3.4 Travel speed range selector switch

Terminal diagnose
1040 Travel range selector switch "Ground connection" Cable breakage in ground line, or X23:8 X X
Signal outside the valid range (see signal description) Connecting cable between switch and ground connection has
come loose
1041 Travel range selector switch "Supply connection" Cable breakage in connecting line, or X23:5 X X
Signal outside the valid range (see signal description) Connecting cable between switch and supply line has come
loose
1042 Travel speed range selector switch Higher contact resistances have possibly caused a faulty X23:11 X X
Signal outside the valid range (see signal description) signal.
The switch must be replaced.

Author: Seis / TE
10.3.5 Travel system

Terminal diagnose
1070 Output travel pump forward The connecting line from the output of the control to the X35:49 X X
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid
proportional solenoid. is defective
1071 Fault of current regulator forward Faults in valve control Check wiring. X X
1072 Fault of current regulator forward Faults in valve control Check wiring. X X
1073 Output travel pump forward Short circuit of connecting line (control to proportional valve) to X35:49 X X
Supply voltage UB applied to the output to the proportional voltage supply
valve.
1074 Error in teaching the surge current forward Machine mechanically blocked X35:49
Travel system bypass valves out of adjustment
1080 Output travel pumps reverse The connecting line from the output of the control to the X35:64 X X
1081 Fault of current regulator reverse Faults in valve control Check wiring. X X
1082 Fault of current regulator reverse Faults in valve control Check wiring. X X
1083 Output travel pumps reverse Short circuit of connecting line (control to proportional valve) to X35:64 X X
valve.
1084 Error in teaching the surge current reverse Machine mechanically blocked X35:64
Travel system bypass valves out of adjustment
1088 Note! Surge currents for travel pump have NOT been The function "Teaching pump surge currents" for the travel X X Note
learned. See 3.6 pump has not yet been executed.
-> New machine/replacement of control
1100 Output front travel motor The connecting line from the output of the control to the X35:46 X X
1105 Speed sensor pulses front travel motor Check connecting lines and plugs on wheel speed sensor, if X35:34 X X
Incorrect or non-existent signal "Frequency" necessary replace the wheel speed sensor
1106 Direction signal pulses front travel motor Check connecting lines and plugs on wheel speed sensor, if X35:37 X X
Incorrect or non-existent signal "Direction" necessary replace the wheel speed sensor

Author: Seis / TE

Terminal diagnose
1107 Output front travel motor Short circuit of connecting line (control to proportional valve) to X35:46 X X
valve.

Author: Seis / TE
1110 Output rear travel motor The connecting line from the output of the control to the X35:47 X X
1115 Speed sensor pulses rear travel motor Check connecting lines and plugs on wheel speed sensor, if X35:12 X X
Incorrect or non-existent signal "Frequency" necessary replace the wheel speed sensor
1116 Speed sensor direction signal rear travel motor Check connecting lines and plugs on wheel speed sensor, if X35:38 X X
Incorrect or non-existent signal "Direction" necessary replace the wheel speed sensor
1117 Output rear travel motor Short circuit of connecting line (control to proportional valve) to X35:47 X X
valve.
1140 Travel system pressure sensor "Signal" The connecting line between control output and pressure X35:31 X X
The current signal is not transmitted (see signal sensor is interrupted, or
specification The pressure sensor is defective
1141 Travel system pressure sensor "Signal range" The pressure sensor is defective X35:31 X X
The current signal is outside the valid range (see signal
specification)
1142 Travel system pressure sensor "no pressure" No pressure connection on sensor or supply line clogged, or X35:31 X X
The electric signal indicates that the travel pressure is No travel pressure built up
permanently missing.
1145 Inclination sensor "Supply connection" Cable breakage in supply line, or connecting cable sensor / X35:?? X X
Signal outside the valid range (see signal description) voltage supply has come loose ..
X35:30
1146 Inclination sensor "Ground connection" Cable breakage in ground line, or connecting cable sensor / X35:1 X X
Signal outside the valid range (see signal description) ground supply has come loose
1300 Seat connect not occupied Cable breakage in signal line or driver's seat not loaded (driver X35:15 X X
not seated!)
1500 Warning "Dangerous condition ASC" Due to counter-rotating drive units the machine was stopped X X
and the brake applied.
After setting the travel lever to brake position the brake can be
released.

Author: Seis / TE
10.3.6 Steering
(Only machine with electric steering)
Terminal diagnose
2060 Output steering valve right The connecting line between control output and proportional X35:20 X
proportional solenoid. The proportional solenoid is defective
2061 Output steering valve left The connecting line between control output and proportional X35:21 X
proportional solenoid. The proportional solenoid is defective
2065 Error when teaching the surge current for the Drum was not moved, maximum current was reached, steering X35:20
right hand valve is blocked (e.g. articulation lock applied)
2066 Error when teaching the surge current for the left Drum was not moved, maximum current was reached, steering X35:21
hand valve is blocked (e.g. articulation lock applied)
2068 Note! Surge currents for steering pump have NOT been The function "Teaching pump surge currents" for the steering (X) Note
learned. See 3.7 pump has not yet been executed.
(Only machine with electric steering) -> New machine/replacement of control
2170 Steering valve (arm rest) "direction change" Wiring fault or steering sensor in left hand arm rest defective X35:18 X
X35:19
X35:40
X35:41
2171 Steering valve (arm rest) "Pulse coverage" Steering sensor in left hand arm rest defective. X35:18 X
High difference in measuring values between sensor 1 X35:19
and 2 X35:40
X35:41
2172 Steering wheel (arm rest) "Sensor 1 pulse range" Check connecting line to steering sensor 1 or X35:18 X
The detected steering pulses on steering sensor 1 are replace the steering sensor in the left hand arm rest, if X35:19
outside the valid range necessary
2173 Steering wheel (arm rest) "Sensor 2 pulse range" Check the connecting lines to steering sensor 2, or replace the X35:40 X
The detected steering pulses on steering sensor 2 are steering sensor in the left hand arm rest, if required. X35:41
outside the valid range
2174 Steering wheel A45 (arm rest) "Sensor 1" Steering sensor in left hand arm rest defective. X35:18 X
X35:19

Author: Seis / TE

Terminal diagnose
2175 Steering wheel A45 (arm rest) "Sensor 2" Steering sensor in left hand arm rest defective. X35:40 X
X35:41
2176 Steering wheel A45 (arm rest) "Sensor 1 cable Check the connecting lines to steering sensor 1, or replace the X35:18 X
breakage" steering sensor in the left hand arm rest, if required. X35:19
2177 Steering wheel A45 (arm rest) "Sensor 2 cable Check the connecting lines to steering sensor 2, or replace the X35:40 X
breakage" steering sensor in the left hand arm rest, if required. X35:41
2190 Steering "steering angle sensor... initialization" Replace the control X

Internal control fault.
2191 Steering angle sensorB65 "Measuring value" Steering angle sensor on the articulated joint X35:29 X
2192 Steering angle sensor B65 "Supply cable Power supply line to the steering angle sensor interrupted, or X35:23 X
breakage" Steering angle sensor on the articulated joint
2193 Steering angle sensor B65 "Ground cable Ground cable to the steering angle sensor interrupted, or X35:1 X
breakage" Steering angle sensor on the articulated joint
2198 Note! Teaching of steering stops for electric steering The function "Teaching steering stops" for the electric steering (X) Note
NOT yet executed. See 3.7 has not yet been executed.
-> New machine/replacement of control
10.3.7 Driver's seat arm rest sensor

(Only machine with electric steering)
Fault Fault description Possible causes Terminal Assignment Input Fault
Code on ESX DH-4 BVC-4 code for reaction
diagnose
2300 Note! "Arm rest raised" The arm rest has been raised or the magnetic switch under the X35:16 X
left hand arm rest is defective
2301 Signal fault Cable breakage in magnetic switch signal line, or X35:16 X
Signal outside the valid range (see signal description) Magnetic switch under left hand arm rest defective
2302 Supply cable breakage Power supply line to the magnetic switch interrupted, or X35:16 X
Magnetic switch under left hand arm rest defective
2303 Ground cable breakage Ground cable to the magnetic switch interrupted, or X35:16 X
Magnetic switch under left hand arm rest defective

Author: Seis / TE
10.3.8 Vibration
Terminal diagnose
3000 Vibration sensor "No signal" Check connecting lines and plugs to the vibration sensor, or X35:35 X X
The sensor in the vibration motor does not pick up any replace the sensor in the vibration motor, if necessary.
pulses.
3001 Valve vibration pump (low amplitude on DH) Details in 3004 – 3008 X35:48 X X
General fault.
3002 Valve vibration pump (low amplitude on DH) System fault! Replace the control X35:48 X X
Internal system fault.
3003 Valve vibration pump (low amplitude on DH) Faults in control line, or X35:48 X X
"Current range" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3004 Valve vibration pump (low amplitude on DH) The connecting line between control output and proportional X35:48 X X
Line interruption solenoid is interrupted, or
The proportional solenoid is defective
changeover relay / bridge missing
3006 Valve vibration pump (low amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X X
"Control fault regulating up" Connection to another potential (e.g. operating voltage)
specification)
3007 Valve vibration pump (low amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X X
"Control fault regulating down" Connection to another potential (e.g. operating voltage)
specification)
3009 Vibration adaptation control (low amplitude on DH) Wear or damage in vibration system hydraulic circuit. X35:48 X X
"Frequency adaptation"
Limits of adaptation range exceeded
(see signal specification)

Author: Seis / TE
3011 Valve vibration pump (high amplitude on DH) Details in 3014 – 3018 X35:48 X
General fault.
3012 Valve vibration pump (high amplitude on DH) System fault! Replace the control X35:48 X
3013 Valve vibration pump (high amplitude on DH) Faults in control line, or X35:48 X
"Current range" Connection to another potential (e.g. operating voltage)
specification)
3014 Valve vibration pump "Cable breakage" The connecting line between control output and proportional X35:48 X
(high amplitude only DH) solenoid is interrupted, or
Line interruption The proportional solenoid is defective
3016 Valve vibration pump (high amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X
"Control fault regulating up" Connection to another potential (e.g. operating voltage)
specification)
3017 Valve vibration pump (high amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X
"Control fault regulating down" Connection to another potential (e.g. operating voltage)
specification)
3019 Vibration adaptation control (high amplitude on DH) Wear or damage in vibration system hydraulic circuit. X35:48 X
"Frequency adaptation"
Limits of adaptation range exceeded
(see signal specification)

Author: Seis / TE
10.3.9 Attachment plates

Fault Fault description Possible causes Terminal Assignment Input Fault
Code on ESX DH-4 BVC-4 code for reaction
diagnose
3051 Vibration pump, plates, valve Details in 3052 – 3058, this fault always is connected with one X35:22 X
General fault. of the faults listed below
3052 Vibration pump, plates, valve "hysteresis" X35:22 X
3053 Vibration pump, plates, valve "current range" X35:22 X
specification)
3054 Vibration pump, plates, valve "Cable breakage" The connecting line between control output and proportional X35:22 X
Line interruption solenoid is interrupted, or
The proportional solenoid is defective
3055 Vibration pump, plates, valve System fault! Replace the control X35:22 X
3056 Vibration pump, plates, valve X35:22 X

"Control fault positive limit"
specification)
3057 Vibration pump, plates, valve X35:22 X
"Control fault negative limit"
specification)
3058 Vibration pump, plates, valve System fault! Replace the control X35:22 X
3060 Warning ! Attachment plate lowered and backward The attachment plates are lowered and an attempt is made to X
travel drive backwards

Author: Seis / TE
10.3.10 Diesel engine

Terminal diagnose
5024 Diesel engine "Coolant level" warning Coolant level too low or sensor defective X26:10 X X
5025 Diesel engine "Coolant level" fault shut-down Coolant level too low or sensor defective X26:10 X X
5026 Diesel engine "Air filter" warning Air filter soiled or sensor defective X26:8 X X
5027 Diesel engine "Air filter" fault shut-down Air filter soiled or sensor defective X26:8 X X
5028 Water separator warning Water or other dirt in fuel filter X27:4 X X
X27:9
5029 Water separator fault shut-down Water or other dirt in fuel filter X27:4 X X
X27:9
10.3.11 Diesel engine EMR

Terminal diagnose
5100 Diesel engine EMR "Warning light" Collective warning X X
F see further fault code for more accurate fault diagnose
5101 Diesel engine EMR "red stop light" Collective message for engine shut down X X
F see further fault code for more accurate fault diagnose
5110 Diesel engine EMR "Nominal speed value" F CAN connection between ESX and EMR interrupted X X
F CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.
F ESX without voltage supply
F Battery charge level too low
5111 Diesel engine EMR "Engine oil filling level" F Engine oil filling level too low X X
5112 Diesel engine EMR "Oil pressure" F Engine oil pressure too low X31:21 X X
5113 Diesel engine EMR "Charge air pressure" F Charge air pressure too low X31:24 X X
5114 Diesel motor EMR "Temperaturein intake line" F Charge air temperature too high X31:4 X X
5116 Diesel engine EMR "Coolant temperature" F Coolant temperature too high X31:9 X X
5117 Diesel engine EMR "Fuel temperature" F Fuel temperature too high X X
5118 Diesel engine EMR "Engine speed" F Speed sensor 1 or 2 defective X31:13 X X
F Connection between EMR and speed sensor 1 or 2 X31:11
interrupted

Author: Seis / TE

Terminal diagnose
5120 Diesel engine EMR "CAN communication" F CAN connection between ESX and EMR interrupted
5121 Diesel engine EMR "CAN communication" F CAN connection between ESX and EMR interrupted
F EMR without voltage supply.
5122 Diesel engine EMR "Nominal speed value" F CAN connection between ESX and EMR interrupted
5123 Diesel engine EMR CAN communication F CAN communication between EMR and ESX X31:12 X X
X31:13
X31:13
X31:13
X31:13
5130 Diesel engine EMR "Oil pressure sensor" F Sensor defective X31:22 X X
F Wire breakage in current path X31:20
F Current path has short circuit to ground
5131 Diesel engine EMR "Charge air pressure sensor" F Sensor defective X31:25 X X
5132 Diesel engine EMR "Charge air temperature" F Sensor defective X31:25 X X
5133 Diesel engine EMR "Coolant temperature sensor" F Sensor defective X31:8 X X
F Wire breakage in current path
5134 Diesel engine EMR "Speed sensor" F Speed sensor 1 or 2 defective X31:10 X X

Author: Seis / TE

Terminal diagnose
X31:12
5140 Diesel engine EMR "unknown fault" Fault diagnostics only possible with DEUTZ diagnostics tool X X
(SERDIA)

Author: Seis / TE
10.3.12 Miscellaneous
Terminal diagnose
5502 "Hydraulic oil filter" warning Hydraulic oil filter soiled or sensor defective X X
5503 "Hydraulic oil filter" fault shut-down Hydraulic oil filter soiled or sensor defective X X
5504 "Oil temperature" warning Hydraulic oil temperature too high or sensor defective X X
5005 "Oil temperature" fault shut-down Hydraulic oil temperature too high or sensor defective X X
10.3.13 Machine type

Terminal diagnose
7011 Warning "Change of machine type" Only change the machine type after applying appropriate X X
This warning is displayed when the machine type is measures; e.g. conversion from D to PD (different rolling
changed. circumference of roller drum)
7012 "Conflict machine type" The machine type has been changed to such an extent, that the X X
This error message is displayed if the set machine does type parameters no longer match the basic parameters → enter
not comply with the basic parameters of the machine. the correct machine code or one of the basic machine
parameters was changed (e.g. different axle)

Author: Seis / TE
Service Training WZ – 4 Description of Input Codes on Control
11 Input Codes for ESX Control

Display and adjustment functions can generally only be accessed by entering "service code" 9999 beforehand!
11.1 Fault log

without service code!
Input code Description of display function Display values

0700 Function "Show stored faults“ activated Fault codes are displayed one after the other
0701 Function "Show stored faults“ deactivated 0000
0710 Delete stored faults once the fault log is deleted it is returned to 0000
11.2 Value displays
11.2.1 General
0555 Display of "machine control software version ( ESX)" e.g.: "1.13" for software version V 1.13
0556 Display of Firmware version "LCD Display" e.g. "1.36" for version 1.36
0557 Display of Firmware version "Data Collector" e.g. "1.11" for version 1.11
0720 Display of "Machine Code" The machine code is displayed (72xx) (see chapt. 3.6)
11.2.2 Brake
1001 Display of voltage at control output "Valve Brake" Display in V (e.g. 12.6 corresponds with 12,6V)
Version/Status: V2.07 / 24.06.05 Description of Input Codes on Control Page 51 of 67

Author: Seis / TE
11.2.3 Travel lever / driving

1020 Display "Travel lever end positions" 100 = Forward
0 = Neutral
10 = Reverse
1000 = Left
10000 = Right
Combinations are possible, e.g. 1100 for forward
1021 Display "Values for axle forward reverse" 0..1000 = Forward
0..-1000 = Reverse
1022 Display "Values for axle right left" left -> - 1000..0..1000 -> right, i.e. brake gate
1025 Display "Travel lever actuating direction" 100 = Forward
0 = Neutral
1 = Reverse
1026 Display "Travel direction" 0 = Neutral
1 = Forward
2 = Reverse
1027 Display "Travel lever release" 0 = locked
1 = released
11.2.4 Travel speed range selector switch

1040 Display "Speed range / gear" Position of travel range selector switch from 1...24
1041 Display "Voltage value for speed range / gear" Stages 0...4 = 4
Stages 5...9 = 3
Stages 10...14 = 2
Stages 15...19 = 1
Stages 20...24 = 0

Author: Seis / TE

1042 Display "Voltage value for speed range / gear standardized" Stage 1 ≈ 956 Stage 2 ≈ 916 Stage 3 ≈ 875
Stage 4 ≈ 835 Stage 5 ≈ 795 Stage 6 ≈ 756
1044 Display "Speed range / gear" end value Stage 1 = 417 Stage 2 = 833 Stage 3 = 1‘250
Stage 4 = 1‘667 Stage 5 = 2‘089 Stage 6 = 2‘500
11.2.5 Travel pump: Travel direction forward

1070 Display "Actual current value travel pump forward" Display in mA (0..350..1300)
1071 Display "Nominal current value travel pump forward" Display in mA (0..350..1300)
1078 Initial current value (learned surge current) of the valve Display in mA (permitted range 350mA..600mA)
1079 Maximum current value (derived end current) of the valve Display in mA (permitted range 1150mA..1400mA)
11.2.6 Travel pump: Travel direction reverse

1080 Display "Actual current value travel pump reverse" Display in mA (0..400..1300)
1081 Display "Nominal current value travel pump reverse" Display in mA (0..400..1300)
1088 Initial current value (learned surge current) of the valve Display in mA (permitted range 350mA..600mA)
1089 Maximum current value (derived end current) of the valve Display in mA (permitted range 1150mA..1400mA)

Author: Seis / TE
11.2.7 Travel motor front (drum)

1100 Actual pump current Display in mA (0..600..1000)
1101 Nominal pump current Display in mA (0..600..1000)
1105 Travel speed Display in m/min
1106 Pulses of speed sensor Counts the pulses up to 99'999 and starts again at 0
1107 Direction signal of speed sensor 2 = Forward
1 = Standstill and reverse
1108 Travel direction logics 1 = Forward
0 = Standstill
2 = Reverse
11.2.8 Travel motor rear (wheel axle)

1110 Actual pump current Display in mA (600..1000)
1111 Nominal pump current Display in mA (600..1000)
1115 Travel speed Display in m/min
1116 Pulses of speed sensor Counts the pulses up to 99'999 and starts again at 0
1117 Direction signal of speed sensor 2 = Forward
1 = Standstill and reverse
1118 Travel direction logics 1 = Forward
0 = Standstill
2 = Reverse
11.2.9 Adaption values for speed regulation

1128 Pre-control factor forward travel 7000..10000
1129 Pre-control factor reverse travel 7000..10000

Author: Seis / TE
11.2.10 Travel pressure sensor

11.2.11
1140 Pressure in bar 0..600
1141 Raw measuring value (voltage in V) 0..5V
1142 Standardized measuring value 0..1000
1143 Function status (internal logic -> diagnose) 0, 1, 2
11.2.12 Inclination sensor

1145 Value in % 0..80%
1146 Raw measuring value (voltage in V) 0..5V. 2.55V = 0%
1147 Standardized measuring value –1000..0..1000. (0 = 0%)
1148 Function status (internal logic -> diagnose) 0, 1, 2
11.2.13 Travel condition values

1150 Current travel speed (in km/h) 0,00..20,00
11.2.14 Speed limitation

1200 Current setting (in km/h) 0 = No limitation
6, 7, 8, 9, 10, 11,12
11.2.15 Arm rest contact

1300 Function status 1= arm rest up; 2= arm rest down
1301 Raw measuring value (voltage in V) Display in mV
1302 Travel operation status by arm rest contact 1= Driving permitted; 2= Driving disabled

Author: Seis / TE
11.2.16 Adaption values traction control

1500 Pre-control factor front 400..24000
1501 Pre-control factor rear 400..24000
11.2.17 Steering: Steering valve

2100 Display "Nominal current value steering valve right" 0– 1200mA
2101 Display "Actual current value steering valve right" Display in mA
2102 Display "Nominal current value steering valve left" 0– 1200mA
2103 Display "Actual current value steering valve left" Display in mA
2106 Display "Minimum current value steering valve left" Display in mA

2107 Display "Maximum current value steering valve left" Display in mA
2108 Display "Minimum current value steering valve right" Display in mA
2109 Display "Maximum current value steering valve right" Display in mA
11.2.18 Steering: Angle sensor in articulated joint

2110 Raw measuring value (voltage in V) 0...8,5VDC
2111 Standardized measuring value -1000...0...1000
2112 Standardized actual steering angle position -1000...0...1000

Author: Seis / TE
11.2.19 Steering: Steering wheel

2120 Standardized nominal steering angle position -1000...0...1000
2130 Steering wheel sensor 1 track 1 absolute pulses Number of total pulses
2132 Steering wheel sensor 1 total pulses of sensor
2133 Steering wheel sensor 1 sense of rotation 1=steering wheel steers to the right (clockwise); 2=steering
wheel steers to the left
2142 Steering wheel sensor 2 total pulses of sensor
2143 Steering wheel sensor 2 sense of rotation 1=steering wheel steers to the right (clockwise); 2=steering
wheel steers to the left
11.2.20 Vibration
3000 Display "Switch for vibration mode" Off = 0
On = 1
3001 Display "Status of vibration relay“ 0 = Relay K43 not switched
1 = Relay K43 switched
3002 Display "Vibration pump valve current" Display value = mA
The display shows the actual pump current.
3003 Display "Vibration pump valve current" (high amplitude on DH) Display value = mA
The display shows the actual pump current.

Author: Seis / TE
11.2.21 Attachment plates, option (only BW213 BVC)

3050 Display "Attachment plates activated" OFF, i.e. software for plates switched off
ON, i.e. software for plates switched on
3051 Display "Sensor for height shut-down" OFF = Sensor has switched, senses metal, plates raised
ON = Sensor has not switched, senses no metal, plates lowered
3052 Display "Sensor for middle position" OFF = Sensor has not switched, senses no metal
ON = Sensor has switched, senses metal, plates in middle
3053 Display "Logic vibration On-Off“ OFF = Vibration switched off

ON = Vibration switched on
3054 Display "Switch for float position" OFF = Switch switched off
ON = Switch switched on
Attention! Float position is not always activated when switch is in
ON-position!
3055 Display "Contact plates coupled" OFF = Plates are not hydraulically connected with the machine
ON = Plates are connected with the machine
3056 Display "Potentiometer value frequency setting of plates" 0..1000 standard, 0 = min. frequency, 1000 = max. frequency
3057 Control status valve "move up" OFF = Output not triggered
(Pin 5 DIOS module) ON = Output triggered
3058 Control status valve "move down" OFF = Output not triggered
3059 Control status valve "retract sideways" OFF = Output not triggered
3060 Control status valve "extend sideways" OFF = Output not triggered
3061 Control status valve "floating position" OFF = Output not triggered
(Pin 13 + 15 DIOS module) ON = Output triggered
3062 Control status valve "Priority change-over" OFF = Output not triggered

Author: Seis / TE
11.2.22 Engine
5000 Actual speed (rpm) 0..3000
5001 Nominal speed (rpm) 0..3000
5010 Idle speed (EMR parameter) (rpm) 600..1000
5011 Maximum speed (EMR parameter) (rpm) 1600..3000
5024 Display "Status engine coolant level" 0= Coolant level OK

1= Coolant level too low
5026 Display "Status engine air filter" 0= Air filter OK
1= Air filter soiled
5028 Display "Status of water separator" 0= Water separator OK
1= Water or dirt in fuel filter
5050 Charge air pressure (in bar * 100) 0..300 -> 0..3bar
11.2.23 Hydraulics
5502 Display "Status hydraulic oil filter" 0= Hydraulic oil filter OK
1= Hydraulic oil filter contaminated

Author: Seis / TE
11.3 Test settings
11.3.1 Brake
0500 Activates the function "Driving against the closed brake" 500 and brake control light stays on when shifting the travel lever
out of the brake gate
0501 Deactivates the function "Driving against the closed brake" O K for 3seconds, then 0000
11.3.2 Disable electric supply to wheel and drum drive motors (switch off)
1120 Enable function
1121 Switch off function "Disable electric supply for drum drive motor"
Motor remains in position: max. displacement.
1122 Function "Disable electric supply for drum drive motor"
Motor remains in position: max. displacement.
11.4 Settings / Teach / Emergency functions
11.4.1 Changing the machine code

7010 Change "Machine code" see chapter "Change machine code"
11.4.2 Automatic detection of surge currents in travel system

1090 Activate the function see chapt. "Teach travel system surge currents"
1091 Function "Determine surge currents forward" (only Vers.1.07 and 1.08) see chapt. "Teach travel system surge currents"
1092 Function "Determine surge currents reverse" (only Vers.1.07 and 1.08) see chapt. "Teach travel system surge currents"

Author: Seis / TE
11.4.3 Speed detection, trimming of measuring values

1158 Enable function
1159 Activate the function Pulses per 10m. 4000 - 15000
11.4.4 Speed detection, teaching of distance pulses

1160 Permit teach function
1161 Activate the function: Measurement over a travel distance of 5m Pulses read
1168 Reset to basic values "saved"

1169 Storing the learned values "saved"
11.4.5 Detection of wheel rotation

1200 Permit teach function
1201 Teach sense of rotation1 Raise travel speed over 10m/min
1
Only optional function! The logical sense of rotation is automatically adjusted

Author: Seis / TE
11.4.6 Steering: Automatic detection of surge currents on steering valve

2000 Activate function "Teach steering start current" see chapter 3.5
2001 Function "Teach steering start current" see chapter 3.5
11.4.7 Steering: Determining the steering stops

2010 Activate function "Teach steering stops" see chapter 3.7
2011 Deactivate function "Teach steering stops" 0000
2012 Function "Accept right hand steering stop" see chapter 3.7
2013 Function "Accept left hand steering stop" see chapter 3.7
11.4.8 Steering: Emergency function

2050 Steering with joystick buttons "OK". In case of steering wheel failure
2051 Steering wioth steering wheel (uncontrolled) "OK". In case of steering angle potentiometer failure
11.4.9 Steering: Other functions

2060 Activates function „Change steering unit“ see chapter 0
2061 Activate: Electric steering unit see chapter 0
2062 Activate: Hydraulic steering unit see chapter 0
11.4.10 Vibration: Cancellation of the vibration permission in dependence on the travel speed
3047 Activate function "Limitation of vibration permission"

3048 Limitation of vibration permission to travel stage 12
3049 Cancelling the limitation of vibration permission

Author: Seis / TE
11.4.11 Plates
3070 Enabling code "Change plate parameters"
3071 Code "Switch on plate operation" Only required if plates have been retrofitted
3072 Code "Switch off plate operation" Only required if plates have been removed
3075 Code "Plate adjustment without sensors" Attention – danger of collision! Use only in case of a sensor fault!
3076 Code "Plate pump energized without plates attached" Only for initial commissioning!

Author: Seis / TE
Service Training WZ – 4
12 Terminology in connection with ESX

Short circuit
A direct, unwanted connection between two different cables or between machine and cables.
Examples:
Two lines rub against each other until the insulation has worn off.
A conductive line rubs off the insulation at the vehicle ground.
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
• torn (not necessarily visible from outside)
• rubbed through
• chafed mostly in connection with a short circuit to ground
Terminal, cable lug

• loosened, slipped off
• broken off,
• corroded,
• socket / plug faulty
Version/Status: V2.07 / 24.06.05 General Terminology Page 64 of 67

Author: Seis / TE
Short circuit to ground

Line, terminal has direct connection to vehicle ground, often in connection with wire breakage
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω;
valve 0% to 100% opened (proportional valve)

Author: Seis / TE
Control
Controlling describes the process during which an input value influences a distance (the value
to be controlled), following a fixed command. For this purpose all possible interfering factors
(e.g. temperature, humidity ...) must be known.
Closed loop control

Closed loop control is a process during which a value, the closed loop control value (e.g.
pressure), is continually measured and compared with a nominal value (guide value). The result
of this comparison will affect the closed loop control value, thereby adapting the closed loop
control value to the guide value.
This sequence occurs in a closed circuit, the co-called closed loop control circuit.
Marking Closed loop control Control

Operating path: closed open
(closed loop control circuit) (control chain)
Measurement and Value to be adjusted is Values to be controlled
comparison of value to measured and compared. are not measured and
be adjusted: compared.
Reaction to faults Counteracts to all faults Does not respond to
(generally): targeting the system to be unknown faults
controlled.
Technical expense: Low expense: High expense if many
Measurement of the value to be faults have to be
controlled, comparison of considered, low expense if
nominal and actual value, power not faults occur.
amplification
Performance in For unstable systems closed In unstable systems
unstable systems loop controls must be used. controls cannot be used.

Author: Seis / TE
Current and voltage measurement
Ohm’s law:
U = R∗I
U = Voltage
U
R = Resistance I=
I = Current R
U
R=
I
Plausibility check
The control (ESX) runs a plausibility check on all inputs. This means the control checks
permanently whether certain state combinations are permitted; e.g. travel lever position forward
and reverse will cause an fault message, because this condition is normally not possible.
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional analogue
ground, which is only to be used for sensors. (see description of the signals on the ESX-
control)
PWM – digital output

Certain outputs on the ESX are designed as so-called PWM – digital outputs. This means that
these outputs are special current outputs. Here it is possible to measure a current, but no
voltage. These outputs are used to trigger proportional valves.

Author: Seis / TE
Inhaltsverzeichnis: BW177..226DH−4
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 582 700 95 Stromlaufplan Circuit Diagram
002 582 700 95 Versorgung, Starten, Hupe supply, starting unit, signal horn
003 582 700 95 Motor Deutz EMR II engine Deutz EMR II
004 582 700 95 Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch
005 582 700 95 Datensammler, LC−Display data−collector, LC−display
006 582 700 95 Lenkung, Vibration steering, vibration
007 582 700 95 Fahrhebel, Vibrationsplatten joystick, vibration−plates
008 582 700 95 Variocontrol, Messtechnik Variocontrol, measurement equipm.
009 582 700 95 Bomag Compaction Management BCM Bomag Compaction Management BCM
010 582 700 95 Beleuchtung und StvZO illumination and StvZO
011 582 700 95 Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph
012 582 700 95 Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater
101 582 700 95 Bauteilliste component listing
28.06.2004
Seis Stromlaufplan 001 001 582 700 95
28.06.2004 circuit diagram
Werner 001
30
K11
2:10
87
K30 11:1
30 4:1 K11:87 5:1
X1:15E X1:16E X1:27E X1:28E X1:30E
X1:9
X1:10
F13 1 F05 1 F95 1 F23 1 F39 1
30A 15A 15A 15A 15A
2 2 2 2 2
X1:15A X1:16A X1:27A X1:28A
X1:30A
6:17
X36:B
X36:A
4:9
X37:A X1:151
30 21 11 31 41 51 61
S00 S01 X3:3

22 12 32 42 52 62
2 x 10qmm
Startschalter NOT−Aus
K32:86
starting swwitch 15 54 58 19 17 50a Emerg.−Stop 11:1
X1:152 X1:155
X1:79
Sicherung Heizflansh
S01:22 3:1
X37:B
F05:2
Hauptsicherung
V01 X1:3 X1:4 5:8

heating−flange
K05 30
X34:P
main fuse
2 1 7:3
125mA
5
87 87a
K14 86 30
K61 K61
13 23
3:19 3 2:6 S03
2 2
F48 F00
125A 125A 85 87 87a X1:7 X1:8 Taster Hupe
push button, horn 14 24
only acc.to air conditioning

1 1 D+ 5:2
B+ 2:11 2:6 B+
nur bei Klimaanlage
D+ MESX 8:2
Anzugsw.:50A / Haltew.:10A
G01 G03 X38:A X1:97 X1:98
+ +
− −
X1:1 X1:101 X1:102
X1:109
167A
30 50
1 B+ D+ 86 86 B11 B11
1 K09 K11 1 2 2 1
G02 M01 V02 XS +
R19 S30 M
12V
2 2 1 V03 1 2 −
85 85 −
2
31 EMR 3:5 B− W
X1:110 X1:168 X1:123 X1:103 X1:104
31 31 3:1
Trennschalter Batter 2:8 12:7 2:16 Starter Signalhörer Steckdose

break switch battery starter warning horns socket
Heizflansch Batterie Batterie Generator Nur bei Geländer/ROPS/SD

heating−flange battery battery generator only at hand−rail/ROPS/sun−roof
28.06.2004
1 1 582 700 95
Seis Versorgung, Starten, Hupe
28.06.2004
Werner supply, starting unit, signal horn 002
2:17 S01:22 S01:22 6:1
X1:95
1
K14
Relais Heizflansch
relay heating−flange 2
X1:179 X1:96
X1:185
Steckerschnittstelle Deutz
connector interface Deutz
X33:7
X33:2
X33:3
X33:5
X33:6
X33:1
X33:4
X33:8
max 7A
8−polig PNEUTRON
A48
Motorsteuerung EMR2
X30:14
engine−controller EMR2
X31:21
X31:22
X31:13
X31:11
X31:14
X31:15
X31:24
X31:25
X31:4
X31:9
X31:5
X31:6
X31:3
X31:2
X31:7
X30:10
X30:11
X30:12
X30:13
X31:20
X31:12
X31:10
X31:17
X31:18
X31:19
X31:16
X31:23
X30:1
X30:2
X31:8
X31:1
AGND
AGND
AGND
AGND
AGND
STG−
STG+
K
L
+5V
+5V
CAN low
CAN high
Signal
Signal
Signal
Signal
Ubat −
Signal Druck
Signal Temperatur
X1:180
X1:181
X57:20
X57:21
X57:22
X57:12
X57:13
X57:10
X57:11
X57:14
X57:15
X57:17
X57:18
X57:19
X57:16
X57:23
X57:24
X57:25
CAN2− 4:11
X57:4
X57:9
X57:8
X57:1
X57:6
X1:183
X1:184
ESX Fahrst.
CAN2+ 4:11
RF REF
RF MESS
RF−
1 2 3 1 2 1 2 7 2 6 1 1 4 3 2 1 2
EMR Stellglied
EMR commander
X32:G
X32:H
X32:K
X32:B
X32:A
X32:L
X1:182
B88 B114 B130 Y137 5 B115 B113

X34:N
Diagnosestecker EMR
diagnosis interface EMR
2:4
X1:186
31 EMR
2:20 31 31 4:1
2:2
Motordrehzahlsensor
sender engine rpm 2
Motordrehzahlsensor EMR Kühlmitteltemperatur

sender engine rpm 1 EMR coolant temperature
EMR Motoröldruck Ladeluftdruck + Temp
EMR engine oil pressure charging air pressure + temperature
28.06.2004
1 1 582 700 95
Seis Motor Deutz EMR II
28.06.2004
Werner engine Deutz EMR II 003
2:14 30 30 5:1
F24:2 5:3 X1:2 3:4 CAN2+ CAN2+ 7:6
EMR Deutz Fahrhebel
3:4 CAN2− CAN2− 7:6
X1:145
X1:42 CAN1+ 5:8
31 CAN1− 5:8 LC−Display, OPUS 21
X1:119 X1:120
S01
2:16
120 OHM 120 OHM
X52:1
X52:2
X1:146 32 1 2 1 2
R22 R20
rt sw X1:17E X1:34E
Diagnosestecker Fahrzeug
F67 1 F84 1 X34:G X34:H X34:C X34:D X34:A X34:B diagnosis interface equipment
B112
15A 10A
2 2
Drucksensor Fahrpumpe X1:17A X1:34A
X1:51
X1:52
X1:53
X1:54
X1:47
X1:48
X1:49
X1:50
pressure sensor drive pump
X1:34A
8:2
120 OHM 120 OHM
1 2 1 2
Drucksensor
Elektronik
Leistung
R23 R21
CAN2+
CAN2−
CAN1+
CAN1−
RxD
TxD
A34
X35:31
X35:56
X35:57
X35:59
X35:60
X35:53
X35:33
X35:5
X35:58
X35:27
X35:26
X35:28
X35:54
X35:4
Fahr−Steuerung
driving controller
X35:38
X35:12
X35:37
X35:34
X35:30
X35:15
X35:24
X35:49
X35:64
X35:46
X35:47
X35:55
X35:65
X35:66
X35:67
X35:68
Gehäuse
housing
Neigung
speed
speed
Richtung
Richtung
Achsmotor
Bandagenmotor
Fahrpumpe vorw.
Fahrpumpe rückw.
Rückfahrwarnsum.
Sitzkontakt
X1:45
X1:44
+45_G=4,5V X1:158 X1:114 X1:121 X1:122 X1:143 X1:141

X1:171
X1:173
X1:175
X1:177
X1:176
+ −45_G=0,5V
B57 1V
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA

bl
ws
br
ws
br
bl
speed
+ + 0,46A
dir. dir.
B60 B59 2,5V X14:B X9:1
speed
S06 + + X16:1 1 X15:1 1 1 1
− X1:172 −
8:2
4V H14 Y17 Y16 Y30 Y31
sw
sw
DIR MESX −
− 2 2 2 2
X1:124
X1:142
X1:142
X1:143
X1:143
11:6 − S X1:46 X16:2 X15:2
X1:82
SPEED TAC X14:A X9:2
X1:174 8:2 X1:178 X1:55 6:4 8:2 X1:149 X1:117 X1:123 X1:123 X1:144 X1:144
SPEED MESX
PITCH MESX
3:20 31 31 5:1
Sensor Achse Sensor Bandage Neigungssensor Sitzkontaktschalter Prop.−Pumpe Vorw. Prop.−Ventil Bandagenmotor
sender axle sender drum slope sensor switch, seat contact prop.−pump forwards prop.−Valve drum motor
Rückfahrwarnsummer Prop.−Pumpe Rückw. Prop.−Ventil Achsmotor

back up alarm buzzer prop−pump backwards prop.−Valve axle motor
28.06.2004
1 1 582 700 95
Seis Fahrantrieb, Neigungssensor, Sitzkontakt
28.06.2004
Werner driving system, slope sensor, seat contakt switch 1 004
30 30 8:1
4:20
2:20 K11:87 K11:87 7:14
4:3 F24:2 F24:2 6:15
X1:29E 2:17 F05:2 F05:2 2:17
1 4:17 CAN1+ CAN1+ 7:14

F24 ESX Fahrsteuerung DIOS Platten
15A 4:17 CAN1− CAN1− 7:14
2
X1:29A
X1:87 X1:88 X1:80 X1:86

X1:41
X1:39
X1:40
X34:R
not connected
not connected
CAN1 high
CAN1 high
CAN1 low
CAN1 low
Ub "30"
Ub "15"
Ub out
VCC
X27:8
X28:6
X29:8
Steckerfarbe: X26−grau; X27−schwarz
A80 A81
X28:1
X27:6
X27:7
X29:7
X28:3
X28:5
connector−colour: X26−grey; X27−black
X28:4
Datensammler LC−Display
data−collector LC−display
X26:10
X26:11
X27:10
X27:11
X27:12
X26:3
X26:5
X26:8
X27:4
X27:9
X27:2
X26:7
X26:9
X26:1
X26:2
X26:6
X26:4
X27:1
X27:3
X29:2
X29:1
X29:3
X29:4
X29:5
X29:6
X26:12
X27:5
X28:2
DIN11
UIN1
GND
GND
GND
DIN10
DIN1
DIN1
AIN1
UIN3
UIN2
DIN3
DIN5
DIN7
DIN9
DIN6
DIN3
DIN5
DIN6
DIN8
DIN2
DIN2
Sepa1
GND/UIN3
DIN4
DIN4
AIN2
Sepa2
X1:106 X1:111 X1:112 X1:107 X1:108 X1:105

BL 10:17 ECO
Low High down up
Wasserabscheider
BR 10:17 23 13 23 13
coolant stock level
hydraulic oil filter
water−seperator
Füllstand Diesel
Kühlmittelvorrat
Hydraulikölfilter
BEL S120
10:4
KLIMA
12:6 S139
air cleaner
fuel−level
24 14 24 14
Luftfilter
X21:1 X8:1 X10:2

B21 1 B03 1 B55 B124
0 .. 67 OHM
D+ R03
2:6 P P Q
Schalter Motordrehzahl
2 2 switch engine−rpm mode switch frequency−control
X21:2 X8:2 X10:3 Schalter Frequenzverstellung
X1:117 X1:94 X1:94 X1:117 X1:154 X1:149 X1:82

31 31 6:1
4:20
28.06.2004
1 1 582 700 95
Seis Datensammler, LC−Display
28.06.2004
Werner data−collector, LC−display 005
3:20 S01:22 S01:22
5:20 F24:2 F24:2
X1:148 Lenkwinkelsensor
X23:1 steering angle sensor
7:1
X1:41
X1:201
X51:1 Lenkeinheit X1:187
B65 + A45 steering unit
Aufnehmer Vibrationsmotor
S X22:1 sensor vibration motor
br +
X1:161 X41:1 X39:1 VCC X39:2
S1 B − X22:2
−
X1:160 X41:3 X40:1 VCC X40:2
X1:203
X1:55 X1:202
bl
B B16
X1:60 FM5 X1:61
X1:58 FM2 X1:59
X1:56 FM1 X1:57

X1:159 X41:4 X40:4 0V S2 A X40:3 sw
B132 2 2 2 ws X22:3
VIB
Schalter Armlehne
X1:162 X41:2 X39:4 X39:3 11:6

Lenkwink.
0V S1 A X22:4
Vib.− Richtung
armrest−switch
1 1 1
X41:5
X41:7
X41:8
X41:6
BTS BREMSE 7:2
X34:J
X1:189
X1:188
−
Sig.
AGND
Vib.− Frequenz
BTS Bremse
X1:205
X1:207
X1:206
X1:208
X1:55
X1:42
4:6
nur BVC
only BVC
8,5V
A34
X35:1
X35:19
X35:17
X35:18
X35:41
X35:35
X35:29
X35:23
X35:40
Fahr−Steuerung
driving controller
X43:2 X43:1
X35:21
X35:20
X35:25
X35:16
X35:22
X35:48
X35:61
X35:2
X35:3
Bremse
Warnsummer
Armlehne
Umsch. Amplitude
Prop. out
K57 30 K56 30
Pumpe Vib.−Platten
30
X51:3
X51:2
6:9 6:8 30
K48 7:2
87 87a 87 87a X1:89
K43 6:12 87 87a
X1:154 87 87a X1:147
KA MESX
8:2 11
X35:16 X1:38
X1:199 X1:198 X1:196 X1:195 X35:16 X35:22 GA MESX
6:9 6:2 7:14 8:2 S01
X1:37
400 ... 1.200mA
400 ... 1.200mA
2:16
X1:116 X1:115 12
400 ... 1.200mA

X1:150
150mA
X1:113 8:2
X6:1 X7:1 BRAKE MESX
Y113 1 Y112 1 1 1 K56 86 K57 86 K43 86 Y08 1 Y07 1 H07
+ Y04 1
Y93 Y92
2 2 2 2 85 85 85 2 2 − 2
max.1.8A
X6:2 X7:2
X1:149 X1:200 X1:200 X1:197 X1:197 X1:82 X1:117 X1:190
X1:118
5:20 7:1
31
31 Anbau 177DH: h.r. Anbau 177DH: h.l.
6:4 6:3 6:14 Anbau 213DH: oben Anbau 213DH: unten
Prop.−Ventil Vibration klein Magnetventil Bremse

prop. valve vibration small solenoid valve brake
Notlenkung links Prop. Ventil lenken links Prop−Ventil Vibration groß
emerg. valve steering left prop. valve steering left prop. valve vibration big
Notlenkung rechts Prop. Ventil lenken rechts Warnsummer Störung
emrg. valve steering right prop. valve steering right warning buzzer, failure
28.06.2004
1 1 582 700 95
Seis Lenkung, Vibration
28.06.2004
Werner TS022 steering, vibration 006
6:2 X23:1 4:17 CAN2+ 5:14 CAN1+ CAN1+ 8:16
ESX Fahrst. LC−Display BTM
4:17 CAN2− 5:14 CAN1− CAN1− 8:16
5:20 K11:87 K11:87 8:1
Taster 1 = Platten rechts
push button 1 = plates right X1:31E
Taster 2 = Platten heben
push button 2 = lift plates 1 F145
Taster 3 = Vibration EIN/AUS Näherungssch. Platten oben
push button 3 = vibration ON/OFF 15A
Taster 4 = Platten links
sensor plates up 2
push button 4 = plates left
Taster 5 = platten senken
Näherungssch. Platten Mitte X1:31A
sensor plates centered
X1:213
X1:214
push button 5 = lower plates
X1:156
X1:157
Taster 7 = Infotaste 1
push button 7 = info button 1
X1:209
Taster 8 = Infotaste 2
BTS BREMSE
push button 8 = Info button 2
B135 + B134 +
6:18 − −
3 2
1 7 Fahrstufenschalter S S
4
5 8 speed range selector
S42
X62:12
X62:10
X62:1
X62:3
X62:9
X62:2
X62:4
+ − S A54
Platten Steuerung
plate−controller
X25:4
X25:2
X25:3
Ub in CAN−
Bremse zu = 0V 1 7
Bremse auf = Ub BTS Bremse CAN+
3 S55 6 X35:22
6:11
X62:11
X62:13
X62:14
X62:5
X62:6
X62:7
X62:8
X1:153 BTS zus.
4 Fahrhebel 5 +5V out
travel lever
0V in 0V (Ref PIN5)
2 8
Add1 AK Ext1
9 11
Add2 AK Ext2
10 12
Stecker X23
Stecker X24
1 2 3 4 5 6 7 8
DK Ext1
DK Ext3
DK Ext5
DK Ext6
DK Ext2
OV out
DK Ext4
Ub out
400 .. 1.200 mA
X50:3
X50:2
X50:1
X1:210
S − + Y123 1 Y143 1 Y145 1
S35 K0G S09 13 S64 13 S36 13 S139 X72:1

13 23 2 2 2
86 86 1 Y122 1 Y142 1 Y144 1

K48 K05 Y98
14 14 14 14
24
2 2 2 2
85 85
X72:2
X1:149 X1:211 X1:212
6:20 31
8:1
6:17 2:12 31
nicht bei BVC Nur bei BVC Schalter Schwimmstellung Platten MV Platten heben MV Platten rechts
not at BVC Only at BVC sw. swimming pos. plates plates up plates right
Frequenzverstellung Platten
freq. adjust plates MV Platten senken MV Platten Schwimmst
Schalter Amplitude Schalter Vibration Ein/Aus Schalter Betriebsart Platten Prop−Pumpe Platten plates down plates float−pos.
switch amplitudes switch vibration on/off modesw. plates prop.−valve plates MV Platten links MV Platten Priorität
plates left plates priority
28.06.2004
1 1 582 700 95
Seis Fahrhebel, Vibrationsplatten
28.06.2004
Werner TS022 joystick, vibration−plates 007
Beschleunigungssensoren Beschleunigungssensoren Aufnehmer Verstellmotor Drucker Bedieneinheit BEM Display Messtechnik BOP
acc. sensor front acc. sensor rear sens. adjust. motor printer control−unit BEM display measurem. BOP
X1:34A
4:9 GND
5:20 30 30 10:1
Pot 30
7:20 K11:87 K11:87 10:1
X2:47
Pot 15
31.1
X2:48 X2:49
+ −
X2:66
X2:70
8:19
nur bei BEM
X42:1
only at BEM
X42:5
X42:3
X42:2
X1:32E X1:35E
X2:77 P16 F1 F2
nur bei BTM+/BTM prof

only at BTM+/BTM prof
1 1 1
F148 F146 X2:56 X2:53 X2:60 X2:57 FM4
10A 15A X2:71
2 2 2
CAN+
CAN−
X1:32A X1:35A X48:2 X48:1 X49:2 X49:1 X2:78 P33
X2:67 X2:68
X4:C
X4:E
X4:D
F148:2 B62 B62
+/sw
+/sw
9:15
−/gg −/gg X47:A X47:B
X42:6
X42:7
X42:8
X42:4
X74:3
X74:5
X74:4
−/sw
nur bei BTM prof

only at BTM prof
15g/bl 15g/bl
20g/br
20g/br
7:20
X2:57 CAN1−
DIOS Platten
B61 P11
+/rt 7:20
X48:3 X48:4 X49:3 X49:4 S/ws
CAN1+
X74:1 X74:2
1 R20 2
X2:54 X2:55 X2:58 X2:59 X47:C
AGND MESX
Aufn. hinten 15g
Aufn. hinten 20g

Aufn. vorne 15g
Aufn. vorne 20g

X4:A X4:B 120 OHM
Elektronik
Leistung
X2:50 X2:51
Erregerpos.
Pot. 15
R21
8.5V
X2:69 X2:64 X2:65 1 2
RxD TxD CAN1+ 120 OHM CAN1−
X44:27
X44:26
X44:31
X44:1
X44:56
X44:57
X44:59
X44:60
X44:30
X44:7
X44:9
X44:5
X44:58
X44:29
X44:23
X44:28
X44:54
X44:4
A83
X44:15
X44:38
X44:35
X44:14
X44:32
X44:36
X44:37
X44:41
X44:47
X44:46
X44:53
X44:33
X44:55
X44:65
X44:66
X44:67
X44:68
X44:3
Messtechnik−Rechner
measurement calc. unit
CAN3+ CAN3−
KA MESX
EVIB
0..6VDC
6:15
Prop.
Prop.
400 .. 1.200mA
400 .. 1.200mA
GND
6:15 GA MESX
SPEED MESX X1:85 9:15
4:3 CAN3−
DIR MESX X2:75 X2:73 X2:60 +
4:3
P07 E 9:15
8:20
4:8 PITCH MESX Y140 1 Y141 1 VIB CAN3+
BRAKE MESX
v.r.
v.l.
6:17 −
31.1
D+ MESX BEL MESX 2 2
2:6 10:4 X2:76 X2:74 X2:63 X2:66 X1:82
31 31 9:1
7:20
Prop−Ventil Erreger auf EVIB−Meter

solenoid−valve exciter up EVIB−meter
Prop−Ventil Erreger ab
solenoid valve exciter down
28.06.2004
1 1 582 700 95
Seis Variocontrol, Messtechnik
28.06.2004
Werner TS022 Variocontrol, measurement equipm. 008
F148:2
8:4
CAN3−
8:18
8:18 CAN3+
CAN3+
1 R242 CAN3−
120 OHM
X2:61 X2:62
R25
1 2
120 OHM
X4:N X4:M
X75:7 X75:2
A87
USB−CAN Schnittst.
USB−CAN Interface BCM
X2:70
X76:1 X4:G
P15 X76:2
X4:F
X2:63
BCM 05
BCM 05
nur bei BCM
only at BCM
8:20 31 31 10:1
28.06.2004
1 1 582 700 95
Seis Bomag Compaction Management BCM
28.06.2004
Werner TS022 Bomag Compaction Management BCM 009
8:3 K11:87 K11:87
8:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
F11 F18 F07 F08
15A 10A 15A 15A
30
X1:301
X1:18A K06 X1:19A X1:25A
X1:26A
10:4 X1:305
X1:83
Schalter StvZO 87 87a
switch, StvZO
13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO L0R Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:306
X1:307
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:302
X3:4 X3:5 with cabin 30 49L 49R

STV1
11:17 A02
STV2
11:17
X1:23E X1:24E
K16 30 31 82 L R
10:9 F09 F10
15A 15A
switch, working head lights
87 87a X1:23A X1:24A

BEL 5:9 BL
5:9
13 BR
5:9
Schalter Arbeitsbele
Arbeitsscheinwerfer hinten rechts
Arbeitsscheinwerfer vorne rechts

S16 14
connection working head
Arbeitsscheinwerfer hinten links

Anschluß Arbeitsschein−
Arbeitsscheinwerfer vorne links
working head lights, front rh.

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

working head lights, rear lh.
X1:304
werfer ohne StvZO
X1:311
X1:310
X1:319
X1:313
X1:312
X1:321
X1:314
X1:309
X1:303
X1:320
X1:322
13 23
01
01
S14
X1:84
X61:1
X61:3
X60:1
X59:5
X60:3
X59:3
X58:5
X58:3
X59:2
X58:2
Warnblinkschalter 14 24
BEL MESX
8:7 switch, hazard light
0,125A
X1:43
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 E08 1 E09 1 E10 1 E11 1
0,125A
2 2 86 2 2 2 2 86 2 2 2 2 + 2 2 2 2
4,6A
4,6A
4,6A
4,6A
K06 K16
X1:324 X61:2
X1:324 X61:4
X1:316 X59:6
X1:316 X59:6
X1:316 X59:6
X1:315 X58:6
X1:315 X58:6
X1:315 X58:6
X1:323 X60:2
X1:323 X60:4
H06
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A
4,6A
4,6A
85 85 −
X3:1
9:20 11:1
31 10:10 Schlußleuchte links 10:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
Anschluß Arbeitsscheinwerfer
parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
Scheinwerfer rechts
Parkleuchte rechts Blinkleuchte HL
head light RH parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schlußleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH
28.06.2004
1 1 582 700 95
Seis Beleuchtung und StvZO
28.06.2004
Werner illumination and StvZO 010
K30 X3:6
2:14 K32:87 12:2
X3:7
K32 30 STV2
X3:8 10:13
11:1 10:13 STV1
87 87a
G H A B C E F
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3 6
5
F42 12:8
F130 11:9 F130 F130 12:7
11:14
A12
1,75A
0,83A
15
K141 30 1 B51 + + 30 01W 7 2 01W 7 2
+ + B51 1 S163 5 1 S38 5
01 01 E72
K32:86 11:16 E29 E70
− − − − 1
87 87a 2 2 2 1
2:19 31 S21 5 4 S20 5 4
Radio
night illumination
radio
Nachtleuchte
inside light, cabin
1 Tachographenmodul
Kontrolleuchte
E71 1
Innenleuchte
module, tachograph
indicator
R80 A2+A3
X3:17
X55:1
X56:1
X55:3
X56:3
X55:4
X56:4
4,6A
4,6A
4,6A
4,6A
2 4 6 A1
Steckdose
4:3 P09 +
2 1 E28 1 E23 1 E25 1 XS
socket
SPEED TAC A16 E27
Heizung Heckscheibe
1 B3 12V
−
heating rear screen
max. 13A
switches interior lights
+ 7,8,9 2 B4 2 2 2 2
Schalter Innenleuche
A01 VIB X3:18 5 3 C3

6:18
A5+A6
S45 TK −
3,8A
3,8A
3
5A
86 S86 + + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
− − M07 −
Abfallverzögert
− M06 4
3 min
85 2,9A
4,7A
ZA
X55:2 X56:2 option
12:18
KABINE 31
Relais Kabine Türkontaktschalter Tachograph Schalter Nachtleuchte
relais cabin door switch tachograph switch, night illumination
X3:1
X3:2
Schalterbel.
switch illum.
10:20 31 31 12:1
11:6 Wascher hinten Wascher vorn 11:2 Arbeitsscheinwerfer vorn

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

windscreen wiper, rear windscreen wiper, rear working head lights, rear rotary beacon
28.06.2004
1 1 582 700 95
Seis Kabinenausrüstung, Beleuchtung, Radio, Tachograph
28.06.2004
Werner cabin−equipment, headlights, radio, tachograph 011
11:19 K32:87
Potential 15 aus Kabine
11:17 F130
F42 Potential 15 aus Kabine
11:9
F31 D Potential 30 aus Kabine
F40 H F15 A
20A 20A 5A
4 8 1
Bedienteil Kabinenheizung/Klimaanlage
1 2 3 12 11 13 14 16
X53:B X53:C control−unit cab−heater /air conditioning X54:4 X54:3 X54:2
Schalter Kabinenzusatzheizung
0123 4 3 2
S44 A72
switch, cab add.−heater

Steuergerät 5
control unit
Schalter Kabinenlüfter 6 11 12 1 Regel aus = 0,4A 0123
E30 Kleine Stufe = 0,67A S28
switch blower cabin X54:6 X54:11 X54:12 X54:1 Zusatzheizung mittleter Stufe = 1,0A
add. heater große Stufe = 1.9A
X3:13 Power Stufe = 2,8A
6 2 1 3
Anlaufstrom beim Start = 8,3A
X53:M
X53:H
X53:L
K09 30
X3:14
temperature sensor air conditioning
2:8
87 87a X1:167 10 9 5 6 8 7 4 15
temperature sensor heating unit

X3:11
X3:10
X3:12
X3:9
X1:169 X18:1
Thermofühler Klimaan
X19:1
Thermofühler Heizung
B131
B103 1
X17:1 X1:163
X17:2 X1:165
X17:3 X1:166
1
_t _t
2 2
monitoring coolant pressure
X19:2
X20:1 X18:2
B104 4
Überwachung Kühlmitt
P
LP 3 HP
1A
X20:4
ge rt or ge rt or
X20:3
Y138 1 1
X1:170 11:19
V06 Y14 KABINE 31
M09 M M09 M 5:9
KLIMA 2 2
Stromaufnahme Lüfter / current blower br br
Stufe 1: 3.0A pro Lüfter
X20:2
Y15 1 2
X17:4 V04 X1:168
3,5A
2 1
X1:164
11:20 31 31
Kabinenlüfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit
Kabinenlüfter
cab ventilator
28.06.2004
1 1 582 700 95
Seis Kabinenheizung, Klimaanlage, Zusatzheizung
28.06.2004
Werner cabin−heater, air conditioning, add. heater 012
Name Bl. Pf. Benennung title TYP
A02 010 17 Blinkrelais indicator relay
A12 011 5 Radio Radio
A16 011 6 Elektronik Tachograph Electronic system, tachograph
A34 004 6 Prozessorplatine Prozessing circuit board
A34 006 5 Prozessorplatine Prozessing circuit board
A45 006 9 Lenkrad Steering wheel
A48 003 3 Elektronische Motorsteuerung Electronic engine management
A54 007 17 Modul Pumpenansteuerung Modul pump control
A72 012 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A80 005 3 Modul Datensammler modul data−collector
A81 005 18 Anzeigeeinheit Display−Unit
A83 008 6 Elektronik Messtechnik electronic measurement−equipment
A87 009 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
Werner
28.06.2004
Seis
28.06.2004
B03 005 3 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B11 002 16 Signalhorn Warning horn
B11 002 18 Signalhorn Warning horn
B16 006 16 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 005 2 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B51 011 4 Lautsprecher Radio Speaker radio
B51 011 6 Lautsprecher Radio Speaker radio
B55 005 4 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B57 004 6 Neigungssensor Stufenumschaltung Slope sensor, speed range selection
B59 004 4 Aufnehmer Bandagengeschwindigkeit Sensor, drum speed
B60 004 2 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 008 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 008 8 Beschleunigungsaufnehmer Acceleration sensor
B62 008 10 Beschleunigungsaufnehmer Acceleration sensor
B65 006 4 Sensor, Lenkwinkel vorn Sensor, angularity steering, front
B88 003 6 Druckgeber Motoroel Sender, engine oil pressure
B103 012 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 012 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B112 004 3 Druckgeber Fahrpumpe pressure sender, driving pump
B113 003 13 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 003 7 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B115 003 11 Geber Ladeluftdruck Sender, charging air pressure
B124 005 5 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 003 14 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B130 003 8 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
B131 012 10 Temperaturschalter Heizung Temperature switch, heating
B132 006 2 Inititator Armlehne links proximity switch left arm rest
B134 007 17 Näherungsschalter Platten oben proximity switch, plate up
B135 007 16 Näherungsschalter Platten mitte proximity switch, plate middle
component listing
E08 010 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
Bauteilliste
E09 010 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 010 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 010 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 010 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 010 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 010 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 010 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 010 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 010 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E23 010 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 011 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 010 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 011 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 010 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 011 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 010 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 011 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 011 3 Innenleuchte Kabine Inside light, cabin 1,75A
E30 012 13 Heizgeraet Heating unit
E32 011 19 Kennleuchte Warning light 5A
E70 011 15 Nachtleuchte Night lamp 0,83A
E71 011 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 011 16 Beleuchtung Bedienschalter illum. Switches
F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A

F05 002 14 Sicherung Steckdose Fuse, socket 15A
F07 010 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 010 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 010 6 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 010 8 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 010 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F15 012 18 Sicherung Heizgeraet Fuse, heating unit 5A
F18 010 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 010 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 010 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 002 18 Sicherung Signalhorn Fuse, warning horn 15A
1
F24 005 2 Sicherung Ueberwachungsmodul Fuse, monitoring module 15A

F31 012 3 Sicherung Kabinenluefter Fuse, cabin ventilator 20A
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 012 13 Sicherung Kabinenheizung Fuse, heating unit cab 20A
F41 011 19 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A
9
F42 011 3 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A

F43 011 10 Sicherung Wischermotor hinten Fuse, wipermotor rear 15A
F44 011 13 Sicherung Wischermotor vorn Fuse, wipermotor front 15A
F48 002 3 Sicherung Gluehanlage Fuse, glow plug system 125A
582 700 95
F67 004 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 15A
F84 004 9 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F95 002 16 Sicherung Motormanagement intern Fuse, engine controller (internal) 15A
FM1 006 6 Platinensicherung Multifuse MULTIFUSE
101

F130 011 15 Sicherung Nachtleuchte Fuse, night lamp 10A
F143 011 2 Sicherung Heckscheibenheizung fuse rear screen heating unit 15A
F144 011 20 Sicherung Kabinensteckdose Fuse cabin−socket 15A
F145 007 18 Sicherung Anhängeplatten fuse vibration plates 15A
F146 008 5 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30) 15A
F148 008 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15) 10A
G01 002 3 Batterie Battery 103A

G02 002 5 Generator Generator
G03 002 4 Batterie Battery 103A
H06 010 15 Meldeleuchte Warnblinker Indicator light, hazard light LED ROT
H07 006 16 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0.15A
H14 004 11 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX O,46A
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28.06.2004
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28.06.2004
K05 007 3 Relais Startstrom Relay, starting current BOSCHW

K06 010 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K14 003 19 Relais Vorgluehen Relay, glow plug system TYCOX
K16 010 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K32 011 1 Relais Kabine Relay, cabin BOSCHW
K43 006 12 Relais Vibration Relay, vibration BOSCHW
K48 007 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K56 006 8 Relais Lenkung Relay, steering system BOSCHW
K57 006 9 Relais Lenkung Relay, steering system BOSCHW
K61 002 6 Relais Ladekontrolle Relay, charge control BOSCHW
K141 011 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
M01 002 11 Starter Starter 2.3 KW

M04 011 12 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 011 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 011 13 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 011 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 012 3 Kabinenluefter Cabin ventilator
M09 012 4 Kabinenluefter Cabin ventilator
P07 008 15 Omegameter Omegameter

P09 011 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 008 14 Drucker Printer
P15 009 16 BCM 03 Bildschirm BCM 03 terminal
P16 008 16 Diagnose, Variomatic Diagnostics, varimatic
P33 008 18 Opus 21 Opus 21
component listing
R03 005 6 Geber Tankanzeige Sender, level gauge 0 .. 67 OHM

R19 002 2 Heizflansch heater flange 167A
Bauteilliste
R20 004 15 Widerstand Resistor 120 OHM

R80 011 2 Heizung Heckscheibe heating rear screen MAX. 13A
S00 002 10 Startschalter Starter switch

S01 002 16 Schalter NOT AUS Switch, emergency off NOTAUSH
S03 002 18 Taster Signalhorn Push button, warning horn
S06 004 10 Sitzkontaktschalter links Switch, seat contact, lh.
S09 007 8 Vibrationsschalter vorne Switch, vibration, front
S14 010 15 Warnblinkschalter Switch, hazard light
S15 010 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S16 010 4 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 011 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 011 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 012 18 Schalter Kabinenheizung Switch, cabin heating
S30 002 3 Batterietrennschalter Switch, battery disconnect
S35 007 7 Vibrationsschalter klein/gross Switch, vibration low/high
S36 007 11 Vibrationsschalter Switch, vibration
S37 010 18 Schalter Blinker Switch, indicator
S38 011 19 Schalter Kennleuchte Switch, warning light
S42 007 11 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S44 012 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 011 3 Schalter Kabineninnenleuchte Switch, cabin inside light
S55 007 6 Schalter Fahrhebel Switch, travel control lever
S64 007 10 Schalter Schwimmstellung Switch, float position
S86 011 3 Schalter Tuer, links Switch door, lh.
S120 005 17 Schalter Motordrehzahl Switch, engine speed
S139 005 19 Schalter Frequenzverstellung Switch, frequency control
S139 007 13 Schalter Frequenzverstellung Switch, frequency control
S158 011 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 011 16 Schalter Heckscheibenheizung switch rear screen heating unit
2
V01 002 7 Diode Diode FE5B

9
V06 012 9 Diode Diode
X1:1 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

582 700 95

102

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28.06.2004

component listing

Bauteilliste

3

9

582 700 95

103

X1:15A 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:15E 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
Werner
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Seis
28.06.2004

component listing

Bauteilliste

4

9

582 700 95

104

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Seis
28.06.2004

X2:47 008 18 WAGO−MESSTECHNIK Wago−measurement equip.
component listing

Bauteilliste

X3:1 010 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 011 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:3 002 19 SETCKER KABINE/ROPS Con cabin/ROPS
X4:A 008 14 KABINENST. MESST. con. measurem.equipm.
X4:B 008 14 KABINENST. MESST. con. measurem.equipm.
X4:C 008 14 KABINENST. MESST. con. measurem.equipm.
X4:D 008 14 KABINENST. MESST. con. measurem.equipm.
X4:E 008 15 KABINENST. MESST. con. measurem.equipm.
X4:F 009 18 KABINENST. MESST. con. measurem.equipm.
X4:G 009 18 KABINENST. MESST. con. measurem.equipm.
X4:M 009 16 KABINENST. MESST. con. measurem.equipm.
X4:N 009 15 KABINENST. MESST. con. measurem.equipm.
5
X6:1 006 13 STECKER VIBRATION GRO conn. vibration big

X6:2 006 14 STECKER VIBRATION GRO conn. vibration big
X7:1 006 15 STECKER VIBRATION KLE conn. vibration small
X7:2 006 14 STECKER VIBRATION KLE conn. vibration small
X8:1 005 5 STECKER WASSERABSCHEI connector water separator
9
X8:2 005 5 STECKER WASSERABSCHEI connector water separator

X9:1 004 11 STECKER RÜCKFAHRALARM conn. backupalarm
X9:2 004 11 STECKER RÜCKFAHRALARM conn. backupalarm
XS 002 19 Steckdose Socket
582 700 95
XS 011 20 Steckdose Socket

X10:2 005 6 STECKER TAUCHROHRGEBE connector fuel level sensor
X10:3 005 6 STECKER TAUCHROHRGEBE connector fuel level sensor
X14:A 004 10 STECKER SITZKONTAKT connector seat contact switch
X14:B 004 10 STECKER SITZKONTAKT connector seat contact switch
105
X15:1 004 13 STECKER FAHRPUMPE RÜC connectoe driving pump back

X15:2 004 13 STECKER FAHRPUMPE RÜC connectoe driving pump back
X16:1 004 12 STECKER FAHRPUMPE VOR connector driving pump front
X16:2 004 12 STECKER FAHRPUMPE VOR connector driving pump front
X17:1 012 3 STECKER LÜFTER HKL conn. blower
X18:1 012 10 STECKER THERMOFÜHLER conn. sender temp.
X18:2 012 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 012 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X19:2 012 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X20:1 012 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X21:1 005 4 STECKER KÜHLMITTEL connector coolant sensor
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Seis
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X21:2 005 4 STECKER KÜHLMITTEL connector coolant sensor

X22:1 006 16 ST. VIBRATIONSAUFNEHM connector vibration sensor
X25:2 007 11 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X26:1 005 8 STECKER DATENSAMMLER connector data collector
component listing

Bauteilliste

X28:1 005 16 STECKER LC−DISPLAY 1 connector LC−display 1
X30:1 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X31:1 003 16 EMR−Stecker Motor EMR−connector engine
6

9

582 700 95

106

X32:A 003 2 EMR − Diagnose EMR−diagnosis
X32:B 003 3 EMR − Diagnose EMR−diagnosis
X32:G 003 3 EMR − Diagnose EMR−diagnosis
X32:H 003 3 EMR − Diagnose EMR−diagnosis
X32:K 003 2 EMR − Diagnose EMR−diagnosis
X32:L 003 2 EMR − Diagnose EMR−diagnosis
X33:1 003 19 Trennstelle EMR II conector EMR II
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X34:A 004 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:B 004 16 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:C 004 12 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:D 004 13 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:G 004 10 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:H 004 11 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:J 006 3 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:N 003 5 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:P 002 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:R 005 2 DIAGNOSESTECKER ESX connector diagnosis ESX
X35:1 006 4 ESX STECKER esx connector
component listing

Bauteilliste

X36:A 002 4 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 5 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 10 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X37:B 002 12 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 12 STECKER STARTER E−KAS connector starter, e−Box
X39:1 006 9 STECKER 1 LENKRAD connector 1 steering unit
7

9
X41:1 006 8 ST. LENKRADKABELBAUM conn. steer. wire harn.

582 700 95

X42:1 008 18 STECKER OPUS21 conn. OPUS21
107

X43:1 006 2 STECKER SCHALTER ARML connector switch arm rest
X43:2 006 1 STECKER SCHALTER ARML connector switch arm rest
X44:1 008 13 MESX STECKER MESX Stecker
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28.06.2004

X47:A 008 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
component listing
X47:B 008 12 STECKER AUFN. PLEIGER conn. sender PLEIGER

X47:C 008 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
Bauteilliste
X48:1 008 8 STECKER AUFN. VORNE conn. sender front

X49:1 008 10 STECKER AUFN. HINTEN conn. sender rear
X50:1 007 13 ST. PLATTENFREQ. conn. plate−freq.
X51:1 006 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X52:1 004 3 STECKER DRUCKSENSOR connector pressure sensor
X52:2 004 3 STECKER DRUCKSENSOR connector pressure sensor
X53:B 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 012 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 012 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:L 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 012 11 STECKER HEIZSTEUERUNG conn. heating controller
X55:1 011 11 STECKER WISCHER HINTE connector wiper rear
X56:1 011 14 STECKER WISCHER VORNE conn. wiper front
X57:1 003 15 Stecker Motor connector engine
8

9

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108

X58:2 010 17 STECKER STVZO VL Con. STVZO FL
X59:2 010 19 STECKER STVZO VR Con. STVZO FR
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X60:1 010 18 STECKER STVZO HL Con. STVZO BL
X61:1 010 19 STECKER STVZO HR Con. STVZO BR
X62:1 007 19 STECKER DIOS PLATTEN con. DIOS−plates
X72:1 007 14 ST. PROP.−PUMPE PLATT con. plate−pump
X72:2 007 14 ST. PROP.−PUMPE PLATT con. plate−pump
X74:1 008 14 STECKER DRUCKER con. printer
component listing

Bauteilliste

X75:2 009 16 SUB−D STECKER BCM INT con. SUB−D BCM
X75:7 009 15 SUB−D STECKER BCM INT con. SUB−D BCM
X76:1 009 17 STECKER VERS. BCM con. Power−sup. BCM
X76:2 009 17 STECKER VERS. BCM con. Power−sup. BCM
Y04 006 17 Magnetventil Bremse Solenoid valve, brake MAX. 1.8A

Y07 006 15 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high 0.4 .. 1.2A
Y08 006 13 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low 0.4 .. 1.2A
Y14 012 14 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 012 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y16 004 13 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 0.4 .. 1.2A
Y17 004 12 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 0.4 .. 1.2A
Y30 004 15 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 0.4 .. 1.2A
Y31 004 16 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear 0.4 .. 1.2A
Y92 006 7 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. 0.4 .. 1.2A
Y93 006 6 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. 0.4 .. 1.2A
Y98 007 14 Magnetventil Vibrationsfrequenz, hinten Solenoid valve, vibrat.freq.,rear 0.4 .. 1.2A
Y112 006 4 Magnetventil Lenkung (Y1) Solenoid valve, steering (Y1) MAX. 1.8A
Y113 006 3 Magnetventil Lenkung (Y2) Solenoid valve, steering (Y2) MAX. 1.8A
Y122 007 16 Magnetventil Platten heben Solenoid valve, lift plates MAX. 1.8A
Y123 007 17 Magnetventil Platten senken Solenoid valve, let down plates MAX. 1.8A
Y137 003 10 EMR Verstellung EMR adjustment
Y138 012 10 Magnetveentil Heizung Solenoid valve, heating unit 1A
Y140 008 10 Magnetventil Erreger auf solenoid valve exciter up 0.4 .. 1.2A
Y141 008 11 Magnetventil Erreger ab solenoid valve exciter down 0.4 .. 1.2A
Y142 007 18 Magnetventil Plattenverschieben Links solenoid valve, plate displace left MAX. 1.8A
Y143 007 18 Magnetventil Plattenverschieben rechts solenoid−valve, plate displace right MAX. 1.8A
Y144 007 19 Magnetventil Platten Schwimmstellung solenoid−valve, plate swimming−position MAX. 1.8A
Y145 007 20 Magnetventil Platten (Priorität) solenoid−valve, plate (priority) MAX. 1.8A
99
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109
X38
X36 X37
X1:301…
X1:324
X1:79 … X1:214
A80
X1:1 … X1:61
Nur bei StvzO

only acc. To StvZO illumination
A02 K05
K16 K06
K11
K09 K43
K48
K61
B57
K57
K56
X32:1-12 X34:1-19
Gez.: 28.06.2004 Seite: 1 von: 2

Name: Seis Übersicht Schaltkasten BW 177...226 DH/BVC-4 page: 1 from: 2
582 700 95
Gepr.: 28.06.2004 Ers. f.: Blatt Nr.: 201
Name: Werner
overview e-box BW 177...226 DH/BVC-4 Replaces: Sheet No.: 201
X2:47 … X2:78
CAN 1
A34
Fahrsteuerung
CAN 2 EMR + Fahrhebel
LCD +
CAN 1 Datensammler
+ OPUS 21
A83
Messtechnik Steuerung
CAN 3 BCM
Gez.: 28.06.2004 Seite: 2 von: 2

Name: Seis Übersicht Schaltkasten-Tür BW 177...226 DH-4/BVC page: 2 from: 2
582 700 95
Name: Werner
overview e-box door BW 177...266 DH-4 Replaces: Sheet No.: 201
WAGO smart DESIGNER 4.0
1 05756417
2 3 x 05756540 "R" + 793-501
5 05756539 "R" + 793-501
6 05756537
7 3 x 05756540 "R" + 793-501
10 05756537
11 05756540 "R" + 793-501
12 05756535 "R" + 793-501
13 05756537
14 2 x 05756538 "R" + 793-501
16 2 x 05756539 "R" + 793-501
18 05756537
19 4 x 05756540 "R" + 793-501
23 05756537
24 4 x 05756540 "R" + 793-501
28 2 x 05756539 "R" + 793-501
30 05756537
31 05756540 "R" + 793-501
32 05756539 "R" + 793-501
33 05756537
34 4 x 05756540 "R" + 793-501
38 05756539 "R" + 793-501
39 05756537
40 4 x 05756540 "R" + 793-501
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:04:26 Seite 1
44 05756537
45 05756540 "R" + 793-501
46 05756535 "R" + 793-501
47 05756537
48 05756540 "R" + 793-501
49 05756535 "R" + 793-501
50 05756537
51 05756538 "R" + 793-501
52 2 x 05756540 "R" + 793-501
54 05756539 "R" + 793-501
55 05756537
56 3 x 05756540 "R" + 793-501
59 05756538 "R" + 793-501
60 05756537
61 3 x 05756540 "R" + 793-501
64 05756535 "R" + 793-501
65 05756537
66 2 x 05756540 "R" + 793-501
68 05756539 "R" + 793-501
69 05756537
70 3 x 05756540 "R" + 793-501
73 05756535 "R" + 793-501
74 05756537
75 2 x 05756540 "R" + 793-501
77 05756539 "R" + 793-501
78 05756537
79 05756417
Artikelnummer :
Ort :
Optional4 :
Optional7 :

02.07.2004 09:04:26 Seite 2
Artikelnummer :
Ort :
Optional4 :
Optional7 :

02.07.2004 09:16:28 Seite 6
Artikelnummer :
Ort :
Optional4 :
Optional7 :

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1 05756417
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Gez.: 28.06.2004 Seite: 1 von: 1

Name: Seis
Steckerübersicht BW 177...226 DH/BVC-4 page: 1 from: 1
582 700 95
Name: Werner
Connector overview BW 177...226 DH/BVC-4 Replaces: Sheet No.: 301

BW216-219DH-4 Service Training PDF

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BW216-219DH-4 Service Training PDF

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Service Training

Single Drum Rollers

Part-No. 008 097 20 08/2005

Technical data and adjustment values B1

DEUTZ diesel engine 2012C with EMR D1

BW 216 / 219 / 226 DH / PDH -4

BW 216 / 219 / 226 DH / PDH -4

• the location of components in the machine eases maintenance work,

BW 216 / 219 / 226 DH / PDH -4 -A1-

with Deutz diesel engine BF6M 2012C EMR

1. Operating and maintenance instructions

BW 216 / 219 / 226 DH / PDH -4 -A2-

BW 216 / 219 / 226 DH / PDH -4 -A3-

• strong ROPS/FOPS according to SAE-standard

• wear free service brake by closed hydrostatic travel circuits

BW 216 / 219 / 226 DH / PDH -4 -A4-

BW 216 / 219 / 226 DH / PDH -4 -A5-

BW 216 / 219 226 DH / PDH -4 -A -

Fahrhebel Travel lever

Fahrhebel Travel lever

BW 216 / 219 226 DH / PDH -4 -A -

BW 216 / 219 / 226 DH / PDH -4 -A -

BW 216 / 219 / 226 DH / PDH -4 -A -

BW 216 / 219 / 226 DH / PDH -4 -B1-

BOMAG Central Service - Technical data and adjustment values

Product type: BW 216 DH Serie 4

Reduction gear, drum:

Travel motor, rear:

Steering and charge pump:

BOMAG Central Service - Technical data and adjustment values

Product type: BW 219 DH Serie 4

Reduction gear, drum:

Travel motor, rear:

Steering and charge pump:

BOMAG Central Service - Technical data and adjustment values

Product type: BW 226 DH Serie 4

Reduction gear, drum:

Travel motor, rear:

Steering and charge pump:

BW 216 / 219 / 226 DH / PDH - 4 -C1-

5.3 Table of fuels and lubri-

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Engine Engine oil ACEA: E3-96/E5-02 or approx. 12,5 litres without

(-20 °C to +40 °C)

(-15 °C to +40 °C)

Diesel Winter diesel fuel approx. 300 litres

Vibration bearings Engine oil SAE 15W/40 approx. 2x0.8 litres

Air conditioning system Refrigerant R134A 1400 g

Engine cooling system Cooling system protection agent approx. 16 litres

Tires Water approx. 195 litres

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

82 BOMAG BW 216 DH-4

5.4 Running-in instructions

The following maintenance work must be per-

After a running-in time of 30 minutes

After 250 operating hours

After 500 operating hours

BW 216 DH-4 BOMAG 83

5.5 Maintenance chart

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours